Download Print this page

HEIDENHAIN iTNC 530 HSCI Service Manual

HEIDENHAIN iTNC 530 HSCI Service Manual

Hide thumbs Also See for iTNC 530 HSCI:

Technical manual (1967 pages)

Table Of Contents

Table of Contents

Advertisement

Quick Links

See also: Technical Manual

Service Manual

iTNC 530 HSCI

February 2012

Table of Contents

Advertisement

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the iTNC 530 HSCI and is the answer not in the manual?

Questions and answers

Summary of Contents for HEIDENHAIN iTNC 530 HSCI

Page 1 Service Manual iTNC 530 HSCI February 2012...
Page 2: Table Of Contents
1 How to use the iTNC 530 HSCI 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 ....................... 13 1.7 Meaning of the symbols used in this manual..............
Page 3 12.2.2 Possible error causes ..................162 12.2.3 Calling and operating the PROFIBUS diagnosis ..........163 12.2.4 Identification of the PLC operands ..............164 12.2.5 Troubleshooting with DriveDiag ............... 164 12.2.6 Log files ......................165 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 4 13 Data media and file management of the iTNC 530 HSCI ..........167 13.1 Introduction ........................ 167 13.2 Structure of the data medium ..................168 13.3 Possible error causes ....................168 13.4 Test of the data medium .................... 169 13.5 Setting the system time ..................... 173 13.6 Settings in the program manager ................
Page 5 21.1.3 Tables for power supply modules, power stages and motors ......332 21.1.4 Reading out power module data ..............338 21.1.5 Error messages ....................339 21.1.6 Possible error causes ..................340 21.1.7 Sequence for finding errors in the control loop ..........340 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 6 21.1.8 Error finding: Axes swapping................341 21.1.9 Error finding: Swapping power modules or output stages of the same type ................343 21.1.10 Error finding: Swapping the HEIDENHAIN expansion boards for the SIMODRIVE 611 system.................. 347 21.1.11 Corrective action..................... 348 21.2 Analog speed value interface ..................349 21.2.1 Introduction ......................
Page 7 26.7 Deselecting and disconnecting the touch probe ............433 26.8 Corrective action ......................434 27 Features of HEIDENHAIN components ................35 27.1 HEIDENHAIN components in a machine too ............. 435 27.2 Hardware identification ....................436 27.3 Display of important system information ..............451 28 Connector designations and pin layouts...............
Page 8 31.4.14 Machining and program run ................625 31.4.15 Hardware ......................631 31.4.16 Spindle, second ....................639 1 Annex: Principle of function of the iTNC 530 HSCI control..........641 1.1 Introduction ........................641 1.2 The control loop......................641 1.3 The HSCI bus........................ 648...
Page 9 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 10: How To Use The Itnc 530 Hsci Service Manual
The HSCI, the HEIDENHAIN Serial Controller Interface, connects the main computer, controller(s) and other control components by means of a bus system. The diagnostic functions of the iTNC 530 HSCI are the same as those of the iTNC 530 plus a special HSCI bus diagnostics.
Page 11: Other Service Manuals
This Service Manual is updated at irregular intervals. You find the current printable version of this SHB iTNC 530 HSCI in HESIS-Web Including Filebase. If you are not a registered customer with access to this HEIDENHAIN database, you will receive this Service Manual either on the occasion of a service training course or from your machine tool builder.
Page 12: Service Training
1.6 Service training HEIDENHAIN Traunreut offers service training courses in German language. We recommend the HEIDENHAIN service training courses for iTNC 530 HSCI for technicians who work with this Service Manual. Please contact HEIDENHAIN Traunreut or visit our website (www.heidenhain.de).
Page 13 1 – 14 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 14: Safety Precautions
2 Safety precautions 2.1 Introduction The safety precautions below are provided to ensure your personal safety and the safety of the machine tool. Please read this information carefully before you start servicing the machine! 2.2 Overview Equipment ground DANGER Ensure that the equipment ground is continuous! Interruptions in the grounding conductor may cause damage or injury to property or persons.
Page 15 EMERGENCY STOP button of the machine is pressed. Liability Attention HEIDENHAIN does not accept any responsibility for indirect or direct damage caused to persons or property through incorrect use or operation of the machine! 2 – 16 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 16: Code Numbers
Note Machine tool builders may define their 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 tool builder! February 2012...
Page 17: Input Of Code Numbers
When you have finished your work, reset all previously entered code numbers: Enter the code number 0 and press ENT to confirm. Press END to exit the code-number page. Note All key codes are reset when the control is restarted. 3 – 18 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 18 Additional As long as the machine parameter list is in the editor, no further code number can be entered. I.e., first close the MP editor if you want to enter a new code number information Figure: As long as the text Machine parameter programming is displayed in the header, no further code numbers are accepted (exception: NET123).
Page 19 3 – 20 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 20: Error Messages
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.
Page 21 Figure: Additional information in the small PLC window Error messages that require a restart of the control ... are displayed in the middle of the screen in a gray window as a plain-language message. Figure: Gray error window 4 – 22 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 22 Reaction of Display only control and A message (info, warning, error) is only displayed. machine 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.
Page 23: Help Key
HELP texts cannot be displayed for error messages in gray windows. The control must be rebooted. For information on these errors refer to the list of NC error messages. --> See ”List of NC error messages” on page 4 – 27. 4 – 24 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 24: Err Key
4.3 ERR key Display all pending error messages in a list. (When you press this key again, the window will close.) If there is an AND symbol (red caret) in the header in addition to the error message, there is more than one error message pending.
Page 25: Ce Key
The columns in the ERR window have the following meanings: Column in ERR window Description Number Error number defined by HEIDENHAIN or the machine manufacturer (-1: No error number defined) Class Error class; defines the reaction of the control: ERROR...
Page 26: List Of Nc Error Messages
This TNCguide information is also available on our website --> www.heidenhain.de/..This list is the official list of NC error messages. It contains all error messages 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.
Page 27 <axis> Check the motor table, power module table, and machine parameters. Check whether the motor and power module are designed for the load. See Service Manual Inverter Systems and Motors. 4 – 28 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 28 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual 8620 Load is too Drive has maximum current and cannot Reduce the load on the drive. accelerate.
Page 29 Encoder cabling defective Check the encoder cable. Motor control board defective Exchange the motor drive-control board. See ”Position encoders” on page 19 – 277. See ”Position encoders” on page 19 – 277. 4 – 30 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 30 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual 8B00 <axis> No encoder signal available Check connection of motor encoder. motor encoder Interruption in motor encoder cable Check the motor encoder.
Page 31 Examine the motor for short circuit in the windings. Exchange the power module. See ”Sequence for finding errors in the control loop” on page 6 – 58. See Service Manual Inverter Systems and Motors. 4 – 32 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 32 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual 8BA0 Incorrect Invalid entry for the line count STR in the Check the entry in the motor table. motor table reference signal or Check the signals from the speed or rotational...
Page 33 %.2s Noise on motor encoder signal Check the motor encoder. Check encoder signal input frequency. See ”Speed encoders” on page 19 – 300. 4 – 34 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 34 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual AC40 CC ampl. The position encoder signal amplitude is too Check connection of encoder. small or the contamination signal is active.
Page 35 See ”Speed encoders” on page 19 – 300. See ”Speed encoders” on page 19 – 300. See Service Manual Inverter Systems and See Service Manual Inverter Systems and Motors. Motors. 4 – 36 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 36 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual C340 Unknown Hardware defective Check the software version. counter compnt. Motor encoder defective Operate the motor at another encoder input.
Page 37 Check the motor table (columns TYPE and STR). Check speed encoder. See ”Speed encoders” on page 19 – 300. See ”Speed encoders” on page 19 – 300. 4 – 38 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 38 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual C410 Rotor Contamination of the speed encoder (Zn track) Exchange the motor. position <axis> Speed encoder cable defective Check the speed encoder cable.
Page 39 Analog axes: Check the servo. Insufficient lubrication Inform your service agency. Mechanical stiffness Machine vibration For analog axes: Servo defective See ”Sequence for finding errors in the control loop” on page 6 – 58. 4 – 40 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 40 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual Movement The motor is moving while the axis slide is Check MP1144.x. stationary or vice versa. monitoring error in Check the backlash.
Page 41 Check the data transmission line. not ready The external device is not switched on or not ready. The transmission cable is defective or incorrect. See ”Connection setup” on page 14 – 183. 4 – 42 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 42 If "Control is ready“ output is defective --> Relays, safety contactor combinations replace UEC or PLB. defective (See ”Exchange of HEIDENHAIN components” “Control is ready“ output is not powered on page 29 – 515.) with 24 V. See ”Checking the enables on the iTNC 530 "Control is ready"...
Page 43 HSCI: IOC file is Entry in OEM.SYS does not exist Restart the control. missing 19845 IOC file does not exist Check the IOC file and OEM.SYS. See ”Bus diagnosis” on page 12 – 147. 4 – 44 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 44 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual HSCI connection A connection error was found on the HSCI bus. Check all devices and connections. error 21113 Check the connector sequence of the HSCI cable (X500 ->...
Page 45 See ”PLC main page” on page 11 – 116. PLC partition: Not Not enough free memory on the PLC partition Inform your service agency. enough memory Delete unneeded files from the PLC partition. 4 – 46 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 46 Error message Possible cause of error Measures for error diagnosis and/or corrective action Additional information and descriptions Additional information and descriptions in the manual in the manual PLC program Time out during initialization of the Profibus or Inform your service agency. HSCI hardware could not be started 20353...
Page 47 See ”Sequence for finding errors in the control loop” on page 6 – 58. Carry out offset adjustment. (See ”Adjusting the electrical offset (drift adjustment)” on page 21 – 355.) 4 – 48 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 48 SE; the infrared signals receiver unit on the MC is defective --> replace cannot be allocated any more; faulty operation. the MC. (See ”Exchange of HEIDENHAIN components” on page 29 – 515.) Interface to touch probe or transmitter/receiver unit on MC defective See ”Touch probes”...
Page 49 There are too many NC software versions on Delete old NC programs that are no longer the control. required. system memory See ”Reloading the currently used NC software” on page 15 – 215. 4 – 50 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 50: Errors
The control does not boot Hard disk defective Exchange MC or HDR or See ”Exchange of drive assembly HEIDENHAIN completely (error messages components” on page 29 – related to the booting 515. procedure may be displayed). The Power interrupted...
Page 51 EMERGENCY STOP chain Check the output See ”Checking the enables interrupted "Control is ready" and on the iTNC 530 HSCI” on DC VOLTAGE MISSING does not acknowledgment I3. page 17 – 225. disappear, although the key 24 V power supply from...
Page 52 The axes cannot be traversed Drive enabling is missing Check the enablings. See ”Checking the enables on the iTNC 530 HSCI” on and the red SH2 LEDs of all page 17 – 225. HEIDENHAIN drive modules light up (or the red LEDs SH2...
Page 53 A defective USB unit is Disconnect all USB units connected to the control. (e.g., touchpad) from the processor iTNC 530 HSCI control and reboot it. slows down until it becomes inoperable. 5 – 54 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 54: Procedures And Tips For Error Diagnosis In The Field
The following systematic procedures have proven themselves for error diagnosis at a machine tool. They are described below. Note Make use of the extensive diagnosis options of the iTNC 530 HSCI. Diagnostic option Description in this manual Integrated drive diagnosis See “DriveDiag”...
Page 55: Sequence For Finding Serious Electrical Errors
Error messages, such as Leakage current in UV 1xx or Overcurrent cutoff Scorch marks and/or burnt smell Destroyed units Note For detailed descriptions on how to find ground faults/short circuits, refer to the Service Manual ”Inverter Systems and Motors”. 6 – 56 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 56 Flowchart Sequence for finding serious electrical errors Switch off the main switch of the machine and take precautions against resetting. Ensure that there is no potential at the primary voltage connection and at the DC-link. Inspect the motors and cables for ground fault and short circuit.
Page 57: Sequence For Finding Errors In The Control Loop
If you need information on lubrication, mechanics, hydraulics, pneumatics, brakes, coupling system, please contact your machine manufacturer! Integrated The integrated oscilloscope for iTNC 530 HSCI is a handy tool for analyzing errors in the control loop. oscilloscope Activation and operation --> See ”Integrated oscilloscope” on page 10 – 95.
Page 58 Correct error in drive system. okay? Inspect control, e.g. interface to drives and to encoders. Control and Replace defective control connected devices or faulty encoders okay? or defective cables. Call the machine tool builder or a HEIDENHAIN service agency. February 2012 6 – 59...
Page 59 Before starting any extensive inspections of the mechanics, the "electrician" can also check the components in the electrical cabinet (power modules, etc.) first. Note For detailed descriptions of how to examine HEIDENHAIN drives, refer to the Service Manual ”Inverter Systems and Motors”. Possible effects...
Page 60: Error Localization By Process Of Interchange
"interchange method" can be used. To do this, interfaces or identical devices are interchanged in order to find out, whether the error "moves". Example: Interchange possibilities on iTNC 530 HSCI with CC 61xx Example: Interchange possibilities on iTNC 530 HSCI...
Page 61 Interchanging PWM interfaces --> See ”Error finding: Axes swapping” on page 21 – 341. Interchanging motor outputs --> See ”Error finding: Axes swapping” on page 21 – 341. Interchanging expansion boards --> See ”Error finding: Swapping the HEIDENHAIN expansion boards for the SIMODRIVE 611 system” on page 21 – 347.
Page 62: Error Localization By Process Of Exclusion
6.6 Error localization by process of exclusion For the "exclusion method" probably defective devices or entire axes are deselected in the NC software and physically separated from the control component, i.e. disconnected from the interface of the control component including the cable. Then a check is made, as to whether the previous error message or error recurs.
Page 63 The units concerned (e.g., position encoder for this axis) are not monitored any more but still supplied with power. The defective scale can thus influence the low voltages of the control, for example. 6 – 64 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 64: Observing Essential Values With The Integrated Oscilloscope
6.7 Observing essential values with the integrated oscilloscope The control receives three actual values: Current Spindle speed Position The actual current is evaluated by means of current sensors in the power output stage. The actual speed is captured via the motor encoder. With direct measurement the actual position is provided by, e.g., the linear scale.
Page 65 Ideally, you have older recordings of the machine which you can now compare with the new ones. Striking signal changes, abrupt fluctuations or continuously high values indicate problems with the mechanics of the axis. 6 – 66 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 66: Finding Position Differences Of Direct And Indirect Encoders
6.8 Finding position differences of direct and indirect encoders This procedure serves to compare the signals of the motor encoder to those of the position encoder. This allows to draw conclusions about the quality of the mechanics and the coupling system. Prerequisite The machine tool to be investigated must be equipped with digital drives and direct encoders (dual encoder system).
Page 67 Ideally, you have older recordings of the machine which you can now compare with the new ones. If the position difference has increased, in most cases improvements of the mechanics or the coupling system are required. 6 – 68 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 68: Error Localization By Switching From Direct To Indirect Position Measurement
6.9 Error localization by switching from direct to indirect position measurement With this procedure, the direct encoder (scale, scale tape, etc.) is deselected. Instead, the position is measured with the motor encoder. Switching to the motor encoder is useful in the following events: The characteristics of an axis have degraded (unusual noise during traverse, poor surface quality, controller oscillations, etc.) Errors occur that do not clearly refer to an encoder or the mechanics of an axis.
Page 69 Observe the quality of the encoder signals (e.g. with a PWT 18 (for 1Vpp) or with PWM 9 while moving the table with indirect path measurement. 6 – 70 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 70: Notes And Tips For The Field Service
6.10 Notes and tips for the field service What is the cause Ask the operator or technician who worked last with or on the machine about the detailed course of events. of this error? Were there any particular incidents such as … A loud bang in the electrical cabinet Overload Leaky hydraulic, coolant or water lines...
Page 71 Attention If HEIDENHAIN expansion boards are used for the SIMODRIVE system, please check whether the grounding is implemented as prescribed. --> See ”Exchanging HEIDENHAIN interface boards in the SIMODRIVE system” on page 29 – 553.
Page 72 For cables in metallic ducting, adequate decoupling can be achieved by using a grounded separation shield. The cross section of potential compensating lines is at least 6 mm Genuine HEIDENHAIN cables, connectors and couplings are used. Cover plates are available for the ribbon cables. Note...
Page 73 Attention Maximum 75 % humidity allowed during continuous operation. Shipping Check whether the shipping brace of the hard disk of the mounted control has been removed. brace of the hard disk 6 – 74 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 74: Creating And Reading Out Service Files
7.1 Introduction Service files can be read out from iTNC 530 HSCI. Files selected by HEIDENHAIN and the machine manufacturer are stored in a ZIP file. The selected files may be located on the TNC or on the PLC partition.
Page 75: Automatic Generation Of Service Files
7.3 Manual generation of service files Service files can be created manually at any time: Press the ERR key. Press the soft key SAVE SERVICE FILES. Figure: The Service file is generated manually 7 – 76 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 76: Generating Service Files With Tncremont
7.4 Generating service files with TNCremoNT With the current TNCremoNT program it is possible to generate service files directly from the laptop/PC: Connect the control to the laptop/PC with TNCremoNT. Click Extras/Create service file in the menu bar. The service file is created and the path TNC:\service\ opened automatically on the control's hard disk.
Page 77: Evaluation Of The Service Files
HEIDENHAIN service agency with comprehensive information on an error that occurred on a machine. Upon agreement, the ZIP file can be sent to the OEM or to HEIDENHAIN. Attention Confidential data (e.g., customer's milling program) can be removed before the service file is sent in ZIP format.
Page 78: Log
8 Log 8.1 Introduction The log serves as a troubleshooting aid. There are 4 MB of process memory available for this purpose. Error messages and keystrokes are recorded in the process memory. When the code number LOGBOOK is entered and the soft key EXECUTE pressed, the log entries are copied from the process memory into an ASCII file on the control's hard disk and are displayed.
Page 79: Calling The Log
Ensure correct spelling when making any changes in the log window. Then start reading out the log by pressing the EXECUTE soft key. An ASCII file with the log entries is generated and displayed on the screen. 8 – 80 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 80: Reading Out The Log With Tncremont And Filtering By Event Types
8.3 Reading out the log with TNCremoNT and filtering by event types With the current version of TNCremoNT it is possible to read the log directly from the laptop/PC and to filter it by event types: Note The local time on the control and the PC/laptop should be identical. Connect the control to the laptop/PC with TNCremoNT.
Page 81 (Event type, Contents, Source, Name, Time, Index, Comment). The screen below is displayed, when you click Event type: Note By clicking Extras/Log filter settings (or the corresponding icon) you can filter out event types. 8 – 82 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 82: Overview Of Log Entries
8.4 Overview of log entries Entry Description RESET Restart the control Error messages --> PLC error message with the line number in the PLC error text file --> NC error message with number Power fail interrupt! --> The control was switched off by a POWERFAIL. Result of the file system test: If the control is not properly shut down, the file system is checked during the next startup and the result is entered in the log.
Page 83 00 03 Programmed stop 00 04 Block end in single block mode 00 05 Geometry error 00 06 END PGM, M02 00 07 TNC STOP button 00 08 Data transmission error (RS-422/RS-232) 8 – 84 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 84 Entry Description INFO MAIN PATH PLCEDIT File for PLC Editor NCEDIT File for NC Editor RUNPGM Main program for program run RUNPALET Pallet table for program run RUNDATUM Datum table for program run RUNTOOL Tool table for program run RUNTCH Pocket table for program run SIMPGM Main program for program test...
Page 85 For test purposes, all LSV-2 telegrams can be entered in the log. After entering the code word LOGBOOK, this function must be enabled with the LSV-2 TELEGRAM OFF/ON soft key. 8 – 86 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 86 Entry of If the control is accessed remotely via LSV2 protocol, the IP address of the external device is entered IP addresses in addition to the entry REMO A_LG. Figure: Log entry of IP address of accessing unit (laptop/PC) The IP address is shown in hexadecimal notation and can be converted to decimal as follows: The first two HEX digits from the left become the first 3-digit decimal number of the IP address;...
Page 87 The code 00 06 in the second line means END PGM, M02. (See ”Overview of log entries” on page 8 – 83.) INFO: MAIN PGMEND Information about the end of program in plain language. 8 – 88 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 88: Log Entries At Program Termination
8.5 Log entries at program termination If an NC program is not terminated properly but aborted before completion due to an error, additional information is entered in the log: Path and name of the aborted NC program Line number of the NC program at program termination ACTUAL position at program termination Offsets to machine datum (preset) Possibly set datum shifts...
Page 89 This display always refers to the datum of the tool holder. To determine the REF position of the tool tip, the tool length needs to be subtracted (-288.9867 - 50.0000 = - 338.9867). 8 – 90 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 90: Drivediag
9 DriveDiag 9.1 Introduction The iTNC 530 HSCI features the diagnosis tool DriveDiag. DriveDiag provides information on ... Operating states and signals; for this purpose, traffic lights (red, yellow, green) are used. Voltage values Current values Temperature values Electronic ID labels...
Page 91 With the screen switchover key you can switch between the screen displays for the machine operating modes, programming modes and DriveDiag. To close DriveDiag, press END and click the OK button. 9 – 92 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 92: Troubleshooting With Drivediag
9.3 Troubleshooting with DriveDiag The use of DriveDiag for troubleshooting is described in the respective chapters of this Service Manual. February 2012 9 – 93...
Page 93 9 – 94 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 94: Integrated Oscilloscope
10 Integrated oscilloscope 10.1 Introduction The iTNC 530 HSCI features an integrated oscilloscope This oscilloscope has six channels, of which no more than four can be used for signals from the current and speed controller. If more than four channels of the current and speed controller are to be displayed, the error message Channel <number>...
Page 95: Activation And Settings
The integrated oscilloscope can also be called by entering the code number 688379. Use the arrow keys to position the cursor to the respective input fields. Press the GOTO key to open one of the drop-down boxes. 10 – 96 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 96 Use the cursor to select a value and confirm it with the ENT key. Operating mode Select the desired setting or choose the circular interpolation test. • YT: Chronological depiction of the channels (function of the time) • XY: X/Y graph of two channels •...
Page 97 Nominal value of the acceleration [m/s ] or [°/s r nominal Nominal value of the jerk [m/s ] or [°/s Pos. diff. Difference between position and speed encoder [mm] or [°] 10 – 98 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 98 [mV] Motor: B Signal B of the speed encoder [mV] CC DIAG Axis-specific signal with additional input box. Consult your machine manufacturer or a HEIDENHAIN service agency. SPLC Reserved SPLC-CC Reserved Compensat. Position compensation value (composed of temperature compensation, axis-error [mm] or [°]...
Page 99 The delta trigger is given as a value relative to the first trigger threshold. If a value of zero (0) is entered for the delta trigger (default setting), then the delta trigger is off. Enter the second trigger threshold for a value range if needed. 10 – 100 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 100: Recording And Adjusting The Signals
10.3 Recording and adjusting the signals Press the OSCI soft key. Press the START soft key. The selected signals are recorded continuously. After recording ends, the memory contents are displayed. You can stop the recording anytime by hand with the STOP soft key. Note The oscillogram remains stored until you start a new recording.
Page 101 This position serves as anchor for time spreading. Use the following soft keys: Display a larger detail of the time axis (up to entire image) Display a smaller detail of the time axis 10 – 102 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 102 The signal details can be made visible: Note The displayed time detail is shown in a small bar at the bottom left (see arrow in the screenshot). Every new recording is displayed with this setting. With the following soft keys the recording can be shifted on the time axis: Shift the display range to the left.
Page 103 If the trigger condition is fulfilled before the corresponding number of grid points have been stored when the pre-trigger is set to 25, 50, 75 or 100%, then correspondingly fewer grid points are recorded. 10 – 104 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 104 Example: Oscillogram with 50 % pre-trigger. The trigger condition was fulfilled immediately when the recording was started. February 2012 10 – 105...
Page 105: Saving And Loading Recordings
10.4 Saving and loading recordings You can save recorded oscillograms together with the related settings to files on the hard disk of the iTNC 530 HSCI. The files must have the extension *.DTA. Record an oscillogram. Exit the oscillogram by pressing the END soft key. --> You return to the setup screen for the integrated oscilloscope.
Page 106: For Error Diagnosis
10.5 For error diagnosis 10.5.1 Triggering on error markers With the integrated oscilloscope, you can make recordings with trigger on the following error markers (defined by HEIDENHAIN): M 4177 (erasable error message) M 4178 (error message that causes an external EMERGENCY STOP)
Page 107 An overload generates an I2T error message on the machine, which in turn triggers an EMERGENCY STOP. The error marker M 4178 changes from zero to one. On the time axis, 75 % before the error event are displayed. 10 – 108 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 108: Circular Interpolation Test
The integrated circular interpolation test with the mounted encoders (e.g., linear encoders) does not serve to test the geometry of the machine. Additional measuring equipment (e.g., KGM grid encoder from HEIDENHAIN) is required for this purpose. Choose the CIRC operating mode in the oscilloscope.
Page 109 Start this NC program in the automatic mode and start oscilloscope recording. Stop recording and adjust the display. Note You can run the circular interpolation test at different positions, at different speeds and with different radii! 10 – 110 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 110: Finding Compensation Values
10.5.3 Finding compensation values To improve the positioning accuracy of machine tools, the machine tool builder can choose from a variety of compensation possibilities the iTNC 530 HSCI offers: Backlash compensation Linear axis error compensation Nonlinear axis error compensation Compensation of thermal expansion...
Page 111 Now you can see, whether or not compensations are effective. 10 – 112 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 112: Working With Delta Triggers
10.5.4 Working with delta triggers With the delta trigger, you can define a "corridor" a physical signal must not leave. Example: You want to observe an actual speed value. This value must not exceed a lower and an upper limit. For example, set the oscilloscope like this: Start the oscilloscope recording.
Page 113: Descriptions In This Manual
10.5.5 Descriptions in this manual Further use of the integrated oscilloscope for error diagnosis is described in the respective chapters of this Service Manual. 10 – 114 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 114: Plc Diagnosis
PLC is a generic term from control technology and is the abbreviation of: Programmable Logic Controller (programmable control). The PLC of the iTNC 530 HSCI is located in different units and is therefore referred to as integrated PLC. Tasks of the PLC...
Page 115 100% may be displayed for the PLC utilization. You do not have to take any action! Only when the permissible PLC utilization is exceeded, is the error message PLC: time out displayed. --> Contact your machine tool builder! 11 – 116 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 116 PLC functions of From the PLC main menu you can use soft keys to access the following PLC functions: the main menu Soft key Function Description in this manual Edit the file located in RAM memory. Call the diagnostic functions. See “DriveDiag”...
Page 117: Error Messages
The shielding of the bus is connected to each electrical cabinet. Result: Compensating currents Additionally Fault in the PROFIBUS for PROFIBUS Fault in a bus (e.g. ASI bus) connected to the PROFIBUS Terminating resistors missing at the ends 11 – 118 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 118: Diagnosis Tools In The Plc Mode
11.4 Diagnosis tools in the PLC mode iTNC 530 HSCI provides comprehensive PLC diagnosis options. Note Since the PLC program was written by the machine manufacturer, PLC diagnosis often requires his support. 11.4.1 The TABLE function The TABLE function provides the possibility of displaying the logic states of of PLC operands in a table.
Page 119 Assignment --> See ”Connector designations and pin layouts” on page 28 – 453. Note It is not possible to measure PLC inputs directly at the handwheel or at the cable adapter for the handwheel. 11 – 120 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 120 Figure: Measurement at a terminal of the I/O module PLD-H 16-08-00 using a needle tip probe Conclusion The logic states in the PLC table must be in agreement with the voltage levels for each input. --> See ”Specifications” on page 11 – 144. If there is a difference (e.g., the voltage level is within the tolerance range but the logic state is 0), you can narrow further the error cause.
Page 121 - Cable or connector defective - Fault in the bus, etc. The input of the control component (MB, UEC, PLB, PLD) is OK. The fault is located in the electrical cabinet or the machine tool. 11 – 122 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 122 Checking the You have called the TABLE. PLC outputs Press the OUTPUT soft key. Place the cursor on the output to be examined (e.g. GOTO O2 ENTER). Observe the logical state of the output to be checked. Check whether the connected actuator (relay, etc.) has triggered or whether the connected device operates.
Page 123: The Logic Diagram
Here you specify how long the signal states are recorded from the defined trigger time point. Four different times are available, depending on the PLC cycle time. 2048 PLC cycles are recorded. 11 – 124 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 124 Figure:Example of selected operands, trigger conditions, trigger logic and recording time Start of Call the LOGIC DIAGRAM again. recording Start the LOGIC TRACE function. Note Recording begins with START LOGIC TRACE and ends when when the trigger event occurs or the STOP LOGIC TRACE soft key is pressed.
Page 125 It is also possible to record bytes, words and double words. the integrated Six channels are available for this purpose. oscilloscope See “Integrated oscilloscope” on page 10 – 95. 11 – 126 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 126: The Trace Function
11.4.3 The TRACE function The TRACE function makes it possible to check the logical conditions of PLC operands (M,I,O,T,C) within the respective PLC files (statement list). Furthermore, the contents of bytes, words and double words can be checked. Activation You are on the PLC main page. Switch to the next soft-key row.
Page 127: The Watch List Function
Otherwise the error message Selection list is empty is displayed. Note If necessary, create a WATCH LIST with the aid of the machine manufacturer. Figure: Example of a selection of symbolic operands 11 – 128 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 128 Selecting absolute You have called the WATCH LIST. operands from Switch to the next soft-key row. the WATCH LIST Press the INSERT LINE soft key. Place the cursor in the ADDR column to the right. Enter the absolute address of the operand, e. g. W1022. Press the ENT key.
Page 129 Press the PGMMGT key. --> The program management is opened. In the path PLC:\DEBUG, place the cursor on the saved WATCH LIST file (e.g. Watch123.wlt). Press the ENT key. --> The file is loaded in the WATCH LIST function. 11 – 130 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 130: The I/O-Force List
11.4.5 The I/O-FORCE LIST Independently of the currently running PLC program and the status of the hardware, the PLC inputs and outputs can be set or reset via the I/O-FORCE LIST. DANGER The I/O-FORCE LIST can overrule safety-relevant monitoring operations in the PLC program! This could lead to damage to property or persons.
Page 131 Press the PGMMGT key. --> The program management opens with the correct path. Place the cursor on the saved I/O-FORCE LIST file (e.g., Force123.flt). Press the ENT key. --> The file is loaded in the I/O-FORCE LIST function. 11 – 132 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 132 Deactivating and closing the I/O-FORCE LIST DANGER After having worked with the I/O-FORCE LIST, it is essential that you terminate this function! Press the EMERGENCY STOP button. Press this soft key. --> OFF must be highlighted! As a precaution remove all PLC operands in the I/O-FORCE LIST with the DELETE LINE soft key. Exit the function I/O-FORCE LIST with the END soft key.
Page 133: Non-Volatile Plc Markers And Words
Press this soft key. --> A preset memory area is displayed. Note The iTNC 530 HSCI automatically enters the maximum defined area of non-volatile PLC markers and words (e.g., B0 ... B127, M0 ... M999). You may change this area after consultation with the machine manufacturer.
Page 134 Switch to the next soft-key row. Call the TABLE function. Switch to the next soft-key row. Press this soft key. --> The iTNC 530 HSCI proposes PLC:\PLCMEM.A as path and file name. Figure: Writing back non-volatile PLC markers and words Confirm the file name.
Page 135: Overviews
Stylus is deflected, probing process is completed 4053 Probing process has been completed or canceled 4054 Battery voltage too low (battery warning at touch probe connection); evaluated only during the probing process 4055 Enable the probing process 11 – 136 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 136 Operand Description Reset 4056 NC stop in all operating modes if stylus is deflected 4057 Touch probe cycle active (FN17: ID990 NR2) 4060 Cycle for tool measurement started 4061 0: Measure the tool 1: Check the tool 4062 0: Wear tolerance not exceeded NC/PLC 1: Wear tolerance exceeded 4063...
Page 137 PLC error message with priority 1 (warning) 4229 PLC error message with priority 2 (info) 4230 NC start via LSV2 4231 NC stop via LSV2 4260 Acknowledgment of control-is-ready signal (I3) 11 – 138 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 138 Markers that can be influenced by machine parameters Operand Description Reset 4300 - Value from MP4310.0 4315 4316 - Value from MP4310.1 4331 4332 - Value from MP4310.2 4347 4348 - Value from MP4310.3 4363 4364 - Value from MP4310.4 4379 4380 - Value from MP4310.5...
Page 139 Write errors from PLC modules in the PLC log 4754 Write diagnostic information in MYDEBUG.LOG PLC error markers Operand Description Reset 4800 - Reserved markers for PLC error messages NC/PLC 4999 11 – 140 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 140 Overview of words Operand Description Reset Gear code NC/PLC NC/PLC S code Code for M function Tool pocket number Tool number Index number of a programmed indexed tool Tool magazine number Line number in help file Mode of op. Code of the depressed key Code of the code number last entered via MOD First numerical value from FN19 Second numerical value from FN19...
Page 141 Reference end position W1056 D1164 Lubrication pulse: Value in MP4050.x exceeded W1058 D1168 Reset the accumulated distance (lubrication) W1060 D1172 Axis-specific feed-rate enable W1062 D1176 Lock the handwheel for specific axes 11 – 142 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 142 Overview of operands Operand Abbreviation Address range Marker M (marker) M0 to M9999 M0 to M999 are free; they are deleted only after entry of the code number 531210, not by a reset (non-volatile range). The range can be reduced in the *.CFG file of the PLC compiler. M1000 to M3999 are free;...
Page 143: Specifications
The PLA-H 08-04-04 features inputs for the Pt 100 thermistors. Device Inputs for Pt 100 thermistors PLA-H 08-04-04 Constant current: 4.096 mA Temperature range: 0 °C to 100 °C Resolution: 0.01 °C Increment: 0.03 °C 11 – 144 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 144: Plc Outputs
11.7.4 PLC outputs Output signals and The switching outputs are transistor outputs with current limitation. addresses Please note: PLD-H: The outputs are short-circuit proof. Permissible load: Resistive load (ohmic load) Inductive loads (e.g. relay, contactor) with an energy content of up to 100 mJ do not require a quenching diode.
Page 145: Analog Outputs
The absolute address of the input or output, the pertaining device, the slot and the terminal name can be seen from the Bus Diagnosis. --> See ”Identification of the PLC operands” on page 12 – 149. 11 – 146 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 146: Bus Diagnosis
12.1.1 Introduction HSCI is the abbreviation of: HEIDENHAIN Serial Controller Interface The main computer (MC 6222, MC 6241), the controller unit (CC 61xx, UEC 11x) and other control components (PLB 6xxx, MB 620) are connected to each other via the HSCI bus.
Page 147: Calling And Operating The Hsci Bus Diagnosis
You can open and close the tree structure on the left side of the window with the arrow keys or the mouse. Navigation is also effected with the arrow keys or a mouse. 12 – 148 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 148: Identification Of The Plc Operands
12.1.4 Identification of the PLC operands By means of the HSCI bus diagnosis you can obtain important information on PLC operands, such as the absolute address, the slot and the terminal name: Figure: Display of the attributes of I_emergency_button_unlocked in HSCI bus diagnosis Figure: PLB 6204 with four PLD-H 16-08-00 inserted, terminal X9.9a on system module February 2012 12 –...
Page 149: Read-Back Outputs
The signal designation is I_RO_MC_RDY (Input Readback Output MC Ready). Figure: The input I_RO_MC_RDY is a read-back output. Figure: The level can be measured at the terminal RO X9.3a. 12 – 150 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 150 Figure: In the table, the read-back output I_RO_MC_RDY is represented as Input 70. February 2012 12 – 151...
Page 151: Master, Slaves And Clients
Client 3 Slave (3) Client 4 Figure: Display of master and slaves in the HSCI bus diagnosis Figure: The HSCI bus is interrupted after Client 3 (= Slave 2 = PL 6204). 12 – 152 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 152: For Error Diagnosis
12.1.7 For error diagnosis In the left window of the HSCI bus diagnosis you can see the arrangement, the names and the status of the HSCI components and terminals. Observe the status of the HSCI components and terminals. Here, you already can detect and locate errors in the HSCI system. Display Color Status...
Page 153 The PLB 6204 and the downstream MB 620 show ERROR condition: If this error occurs, the LEDs on the PLB 6204 behave as follows: Status Orange LED Green LED Fast blinking Fast blinking Fast blinking Slow blinking HSCI 12 – 154 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 154 Example 2: PLC supply voltage interrupted at PLB 6204 system module The following error messages may be displayed: The PLB 6204 is not powered with 24 V (PLC) and shows ERROR condition: The green LED for the 24 V PLC supply voltage of the PLB 6204 is extinguished: February 2012 12 –...
Page 155 The PLD-H 16-08-00 is no longer powered with 24 V (PLC) and shows WARNING condition: The green LED for the 24 V PLC power supply is not lit; neither are the associated orange LEDs for the PLC outputs: 12 – 156 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 156 HSCI errors Example 1: during start-up HSCI connection X502 interrupted at PLB 6204 system module The following message is displayed: The control has detected that an HSCI device is missing. In the columns Previous and Now the display stops at where there are differences. In this example there is no communication with the PLB 6204.
Page 157 Now you can see which HSCI devices cannot be addressed. The PLB 6204 and the downstream MB 620 show ERROR condition: If this error occurs, the LEDs on the PLB 6204 behave as follows: Status Orange LED Green LED HSCI 12 – 158 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 158 Example 2: PLC supply voltage interrupted at PLB 6204 system module The following message is displayed: The control has detected that an HSCI device is missing. In the columns Previous and Now the display stops at where there are differences. In this example there is no communication with the PLB 6204.
Page 159 Now you can see which HSCI devices cannot be addressed. The PLB 6204 and the downstream MB 620 show ERROR condition: The green LED for the 24 V PLC supply voltage of the PLB 6204 is extinguished: 12 – 160 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 160 Example 3: PLC supply voltage interrupted at the PLD-H 16-08-00 input/output module It may not be possible to switch the control on (depending on which PLC outputs are concerned). The PLD-H 16-08-00 is not powered with 24 V (PLC) and shows WARNING condition: The green LED for the 24 V PLC power supply is not lit;...
Page 161: Profibus
12.2 PROFIBUS 12.2.1 Introduction The iTNC 530 HSCI also cooperates with PROFIBUS components. For this purpose, the MC must feature a PROFIBUS interface board. PROFIBUS components are available from HEIDENHAIN or other manufacturers. The machine manufacturer configures the PROFIBUS system.
Page 162: Calling And Operating The Profibus Diagnosis
12.2.3 Calling and operating the PROFIBUS diagnosis Select the Programming and Editing operating mode. If open: Close the program management by pressing the END button. Note Pressing the MOD key while the program manager is open calls screen where you can make the interface settings.
Page 163: Identification Of The Plc Operands
Here, you already can detect and locate errors in the PROFIBUS system. Display Status Error ( further information in the text window) Warning (further information in the text window) Undefined condition (further information in the text window) 12 – 164 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 164: Log Files
All these files are saved in the path PLC:\PROFIBUS. Note For the analysis of a PROFIBUS error, read out this folder from the control using TNCremoNT and send the data to your machine manufacturer or to a HEIDENHAIN service agency. February 2012 12 – 165...
Page 165 12 – 166 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 166: Data Media And File Management Of The Itnc 530 Hsci
PLC: 1 GB SYS: 2 GB The data medium of the iTNC 530 HSCI contains the TNC and PLC data as well as all NC software. Attention Defects in the data medium may have the result that no functions can be called any more.
Page 167: Structure Of The Data Medium
The PLC partition is visible only after you have entered the code number 807667. SYS: System-specific data: This partition contains the entire NC software (NC dialogs, HEIDENHAIN cycles, etc.) and the HeROS operating system (HEIDENHAIN real-time operating system). A daily password is required to open the SYS partition.
Page 168: Test Of The Data Medium
If the control still communicates with the data medium, some tests might be carried out in the field. with the data --> See following instructions. medium Here too, additional and more comprehensive tests can only be performed at HEIDENHAIN agencies! Attention Do not use your own data medium test or repair programs! Data recovery at HEIDENHAIN or a specialized company could thereby become more difficult or even impossible.
Page 169 The NC software is terminated and an EMERGENCY STOP triggered, before the file system will be checked. Then the file systems of the SYS partition (hda5/sda5), the PLC partition (hda6/sda6) and the TNC partition (hda7/sda7) are checked and automatically repaired, if necessary. 13 – 170 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 170 Figure: Excerpt from the log with entries after checking the file system If corrupted files or clusters were found, you should exchange the data medium. --> Contact the machine tool builder or a HEIDENHAIN service agency! February 2012 13 – 171...
Page 171 If the NC software no longer starts up completely, data medium tests can also be performed on the test on the HeROS level (HEIDENHAIN real-time operating system). HeROS 5 level Contact the HEIDENHAIN helpline! 13 – 172 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 172: Setting The System Time
13.5 Setting the system time Select the Programming and Editing operating mode. Press the MOD key. Switch to the next soft-key row. Press the soft key. --> The following window opens: Choose, whether you want to make the settings by hand, or whether they should be synchronized via the NTP server.
Page 173: Settings In The Program Manager
Select a setting and confirm with the ENT key. Leave the settings page with the END soft key or the END key. Note For the descriptions in this iTNC 530 HSCI Service Manual the program manager was set to Enhanced 1. 13 – 174...
Page 174: File Management In The Tnc Partition
TNC partition Call the Program Management. Figure: Program management of iTNC 530 HSCI The directory structure is displayed on the left side, the associated files are listed on the right. With the +/- key or with ENTER you can open and close subdirectories.
Page 175 Date on which file was last changed Time Time at which the file was last changed Note Refer to the iTNC 530 HSCI User’s Manual for detailed information about file management. 13 – 176 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 176: File Management In The Plc Partition
All other PLC files can still be read but not edited any more. Call the Program Management. Figure: Program management of iTNC 530 HSCI The directory structure is displayed on the left side, the associated files are listed on the right.
Page 177 The filter setting is displayed above the file list, for example PLC:\*.SRC. To remove this filter use the soft keys SELECT TYPE --> SHOW ALL. Which file type is to be listed? Use this key to switch between soft-key rows. 13 – 178 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 178 This file has dependent files (section file, tool usage file; see User's Manual). Date Date on which file was last changed Time Time at which the file was last changed Note Refer to the iTNC 530 HSCI User’s Manual for detailed information about file management. February 2012 13 – 179...
Page 179 13 – 180 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 180: Data Backup
You should always back up the original machine parameters before you make any changes to the settings of the machine. This can be done on the HDR or SSDR of the iTNC 530 HSCI without having to transfer data to an external medium.
Page 181 The figure shows the correct setting in the TNCremoNT configuration: Note The data of an iTNC 530 HSCI are archived externally in the defined ASCII format as the BINARY format on the control may be changed, e.g., after an NC software update.
Page 182: Connection Setup
Here, it is of no importance, whether the connected Ethernet cable is transposed or non- transposed. Management of The Ethernet interface is managed by the HeROS HEIDENHAIN operating system. The settings of the the Ethernet Ethernet interface can be requested via the code number NET123.
Page 183 Ethernet settings Press the DEFINE NET soft key. --> The window Network Settings opens: on the control Click the Interfaces tab. Click the line of connector X26. Click the Configuration button. 14 – 184 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 184 If the IP address is fixed, you can read it here: If the IP address is generated automatically, click the Status Information tab. You can read the IP address of the control in the line inet addr. February 2012 14 – 185...
Page 185 You can also find this information in My Computer \ Control Panel \ Network ... Adjusting Ethernet If you want to adapt your laptop to the iTNC 530 HSCI: settings on the First, write down the Ethernet settings of the control. (See ”Requesting Ethernet settings on the laptop control”...
Page 186 You require a fixed IP address. --> Define this accordingly! Enter an appropriate IP address. Note We recommend using the IP address of the iTNC 530 HSCI and increasing the last place by one. Example: Address of the iTNC 530 HSCI: 160.1.180.5...
Page 187 Adjusting Ethernet If you want to adapt the iTNC 530 HSCI to your laptop: settings on the Write down the IP address and subnet mask of your laptop. control (See ”Requesting Ethernet settings of the laptop” on page 14 – 186.) Enter the code number NET123.
Page 188 TNCremoNT Start the HEIDENHAIN data transfer program TNCremoNT. Click this icon to open the configuration window. (Can also be called via Extras / Configuration ..) Now click on Connection and select Ethernet (TCP/IP). Subsequently, click on Settings and enter the IP address of the control.
Page 189 Press ENTER to confirm. --> If the connection works, the control will respond. If the connection does not work, a timeout message is displayed. Figure: Pinging from the laptop to the control successful 14 – 190 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 190 10 Mb network Restoring the After having finished data back-up, etc. and separated the connection, do not forget to reactivate the original settings original network settings of your laptop or of the iTNC 530 HSCI. February 2012 14 – 191...
Page 191: Via Rs-232-C/V.24 Serial Interface
If this is not the case, note that mostly you must use a different data transfer cable for direct connection of the iTNC 530 HSCI . --> See ”Cable overview” on page 14 – 209. Now configure the serial interface on the iTNC 530 HSCI.
Page 192 Then click on Settings and select the serial interface (e.g. COM1). Activate automatic detection of the data transfer rate on connection setup. --> The baud rate you have set on iTNC 530 HSCI is activated. Note If you use a USB/RS -232-C adapter, automatic detection of the baud rate should not be active.
Page 193 ... external access to the data medium of the control is not permitted! In this case press the MOD key and subsequently the EXTERNAL ACCESS ON/OFF soft key in order to permit access. 14 – 194 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 194: Via Usb
USB cable, max. 6 m (for longer cables amplifiers must be used) Note iTNC 530 HSCI identifies standard USB flash drives. HEIDENHAIN cannot guarantee that all USB flash drives available on the market work with the iTNC 530 HSCI. Connecting the Call the Programming and editing mode of operation and press the PGMMGT key.
Page 195: Reading In And Out Individual Files And Directories
Note Information on setting data interfaces and transferring data (e.g., TNCserver operation) can be found in the User's Manual for the iTNC 530 HSCI. Connection setup Connect a USB flash drive. --> See ”Connection setup” on page 14 – 183.
Page 196 Place the cursor on the new directory. Press the WINDOW soft key (you may have to switch to the next soft-key row). --> The display changes to split screen: Place the cursor in the right half on the directory, subdirectory or file you wish to transfer. Note Press the soft keys PATH and FILES to activate the respective view.
Page 197 Place the cursor in the right half on the directory or subdirectory to which you wish to transfer the data. Note Press the soft keys PATH and FILES to activate the respective view. Return to the other side now. Select a file or a directory. 14 – 198 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 198 For the data to be read out, you can create a folder on your laptop with TNCremoNT. For this purpose, click the icon Create folder or select File / Create folder ... from the menu. In the lower half of the screen (iTNC 530 HSCI contents), select the source drive and the source directory: Click the bar with the drive information.
Page 199 Release the mouse button. --> The directory or the file is being transferred. Figure: Read-out file Note When data is transferred with TNCremoNT, the data format is automatically converted from BINARY (control) to ASCII (laptop/PC). 14 – 200 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 200 Reading in data In the lower half of the screen (iTNC 530 HSCI contents), select the target drive and the target using TNCremoNT directory: Click the bar with the drive information. --> Its color changes, and two buttons appear at the right side in the bar.
Page 201: Backup On An External Data Medium
Double-click the newly created folder. --> It appears in the bar. Selecting the Select the source directory from the lower half of the display (contents of iTNC 530 HSCI): control partition Click the bar with the drive information. --> Its color change, and two buttons appear at the right side in the bar.
Page 202 Figure: PLC partition selected for data backup Calling the Activate the backup menu with this icon (or via Extras/Backup/Restore ...). backup function The following window appears: February 2012 14 – 203...
Page 203 The backup should have an identifying name (for example the machine number). Note HEIDENHAIN recommends creating separate archives for the TNC partition (customer data) and the PLC partition (data of the machine tool builder). As long as no changes are made to the machine (modifications, NC software updates, etc.) the data in the PLC archive is up-to-date.
Page 204 Starting the backup Click Run/Backup (or the corresponding icon). The following window appears: Enter an identifying name for the backup file in the line File name, e.g. Machine HUGO PLC data. Start the data transfer with Save. The following window appears: When the backup is finished, this window is closed.
Page 205: Extracting Files From The Backup File
Do not save the changes you made to the blue check marks. Attention If you store the changes in your *.LST file after the extraction, only the marked files of this backup will be restored in a later process! 14 – 206 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 206: Restoring Data
--> See ”Extracting files from the backup file” on page 14 – 206. Connection setup Set up a connection to the iTNC 530 HSCI via TNCremoNT. --> See ”Connection setup” on page 14 – 183. Selecting the...
Page 207 You can now close the TNCbackup window. Separate the connection. Close the TNCremoNT window. Restart the control after successfully restoring the machine backup (reboot). Now the machine should operate as usual. 14 – 208 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 208: Cable Overview
14.7 Cable overview Please note the maximum cable lengths: Interface Maximum cable length Ethernet Unshielded 100 m Shielded 400 m RS-232-C (V.24) Up to 20 m Note Do not use self-made cables (shielding problems, contact problems, short circuits, etc.). Mark your cable as "transposed" or "non-transposed". 14.7.1 Ethernet interface RJ45 connection For direct connection between laptop and control ("peer-to-peer") you require a transposed Ethernet cable ("crossover cable“).
Page 209: Rs-232-C (V.24)
14.7.2 RS-232-C (V.24) Note The RS-232-C has different pin layouts at the iTNC 530 HSCI (connector X27, X127) and at the RS-232-C adapter block (D-sub connector on electrical cabinet). Exception: The cable with the ID 366964-xx may be connected to the 9-pin adapter block or directly to the control.
Page 210 Accessories The following accessories can be helpful; they are available in specialized computer stores: D-sub adapter connector, 25-pin "OptoBridge" Metallically isolates the serial interface by means of integrated optocouplers and thus protects from: - Overvoltages - Different load potentials due to different supply circuits - Interference voltages on ground lines Please note: If the machine manufacturer has already mounted an opto...
Page 211 Adapts 25-pin connector to 9-pin connector Background: The adapter block RS -232-C on the electrical cabinet usually has a 25-pin connector, the COM interface on the laptop usually a 9-pin connector. 14 – 212 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 212: Operating Modes Of The Data Interfaces
Leave the interface settings with the END soft key or the END key. Note The iTNC 530 HSCI automatically recognizes when the LSV-2 protocol is used (e.g., data transfer with TNCremoNT). No setting in the line operating mode is required for this purpose! February 2012 14 –...
Page 213: Drive Symbols
14.9 Drive symbols The drives are shown in the program management of the HEIDENHAIN control: RS232:\..V.24 data interface (X27) RS422:\..V.11 data interface (X28) TNC:\ TNC partition (user data) PLC:\ PLC partition (machine data via code number) Depending on the selected operating mode, a symbol is displayed in front of the external drive symbol:...
Page 214: Reloading The Currently Used Nc Software
Test of the Run a test of the SYS partition of the data medium before you reload the NC software. The Test for bad clusters must be activated for this purpose. Contact a HEIDENHAIN service agency if you wish data medium to carry out this special data medium test.
Page 215: Procedure
A change to another NC software version is not described in this Service Manual and may only be made in agreement with the machine manufacturer. Press the SELECT soft key. Confirm your selection with the YES soft key. 15 – 216 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 216 The control now displays the iTNC530 Software Update menu. Select a language and confirm the following questions by pressing ENT or by mouse click. --> The NC software is loading. Note If the error message Not enough space on SYS: is generated, delete compressed NC software versions and service packs from the SYS partition.
Page 217 15 – 218 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 218: Loading Service Packs
It is possible to downgrade to full software versions. Screen display If a service pack is installed on the iTNC 530 HSCI , a corresponding message is shown after the control has started up (before the Power interrupted message is confirmed).
Page 219: Preparations
NC software (e.g., 606420 01 SP5). Export restrictions As iTNC 530 HSCI features more than 4 axes interpolating with each other (contouring with calculation of more than 4 axes), it is subject to export licensing. An export license is thus required for:...
Page 220: Procedure
Note iTNC 530 HSCI identifies standard USB flash drives. HEIDENHAIN cannot guarantee that all USB flash drives available on the market work with the iTNC 530 HSCI. If the USB device is not detected, you can use TNCremoNT to transfer the service pack to the data medium of the control.
Page 221 --> The control now displays the iTNC530 software update menu. Select a language and confirm the following questions by pressing ENT or by mouse click. --> The service pack is loading. 16 – 222 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 222 When the service pack has been successfully loaded, the following message is displayed: Disconnect the USB drive and click OK or press the ENT key. --> The control restarts. The control may display the following window: February 2012 16 – 223...
Page 223 PLC:\servicepack), you may delete it from the laptop in order to free memory space on the hard disk. The service pack was automatically archived in the SYS partition of the hard disk and can be called at any time. Functional test Finally, check the machine functions! 16 – 224 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 224: Checking The Enables On The Itnc 530 Hsci
530 HSCI itself (through a PLB 62xx system module or a UEC 11x controller unit) The "Control is ready" output of the iTNC 530 HSCI switches, for example, a relay whose contacts are part of the EMERGENCY STOP chain.
Page 225 Either the "Control is ready" output and input on the PLB 62xx system module or on the UEC 11x compact controller unit are used. Control-is-ready The iTNC 530 HSCI receives information on the status of the EMERGENCY STOP chain trough the two acknowledgement signals ES.A and ES.B (PLC inputs).
Page 226 Many analog servo drives provide a ready signal that can be evaluated by the PLC program of the iTNC 530 HSCI . Normally, the drive is only enabled, after the servo drives have reported that they are ready. --> Observe LEDs and LCD displays of the drives! A number of servo drives do not provide a "ready"...
Page 227: Examination
The iTNC 530 HSCI features comprehensive diagnosis tools, such as DriveDiag, HSCI bus diagnosis, PLC-TRACE or PLC-TABLE. These diagnosis tools are suitable for checking the enables on the iTNC 530 HSCI . Moreover, the service engineer requires measuring equipment, such as a multimeter, etc.
Page 228 Control-is-ready Activation --> See ”HSCI bus” on page 12 – 147. in the HSCI bus diagnosis Excerpt from Here you can see the terminals on PLB 62xx that can be measured. the basic circuit diagram February 2012 17 – 229...
Page 229 If the error message EMERGENCY STOP defective is displayed or if the following display appears ... EMERGENCY STOP defective ... that provides the following information after you have entered the PLC code number ..carry out the error diagnosis as follows: 17 – 230 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 230 Error message 'EMERGENCY STOP defective' or EMERGENCY STOP wiring faulty Switch on the main switch of the machine; confirm the Power interrupted message. Do not yet press the CONTROL ON key! Measure the voltage at the Control is ready. input (UEC 11x: X4/1a or PLB 62xx: X9/1a) Find the cause (e.g.
Page 231: Axis-Specific Drive Enable Via Axis Groups
Check (e.g. by means of the HSCI bus diagnosis or in the PLC table), whether the PLC input for the axis group to be traversed is set to the value 1. Measure, whether 24 V are available at the PLC input for the axis group to be traversed. 17 – 232 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 232: Readiness Of The Inverter System
17.2.3 Readiness of the inverter system Switch on the machine. Check with DriveDiag, whether the power supply unit is ready and the DC-link voltage built up: Power supply unit Activation --> See ”DriveDiag” on page 9 – 91. in DriveDiag Check with DriveDiag, whether the power modules are ready: Power module in DriveDiag...
Page 233 Open the electrical cabinet and check, whether the compact inverter / power supply unit / UEC 11x controller unit with integrated inverter are ready (green READY LEDs). on the drives (Non-HEIDENHAIN inverters presumably feature such an LED or display as well.) Inverter Green LED...
Page 234 HEIDENHAIN expansion board for the SIMODRIVE system for the axis to be traversed / the spindle to be rotated. (A non-HEIDENHAIN inverter is probably also equipped with a corresponding LED or display.) Figure: READY LEDs on a two-axis module Note The UEC 11x compact controller units feature LEDs that can change color from red to green.
Page 235 SH2 / STO B is indicated by a red LED on the inverter system SH 2 / STO B is generated by the controller (CC 61xx or UEC 11x) of the iTNC 530 HSCI SH 2 / STO B is low-active, i.e. line-break proof If an axis or spindle is not controlled, SH 2 / STO B is active and the red LED is on.
Page 236 LEDs SH 1 and SH 2. For further information on the drives please refer to the service manual "Inverter Systems and Motors". Figure: LEDs READY, SH 1 and SH 2 on a HEIDENHAIN expansion board February 2012 17 – 237...
Page 237: Plc Modules, Markers And Words For Drive Enabling
Call the PLC TABLE of the words. Set the display to HEX. Check the value in the word 1024 or the double word 1100. The word W1024 contains the axes enabled by the NC. 17 – 238 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 238 Check the value in the word W1060 or the double word 1172, or whether the marker 4563 is set. The word W1060 contains the axes for which the feed rate was individually enabled by the PLC. If the marker M4563 is set, the PLC enables the feed rate in all axes. (Either W1060 or M4563 is used.) Check the value in the word 1040 or the double word 1132.
Page 239: Emergency Stop Test During Switch-On
(ES.A, ES.B, STO.A.G). But it still applies that, in the event of an error, a drop-off of the control-is-ready output (MC.RDY or STO.A.G) always triggers an emergency stop. 17 – 240 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 240 Time diagram Time diagram of essential signals after the control is booted and during the self-test: Step Function Screen display Start of the self-test, immediately after compilation of the Pop-up window PLC program Self test Phase 1 of the self-test: HSCI components are Triggering and detection of essential internal signals are tested.
Page 241 24 V- supply of connector X9/1a (PLB 62xx) or X4/1a (UEC 11x) is missing MC defective Wiring defective, contactors defective or too slow Troubleshooting See “"Control is ready" output and input (EMERGENCY STOP chain)” on page 17 – 228. 17 – 242 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 242: Power Supply
18 Power supply 18.1 Introduction A machine tool uses different voltages ranging from few volts up to almost 1000 volts. Some examples: 5 V voltage for powering the electronics 24 V voltage for powering the PLC 12 V voltage for powering the handwheel 650 V dc-link voltage for powering the drives The voltages are supplied from different voltage sources.
Page 243 Motor holding brakes PLC sensors and actors PLC component (PLC input/output assemblies) of PLB 6xxx and PLB in UxC The CC 6xxx controller unit is powered via the X69 supply bus of the HEIDENHAIN supply module and X74 (+5 V). When using...
Page 244 Message If the 24 V power of an HSCI component is already missing on power-on, the HSCI bus system does Hardware/firmware not detect this component. change detected The message Hardware/firmware change detected is displayed during startup. Example: During startup, the 24 V NC supply is missing at X3/terminal 1 of a PLB 62xx. The PLB 62xx is not detected by the HSCI bus system.
Page 245: Psl 130 Low-Voltage Power Supply Unit
The connection to X33 is obligatory, that to the conductor bar optional, though recommended by HEIDENHAIN. Further information and connector layouts --> See ”Connector designations and pin layouts” on page 28 – 453. Power consumption: max. 1000 W Internal protection: 18 – 246 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 246 LED display The operational status indicator is the green ON LED: Functional check Is the green ON LED lit? Are the fans running? Are the output voltages +24 V NC and +24 V PLC present? Possible causes Supply voltage missing at L1 and L2 of error Fan has failed Fuse on board of the PSL 130 has blown...
Page 247 Check the fuses. Exchange the fuses as Fuses OK? described in this chapter. The PSL 130 is defective and must be replaced. 18 – 248 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 248 Fuses in the PSL 130 DANGER Danger of electrical shock! A switching power supply is located in the PSL 130. This switching power supply may still be under voltage although separated from the power source. (Without consumer, the voltage on the board only reduces very slowly.) Therefore, do not touch the board or the fuses with bare hands! Use insulated pincers, if you intend to remove the fuses!
Page 249: Psl 135 Low-Voltage Power Supply Unit
Further information and connector layouts --> See ”Connector designations and pin layouts” on page 28 – 453. Power consumption: max. 1000 W Internal protection: LED display The operational status indicator is the green ON LED: 18 – 250 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 250 Functional check Is the green ON LED lit? Are the fans running? Are the output voltages +24 V NC and +24 V PLC present? Is the +5 V output voltage present? Possible Supply voltage missing at L1 and L2 causes of error Fan has failed Fuse on board of the PSL 135 has blown PSL 135 defective...
Page 251 Danger: There could still be residual voltage in the power supply unit; do not touch any components! Check the fuses. Exchange the fuses as Fuses OK? described in this chapter. The PSL 135 is defective and must be replaced. 18 – 252 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 252 Uz of a When using a non-HEIDENHAIN inverter system (e.g., Simodrive 611), the power supply from HEIDENHAIN the DC-link is mostly conducted via a protective PCB. This board is mounted to the conductor bars of inverter system non-HEIDENHAIN inverter. DANGER...
Page 253 Mounting the PSL 135 DANGER Do not confuse the leads for the +24 V NC and +24 V PLC supply voltages! Restore the ground connections by means of lines and/or conductor bars! 18 – 254 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 254: Power Supply For The Mc 62Xx Computer Unit
18.5 Power supply for the MC 62xx computer unit Device powering the MC 62xx Connector for MC 62xx Devices powered by the MC 62xx (alternatives) power supply UEC 11x X101 USB devices PSL 130 TE 6xx PSL 135 Further information and connector layout of X101 --> See ”Connector designations and pin layouts” on page 28 –...
Page 255 One possibility is the USB hub from HEIDENHAIN. Disconnect all USB devices, the RS-232-C and Ethernet interfaces and the TE 6xx keyboard unit from the MC 62xx. 18 – 256 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 256: Buffer Battery
18.6 Buffer battery Introduction The buffer battery ... is the power source for the RAM when the machine is switched off. is mounted inside the MC 62xx. has a rated voltage of 3 V. has a typical service life of three to five years. For safeguarding the RAM data during battery exchange, a special capacitor ("Gold cap") was integrated onto the PCB of MC 62xx.
Page 257 Remove the old buffer battery. Insert the new buffer battery. Due to the non-symmetric shape of the battery there is only one possibility of inserting. Battery type: Lithium battery, type CR 2450N (Renata), ID 315878-01 18 – 258 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 258 Note The buffer battery can be purchased from specialized dealers (e.g. www.renata.com). Screw the cover plate back on and remount the MC 6222 in the console. Note If the battery was exchanged although the Gold cap was not loaded sufficiently, the battery- buffered ranges of the RAM may be deleted.
Page 259 --> Ask the machine tool builder! The datum and the time of the BIOS setting were lost. Set these values again. --> See ”Setting the system time” on page 13 – 173. 18 – 260 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 260: Information Menu
18.7 Information menu Activation Enter the code number 79513. Press ENTER to confirm. --> The following screen appears: Description The following information is displayed on the screen (the stack information is not important for the service technician): U [BATT] 3.049 V Voltage of buffer battery U [ACCU] 3.049 V...
Page 261: Power Supply Of The Cc 61Xx Feedback Control Unit
Polyfuses are equipped with a self-resetting function ("self-healing effect"). LED display The CC 61xx features green LEDs (on top) as operational status indicators for each drive-control board; these LEDs indicate the HSCI address by a blink code. 18 – 262 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 262 Power supply via compact inverter February 2012 18 – 263...
Page 263 Power supply via modular inverter system 18 – 264 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 264 Error messages Note The most important voltage for powering the electronics is the 5 V supply voltage. The control monitors these 5 V and generates an error message (e.g. CC +5V out of tolerance), if the deviation becomes too large. Other error messages that may be displayed: B900 CC supply voltage 5-V power supply too high...
Page 265 Figure: Display of the +5 V supply voltage of the drive-control boards in the CC with DriveDiag Disconnect the position and speed encoders and the PWM outputs from the CC (label them beforehand). Then observe, whether the 5 V voltage is stable. 18 – 266 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 266: Power Supply Of The Uec 11X Feedback Control Unit
18.9 Power supply of the UEC 11x feedback control unit Power supply of UEC 11x Connector for UEC 11x Devices and outputs powered power supply by UEC 11x 3 x 400 Vac (+/- 10%) MC 62xx Speed encoders 3 x 480 Vac (+/- 10%) Position encoders Touch probes PLC outputs...
Page 267: Power Supply Of The Mb 620 Machine Operating Panel
If available: Check the function of the connected handhweel. You may have to disconnect it from the MB. In the window Hardware/firmware change detected, click reject and then call the HSCI bus diagnosis. --> See ”Bus diagnosis” on page 12 – 147. 18 – 268 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 268: Power Supply Of The Bf 250 Visual Display Unit
If USB components that are connected to X141 to X144 require more than 0.5 A, a separate power supply becomes necessary for these components. One possibility is the USB hub from HEIDENHAIN. Disconnect all USB devices and the TE 6xx keyboard unit from the BF 250.
Page 269: Power Supply Of The Te 6Xx Keyboard Unit
USB hub fromHEIDENHAIN. Disconnect the USB devices from the USB connector type A on the TE 6xx. Figure: USB connectors type A and B on the rear side of the TE 630 18 – 270 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 270: Power Supply For The Control-Is-Ready Signal
Note The Control-Is-Ready output must be integrated correctly in the EMERGENCY STOP chain. --> See ”Annex: Basic circuit diagrams of the iTNC 530 HSCI control” on page 2 – 651. Troubleshooting UEC 11x: Measure the 24 V voltage at connector X4 between terminal 1a and 6a (tolerance range 20.4 - 28.8 V).
Page 271: Power Supply Of The Plb 62Xx System Module
If the 24 V PLC voltage at X3 / terminal 4 drops during machine operation, the following error messages may be issued: Try to delete all error messages with the CE key. --> The permanent errors will remain in the ERR list. 18 – 272 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 272 If the 24 V-PLC supply voltage at X3 / terminal 4 is already missing during startup, the PLB 62xx is not found in the HSCI bus system. The message Hardware/firmware change detected is displayed. --> See ”Message Hardware/ firmware change detected” on page 18 – 245. If the 24 V NC voltage at X3 / terminal 1 drops during machine operation, the following error messages may be issued: Try to delete all error messages with the CE key.
Page 273: Supply Voltage For Plc Outputs
18.15 Supply voltage for PLC outputs 18.15.1 Introduction The following components of iTNC 530 HSCI have PLC outputs: UEC 11x PLB 62xx PLD-H 16-08-00 PLD-H 08-16-00 MB 620 The PLC outputs are powered by the 24 V control voltage of the machine (in accordance with VDE 0551).
Page 274: Supply Voltage For Plc Outputs On The Uec 11X
18.15.2 Supply voltage for PLC outputs on the UEC 11x X31: Pin layout on the UEC 11x Connecting terminal Assignment 400 Vac +/- 10% 50 Hz to 60 Hz Error messages and analysis with incorrect power supply at X31 --> See ”Power supply of the UEC 11x feedback control unit” on page 18 – 267. 18.15.3 Supply voltage for PLC outputs on the MB 620 X101: Assignment on MB 620:...
Page 275: Supply Voltage For Plc Outputs On The Pld-H Xx-Xx-Xx
(depending on the PLC outputs concerned). Troubleshooting Observe the LEDs on the PLD-Hxx-xx-xx input/output module. Further analysis --> See ”Bus diagnosis” on page 12 – 147. 18 – 276 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 276: Encoder Interface
19 Encoder interface 19.1 Position encoders 19.1.1 Introduction Position encoders are also referred to as linear encoders or angle encoders. They report positions and movements of the machine to the control. The iTNC 530 operates with incremental and absolute encoders. Permissible encoders: Encoders with one reference mark Encoders with distance-coded reference marks...
Page 277 X203 7.5 A (stronger axis) X204 UEC 112 Motor output Rated current at 5 kHz Speed input Position input 20 A (spindle) X201 X202 X203 7.5 A (stronger axis) X204 X205 19 – 278 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 278: Machine Parameters
EnDat encoders EnDat encoders may be connected to all position encoder inputs of a CC 61xx or a UEC 11x. Memory areas in EnDat encoders offer the possibility of storing machine or system-dependent data in the memory the EnDat encoder area reserved for the machine tool builder.
Page 279: Error Messages
Position encoder: Amplitude too high Position encoder: Amplitude too small Position encoder defective Position encoder: Frequency too high Ref. mark: Incorrect spacing Note Other error messages may also indicate problems with a position encoder. 19 – 280 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 280: Possible Error Causes
19.1.4 Possible error causes Contamination of the position encoder Chips inside the scale housing Damage to the position encoder Scanning head misaligned (parallelism, distance, etc.) Roller bearing in scanning head defective Cable damaged Signal error caused by high frequency, strong magnetic fields, etc. Penetration of humidity Short circuit in cable or scanning head Light unit defective (LED)
Page 281 Swapping power output stages with different rated currents for testing and not assigning them correctly (MP2100.x) may cause damage to the machine or personal injury! DANGER Always secure vertical axes to prevent them from falling down before you perform tests on these axes! 19 – 282 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 282 Block diagrams for axis swapping Figure: Swapping axes on a CC 61xx Figure: Swapping axes on a UEC 11x Note Always swap both the cable and the interface assignment by machine parameter! February 2012 19 – 283...
Page 283 After you have restored the cables and parameters to their original state, enter the original values in MP7690 (evaluation of the electronic ID labels). Note This flowchart does not apply for swapping a single-speed with a double-speed axis! 19 – 284 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 284 Swapping axis and spindle on a CC 61xx Before the exchange, deactivate the evaluation of the electronic ID labels. For this purpose enter the value 1 for each bit in MP7690. Shut down the control and switch off the power switch at the machine tool. Label and swap the position and speed encoder cables and the PWM outputs of the spindle and the axis concerned at the CC 61xx (e.g.
Page 285 After you have restored the cables and parameters to their original state, enter the original values in MP7690 (evaluation of the electronic ID labels). Note This flowchart does not apply for swapping a single-speed with a double-speed axis! 19 – 286 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 286 Look up in MP130.x how the axes are assigned in the parameter group MP2xxx.y. In MP2100.x correctly assign the power modules for the axes concerned. (E.g. MP2100.0: HEIDENHAIN-UEC1xx-X83, MP2100.2: HEIDENHAIN-UEC1xx-X81, X82, X84). Is the same Enter 5 kHz for all frequency entered in axes/spindles for testing.
Page 287 Look up in MP131.x/132.x how the spindle is assigned in the parameter group MP2xxx.y. In MP2100.x correctly assign the power modules for the spindle and the axis concerned. (e.g. MP2100.0: HEIDENHAIN-UEC1xx-X80, MP2100.12: HEIDENHAIN-UEC1xx-X81, X82, X84). Is the same Enter 5 kHz for all frequency entered in axes/spindles for testing.
Page 288: Possibilities With Drivediag
19.1.6 Possibilities with DriveDiag EnDat position On the info screen "EnDat Position Encoder" you can see, whether alarm bits are set: encoder Calling the screen --> See ”DriveDiag” on page 9 – 91. Position encoder The integrated diagnostic functions and DriveDiag also feature a simple position encoder test: test Calling the screen -->...
Page 289: Possibilities With The Integrated Oscilloscope
Move the X axis at very low speed in the manual mode. Start the oscilloscope recording. Stop recording. Adapt the signals taking the zero line into account. Adapt the time axis to get a more detailed view. 19 – 290 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 290 The A and B signals must be of equal size and move symmetrically about the same vertical axis (no vertical offset)! The 90° offset of the signals A and B on the horizontal axis is clearly visible. A drop of the amplitudes during traverse could e.g. be an indicator of a contaminated scale section. If the amplitude is too low in standstill, the scanning head may be contaminated.
Page 291 Observe the signal in the oscilloscope while traversing the X axis at low speed: If signal evaluation is correct, a circle will be displayed. If the display shows an oval, the scanning head is probably poorly adjusted or partly contaminated. 19 – 292 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 292: Corrective Action
0.6 ... 1.2 Vpp For 11 µApp encoders: 7 ... 16 µApp The exact tolerances of the encoders can be found in the HEIDENHAIN mounting instructions and brochures. Note The scanning head of an EnDat linear encoder is programmed to match the scale (datum shift, etc.)
Page 293: Determining The Field Angle On Linear Motors, Torque Motors And Synchronous Spindles
The method of defining the field angle of the respective axis / spindle is defined by the machine manufacturer. Follow the instructions of the machine manufacturer. Note If only the scanning unit (AE) of an encoder was exchanged, the field-angle adjustment may not be required. 19 – 294 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 294: Resetting The Machine Datum
19.1.10 Resetting the machine datum As the machine datum (machine reference) refers to the position encoder datums, it may be necessary to reset it after removing and mounting scales, scale tapes, scanning heads or angle encoders. Note On simple 3-axis machines, it is often not required to reset the machine datum. Here, it is sufficient to the check the software limit switches and to reset them, if necessary.
Page 295 Set the display to ACTL. If necessary, ask the customer to mill a workpiece and check it for dimensional accuracy. Further information --> See ”Reference run” on page 20 – 323. 19 – 296 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 296 Gantry axes with two linear encoders Figure: Example of a combination of gantry and master-slave torque drive Note If a position encoder fails in a gantry combination, the machine datum stays as it is because of the second position encoder. As the mechanical structure is rigid (portal, etc.), the unchanged axis can be used to find the value for MP960.x for the axis to be reset.
Page 297 Set the display to ACTL. If necessary, ask the customer to mill a workpiece and check it for dimensional accuracy. Further information --> See ”Reference run” on page 20 – 323. 19 – 298 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 298: Restoring The Spindle Orientation
19.1.11 Restoring the spindle orientation If you have replaced an angle encoder used for oriented spindle stop (e.g. for tool change), you must now readjust the spindle preset. DANGER Ask the machine manufacturer and observe the machine manufacturers's safety precautions (set-up mode, etc.)! Set MP3430 to zero.
Page 299: Speed Encoders
On the CC 61xx there is a fixed assignment between the PWM output, the input of the speed on CC61xx and encoder and the input of the position encoder: UEC 11x CC 6106 PWM output Speed input Position input X201 X202 X203 X204 X205 X206 19 – 300 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 300 CC 6108 PWM output Speed input Position input X51A X15A X201A X52A X16A X202A X53A X17A X203A X54A X18A X204A X51B X15B X201B X52B X16B X202B X53B X17B X203B X54B X18B X204B CC 6110 PWM output Speed input Position input X51A X15A X201A...
Page 301: Machine Parameters
(connector X15 and following). MP121 contains the assignment of the spindles to the PWM/motor outputs and thus also to the speed encoder inputs (connector X15 and following). (In special cases, also refer to MP113.) 19 – 302 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 302: Error Messages
19.2.3 Error messages The following error messages may be displayed, if there are problems related to speed encoders: 8140 Error field orientation 8830 EnDat: No field angle 8860 Input frequency from speed encoder 8B00 Zn track error 8B20 Error field orientation 8BA0 Incorrect reference signal or line count 8BA0 Incorrect line count 8BF0 Input frequency from speed encoder...
Page 303: Troubleshooting
Swapping axes with different different rated current rated current on a UEC 11x Swapping single-speed axis <--> single-speed spindle or double- Swapping axis and spindle on a speed axis <--> double-speed spindle UEC 11x 19 – 304 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 304 Notes and CC 61xx: If axes/spindles with different power modules and motors are supposed to be swapped, these preparatory devices (if equipped with electronic ID labels) would try to log on to the control during start-up. action A new assignment would be requested according to the changed wiring, even before the service engineer can edit the machine-parameter values.
Page 305: Possibilities With Drivediag
19.2.6 Possibilities with DriveDiag On the info screen "EnDat rotational speed encoder" you can see, whether alarm bits are set: Calling the screen --> See ”DriveDiag” on page 9 – 91. 19 – 306 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 306: Possibilities With The Integrated Oscilloscope
19.2.7 Possibilities with the integrated oscilloscope With the integrated oscilloscope you can record the incremental signals (A, B ) of motor encoders. Activation and operation --> See ”Integrated oscilloscope” on page 10 – 95. Example of an oscilloscope recording of motor encoder signals: Make the following settings: Move the X axis at very low speed in the manual mode.
Page 307 The 90° offset of the signals A and B on the horizontal axis is clearly visible. The signals are displayed in mV. Now you can switch the oscilloscope display to XY (Lissajous figure): 19 – 308 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 308 Observe the signal in the oscilloscope while traversing the X axis at low speed: If signal evaluation is correct, a circle will be displayed. Note If the signal 'pumps' or fluctuates, the encoder does not work correctly. In most cases, the encoder is contaminated. February 2012 19 –...
Page 309: Corrective Action
If you have found that the motor encoder interface on the CC 61xx or UEC 11x is defective: components Exchange of CC 61xx or UEC 11x --> See ”Exchange of HEIDENHAIN components” on page 29 – 515. 19 – 310...
Page 310: Readjusting The Trip Dog For Reference End Position
19.2.9 Readjusting the trip dog for reference end position For position capture using a conventional motor encoder (not an EnDat encoder), one reference pulse is produced at each revolution of the encoder. To ensure that always the same reference pulse is evaluated when the machine is switched on, a trigger signal is used (PLC input).
Page 311: Resetting The Machine Datum
The procedure for restoring the spindle orientation when using motor encoders is the same as with angle encoders. --> See ”Restoring the spindle orientation” on page 19 – 299. 19 – 312 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 312: Error Codes For Encoders With Endat Interface
19.3 Error codes for encoders with EnDat interface In the event of a disturbance, the error message EnDat defective <error code> <axis> will appear. The error code is shown in hexadecimal notation. Error codes may also appear combined, in which case they are added together.
Page 313: Further Examination Of Position And Speed Encoders
Note A detailed explanation of the device is part of our training courses on measuring systems. We recommend that you participate in a HEIDENHAIN service training course so that you can use the PWM 9 correctly and efficiently. Contact HEIDENHAIN Traunreut or your regional agency.
Page 314 Note A detailed explanation of the device is part of our training courses on measuring systems. We recommend that you participate in a HEIDENHAIN service training course so that you can use the PWT correctly and effectively. Contact HEIDENHAIN Traunreut or your regional agency.
Page 315 Note A detailed explanation of the device is part of our training courses on measuring systems. We recommend that you participate in a HEIDENHAIN service training course so that you can use the IK 215 correctly and effectively. Contact HEIDENHAIN Traunreut or your regional agency.
Page 316: Position Measurement Via Motor Encoder (Indirect Position Measurement)
Normally, this quickly results in error messages such as Excessive servo lag, etc. and the control generates an EMERGENCY STOP. Moreover, the iTNC 530 HSCI runs an automatic plausibility check for the MP1040.x (sign of nominal speed value). The error message Incorrect entry in MP1040.x means that MP1040 must be inverted now.
Page 317 Press the soft key with the motor symbol. Press the SHOW ACTUAL VALUE soft key. Press the right arrow key until the cursor is in the STR column. Read the line count of the encoder (e.g. 2048). 19 – 318 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 318 Flowchart for an individual axis Position measurement via motor encoder (indirect position measurement) of an individual axis The machine is switched off. Press the EMERGENCY STOP button and turn the feed rate potentiometer to zero. Switch on the main switch of machine. Do not acknowledge the Power interrupted message but call the MP list.
Page 319 Incorrect entry in MP1040.x or sign of the nominal speed Movement monitoring, Standstill value) or MP210.x monitoring, etc.? (counting direction of the position encoder signals). Now you can traverse carefully with indirect position measurement. 19 – 320 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 320: Switching Over The Position Display For Servicing
19.6 Switching over the position display for servicing When servicing it is often important to switch over the position display (e.g., to REF when resetting the machine datum). Activation Press the following key combination to switch the position display: Select a machine operating mode (Manual Operation, Program Run/Full Sequence, etc.) Press the MOD key.
Page 321 19 – 322 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 322: Reference Run
Reference marks HEIDENHAIN linear encoders (except EnDat) feature one or more reference marks. The reference marks identify an axis position at a known distance from the machine datum. The position of the datum selected by the machine operator is defined with respect to the machine datum.
Page 323: Traversing The Reference Marks
(inside the scale housing, where there is the ref. mark label on the outside the scale housing) Enamel wiped off or damaged (On some scales the ref. marks were deactivated with enamel; if it is removed by using unsuitable cleaning agents and equipment, these marks are "reactivated".) 20 – 324 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 324: Troubleshooting
20.5 Troubleshooting Examining the See “Encoder interface” on page 19 – 277. encoders Examining the See “Further examination of position and speed encoders” on page 19 – 314. reference mark Examining the Ask the machine manufacturer for the PLC input for the trigger signal. trigger signal of Move the axis to the presumed position of the trip dog.
Page 325: Corrective Action
(filler pieces)! Readjust the displaced ref. mark selector plate. Use a special slider for this purpose. --> Ask a HEIDENHAIN service agency! Have the removed or damaged enamel repainted. --> Ask a HEIDENHAIN service agency! Adjust the trip dog to the reference pulse of the motor encoder. --> See ”Readjusting the trip dog for reference end position”...
Page 326: Interfaces To The Drives
21.1 Digital PWM interface 21.1.1 Introduction HEIDENHAIN controls feature position, speed and current controllers. The "result" of position, speed and current control - i.e. the controller output - is pulse-width modulated. Digital servo amplifiers are controlled via PWM interfaces (PWM = pulse-width modulation).
Page 327 Position input X51A X15A X201A X52A X16A X202A X53A X17A X203A X54A X18A X204A X51B X15B X201B X52B X16B X202B X53B X17B X203B X54B X18B X204B X55B X19B X205B X56B X20B X206B 21 – 328 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 328 On the UEC 11x there is a fixed assignment between the motor output, the input of the speed encoder and the input of the position encoder: UEC 111 Motor output Rated current at 5 kHz Speed input Position input 20 A (spindle) X201 X202 X203...
Page 329: Machine Parameters
If a control loop is operated at double the fundamental PWM frequency, the current controller cycle time is halved. However, this is possible only with double-speed control loops. In a configuration with double-speed control loops and higher PWM frequencies the adjacent PWM outputs are not active! 21 – 330 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 330 Machine Meaning Examples stages and motors parameter MP2100 Power stages (inverter modules) and HEIDENHAIN UM121BD output stages that are used HEIDENHAIN UEC1xx-X81,X82,X84 MP2196 Designator for the power supply module P, Q, R or T defined in MP2198.x (e.g. to display the power supply...
Page 331: Tables For Power Supply Modules, Power Stages And Motors
UEC1xx inverter. Note The original HEIDENHAIN table of the power supply modules is stored in the SYS partition of the data medium. The OEM can create his own table of power supply modules (with additional power supply modules and/or edited data) which is stored in the PLC partition of the data medium.
Page 332 Press the SHOW ACTUAL VALUE soft key. --> The specifications of the selected power supply module are displayed: You can now move the cursor in the line of the highlighted power supply module and read all available data. Note The meaning of the selected column is displayed in the header (e.g. Rated power [W]). Press the END key to exit the supply module table.
Page 333 HEIDENHAIN controller units with integrated UEC1xx inverter. Note The original HEIDENHAIN table of the power stages is stored in the SYS partition of the data medium. The OEM can create his own table of power stages (with additional power stages and/or edited data) which is stored in the PLC partition of the data medium.
Page 334 Attention The specifications of the power modules depend on the PWM frequency. As a rule, HEIDENHAIN power modules are operated at 5000 Hz. Check the PWM frequency selected for this axis in MP2180. Highlight the correct line! Note The meaning of the selected column is displayed in the header (e.g.
Page 335 Note The original HEIDENHAIN motor table is stored in the SYS partition of the data medium. The OEM can create his own motor table (with additional motors and/or edited data) which is stored in the PLC partition of the data medium.
Page 336 Press the SHOW ACTUAL VALUE soft key. --> The specifications of the selected motor are displayed: You can now move the cursor in the line of the highlighted motor and read all available data. Attention Especially spindle motors can be operated with wye or delta connection (depending on the spindle speed).
Page 337: Reading Out Power Module Data
When the control is started up, the CC 61xx controller unit fetches the data (ID number, serial number, etc.) of the HEIDENHAIN power modules (UM xxx D) via the PWM ribbon cables. The sequence for reading out is defined by the HSCI addresses of the controller basic boards (MP108/MP109) and the connectors (X51, X52 and following) on the CC 61xx.
Page 338: Error Messages
21.1.5 Error messages The following error messages may be displayed, if there are problems related to drives: Possible error messages 8040 Heat sink temp. in UV 1xx E150 Inverter ready 8041 Excessive Iz in UV 1xx E160 Inverter is not ready 8042 Leakage current in UV 1xx Axis motor current not equal 0 8043 No inverter-ready signal...
Page 339: Possible Error Causes
Poor shielding and grounding HEIDENHAIN expansion board for the SIMODRIVE 611 drive system defective Old HEIDENHAIN expansion board in a modified SIMODRIVE 611 power module Wrong grounding in connection with the HEIDENHAIN expansion boards PWM interface or CC 61xx defective...
Page 340: Error Finding: Axes Swapping
21.1.8 Error finding: Axes swapping To find out whether the connected drive system or the PWM output of the CC or the motor output of the UEC is defective, you can use the interchange method. Note Error messages related to the drives of a machine tool are mostly caused by the machine tool (mechanics, hydraulic/pneumatic system, lubrication), the tools or the electrical drives (motors, power modules, output stages of a UEC) themselves.
Page 341 If you have found that the error is outside the CC 61xx (servo amplifier, motor, cables, etc.) run the following routine. --> See ”Error finding: Swapping power modules or output stages of the same type” on page 21 – 343. 21 – 342 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 342: Error Finding: Swapping Power Modules Or Output Stages Of The Same Type
Or a replacement unit Note It is not necessary to swap any machine parameters for this test routine! It is of no importance, whether the power stages in the machine are from HEIDENHAIN or other manufacturers. DANGER Before you connect drives to other interfaces for error localization: Make sure that there are no ground faults or short circuits in the drive components (inverters, motors, etc.) -->...
Page 343 Systems and Motors)! Background: Motor brakes can be connected to current HEIDENHAIN power modules (inverter modules) and compact inverters. The motor brake is also powered with 24 V via a connector on the inverter. The trigger signals for the motor brakes are transmitted via the PWM bus.
Page 344 Systems and Motors)! Background: Motor brakes can be connected to current HEIDENHAIN power modules (inverter modules) and compact inverters. The motor brake is also powered with 24 V via a connector on the inverter. The trigger signals for the motor brakes are transmitted via the PWM bus.
Page 345 PWM ribbon cable or (e.g. from X to Y)? the interface at the control. It is likely that the power module or the output stage is defective. 21 – 346 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 346: Error Finding: Swapping The Heidenhain Expansion Boards For The Simodrive 611 System
21.1.10 Error finding: Swapping the HEIDENHAIN expansion boards for the SIMODRIVE 611 system When a SIMODRIVE 611 system is used with a HEIDENHAIN control, there are HEIDENHAIN expansion boards in the SIEMENS drive modules to adapt the PWM signals. Attention...
Page 347: Corrective Action
Replace the CC 61xx. --> See ”Exchanging the CC” on page 29 – 550. If you have found that the UEC 11x controller unit is defective: Replace the UEC 11x. --> See ”Exchanging the UEC” on page 29 – 551. 21 – 348 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 348: Analog Speed Value Interface
The module is inserted into a slot of the CC 61xx or UEC 1xx controller units. For the operation of analog axes and spindles, the position controller is in the HEIDENHAIN control, the speed controller and the current controller are in the analog servo amplifier.
Page 349: Machine Parameters
The following error messages may be displayed, if there are problems related to analog drives: Movement monitoring Nominal speed value too high Excessive offset Positioning error Excessive servo lag Standstill monitoring Note Other error messages may also indicate problems with an analog drive. 21 – 350 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 350: Possible Error Causes
21.2.4 Possible error causes Excessive machining feed rate Spindle speed too low Blunt tool Insufficient lubrication Mechanical shock, strong machine vibrations Mechanical stiffness Wear and tear of mechanical parts, aging of the machine tool Mechanical defects Fault in hydraulics Fault in pneumatics Overloaded driver Motor (carbon brushes, tachometer brushes, winding, etc.) defective Servo defective...
Page 351: Checking The Analog Speed Value Interface
"STIB" symbol (control-in-operation) must be displayed when NC START or an axis-direction button is pressed, the feed rate display (F ...) must not be highlighted, the position display (ACTL, NOML) changes when the axis moves. If necessary, ask the machine operator! 21 – 352 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 352 Flowchart Analog axis does not move Shut down the control and switch off the power switch at the machine tool. Connect the multimeter to the terminal block of the servo drive of the axis to be inspected (use the circuit diagram of the machine tool). Press EMERGENCY STOP, turn the feed-rate potentiometer to minimum and switch on the power switch of the machine.
Page 353 CMA-H (in CC 61xx or UEC 11x) or nominal speed value cable defective. Battery box If you have a "battery box" (not a HEIDENHAIN product), you can check whether the analog servo amplifier can be operated with it. This battery box replaces the control and provides the analog servo amplifier with a nominal speed value around ±10 V.
Page 354: Adjusting The Electrical Offset (Drift Adjustment)
CMA-H 04-04-00 Note Offset adjustment is only required for analog axes or spindles. First the analog servo amplifier is adjusted, followed by fine adjustment in the HEIDENHAIN control. Offset adjustment at the analog servo...
Page 355 (and possibly on a pulley in addition). Restore the original condition (cabling, parameters). Carry out offset fine adjustment with the code number 75368. -->See ”Offset fine adjustment in the control” on page 21 – 357 21 – 356 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 356 Offset fine adjustment in the control Note Before you carry out offset fine adjustment via code number, you must first adjust the offset at the servo amplifier! With the offset fine adjustment via code number the control can only compensate ±100 mV. This corresponds to 1% of the ±10 V interface.
Page 357: Speed Adjustment At The Servo Amplifier (Tachometer Adjustment)
Suggestion for performing the adjustment Note Analog servo amplifiers are not HEIDENHAIN products. Follow the instructions of the servo manufacturer (operating instructions, etc.)! Below you find a proposal: Set the machine parameter as follows (note down its original value): • MP7290.x (display step): 6 (0.1 µm)
Page 358 Using the servo lag display, adjust the tachometer at the servo amplifier as follows: Operation with ... Displayed servo lag Velocity feedforward control Ideally 0 Servo lag According to the following formula: Traversing speed LAG [mm] = kv factor Note Read the traverse speed from the display.
Page 359: Corrective Action
If you have found that the analog servo amplifier or the motor is defective: components Replace the drive component. --> Ask the respective manufacturer. Control If you have found that the CMA-H 04-04-00 is defective: components Replace the CMA-H 04-04-00. 21 – 360 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 360: Visual Display Unit
Note If USB components that are connected to the MC 6222 or BF 250 require more than 0.5 A, a separate power supply becomes necessary for these components. One possibility is the USB hub from HEIDENHAIN. Power distribution switches Note The MC 6222 and BF 250 feature power distribution switches.
Page 361: Possible Error Causes
24 Vdc (e.g. +24V-NC from PSL 130). receives display signals from the MC 6241. The HDL display interface (HEIDENHAIN display link) ... Connector X249 on the MC 6241 Connector X2 on the BF 250 ... is HEIDENHAIN-specific.
Page 362: Troubleshooting
530 HSCI may be data on your laptop? defective. The graphics card of the iTNC 530 HSCI is probably OK. Note By means of a dongle for the USB interface, TNCremoNT can be enhanced to TNCremoPlus. With this version you can view the control display on your service laptop.
Page 363: Corrective Action
If you have found that the BF 250 is defective: Exchange the BF 250. If you have found that the MC 6222 is defective: Replace the MC 6222. --> See ”Exchanging the MC 6222” on page 29 – 531. 22 – 364 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 364: Keyboard Unit
23 Keyboard unit 23.1 Introduction Photo: TE 630 Photo: TE 635 Q (keyboard and machine-operating panel) February 2012 23 – 365...
Page 365 These are electronic fuses that separate USB devices that draw too much current from the TE 6xx. Active handwheel If an HR 520 electronic handwheel is active, machine operation via keyboard is locked. 23 – 366 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 366: Signal Paths In The Console And To The Mc 62Xx
23.2 Signal paths in the console and to the MC 62xx The illustration below shows: Signal paths Signal directions Power supplies Different bus systems Various cables Fig.: Signal paths in the console and to the MC 6241 February 2012 23 – 367...
Page 367 Fig.: Signal paths in the console when using an MC 6222 23 – 368 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 368: Possible Error Causes
23.3 Possible error causes Heavy contamination --> Key functions may be impaired. Jammed chips --> Key gets stuck. Pressure contact defective. --> Key no longer reports actuation. Note Defective keys either do not contact any more or are in permanent contact. Liquid has penetrated Defective keyboard PCB Defective ribbon cable between screen and keyboard (screen soft keys)
Page 369: Checking The Keys
Press the key to be examined and check, if the display changes to a key code or if the reaction expected for this key takes place. Figure: Key code in the PLC table 23 – 370 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 370 Note The key code is of secondary importance. Important is, whether or not the control detects the keystroke. The key code can bee seen very well in the integrated oscilloscope: Switch on the machine. Press the EMERGENCY STOP button. Call the integrated oscilloscope. --> See ”Integrated oscilloscope” on page 10 – 95. Make the following selection: Start recording.
Page 371 If a key does not produce a reaction of the control, one does not know, whether the pushbutton itself or the keyboard PCB, the USB cable or the control component is defective. Further tests can be performed. --> See descriptions later on in this chapter. 23 – 372 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 372 The USB interfaces on the MC 6222 or BF 250 are defective. Note The key assignment of a HEIDENHAIN keyboard differs from that of a standad computer keyboard. For example, F12 switches the screen, and the DEL key on the numerical keypad executes the CE command.
Page 373 PCB. Press this key. Is there any reaction? The matrix lines (plug connections, soft-key rows, keyboard PCB) are okay! It is likely that the key's pressure contact is defective. 23 – 374 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 374 Measure An almost complete statement about the condition of the keys can be made by way of ohmic key matrix measurement of the key matrix. Shut down the control and switch off the machine. Attention Observe the ESD precautions. --> See ”Important information” on page 29 – 515. Remove the keyboard from the console.
Page 375: Checking The Potentiometers
Check, whether the display changes from 0 to 15000 (with nonlinear characteristic curve) or from 0 to 150 (with linear characteristic curve). The characteristic curve is defined in MP7620, bit 3. 23 – 376 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 376 Potentiometer You can also use the integrated oscilloscope to record the states of PLC operands. values in The advantage of this method is that possible interruptions of the potentiometer wipers can be the integrated detected more easily than in the PLC TABLE. oscilloscope Proceed as follows: Switch on the machine.
Page 377 Shut down the control and switch off the machine. Reconnect the ribbon cable; make sure that the connection is correct. If necessary, check whether the connection on the MB 620 is correct. 23 – 378 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 378 Measure Switch off the machine, take precautions against resetting, ensure that the equipment is free of potential. potentiometer values directly Dismount the keyboard. Disconnect the ribbon-cable connector of the potentiometer. Using a multimeter, check the resistances of the potentiometer. (Normally, pin 1 is distinguished by a colored strand of the ribbon cable and a notch on the ribbon connector.) Measurement between the pins Resistance value...
Page 379: Checking The Touchpad
Test the function. Note The laptop must feature a Windows operating system with the appropriate mouse driver. If necessary, adapt the Windows settings. --> "My computer / Control Panel / Mouse ..." 23 – 380 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 380: Corrective Action
If you have found that the USB interface of the TE 6xx or MC 6222 or BF 250 is defective, replace components the control component. --> See ”Exchange of HEIDENHAIN components” on page 29 – 515. February 2012 23 – 381...
Page 381: Key Matrix Of The Keyboard Units
RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 Picture showing the assignment of X57 --> See ”Terminal strip X57 for the key matrix” on page 23 – 375. 23 – 382 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 382 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 February 2012 23 – 383...
Page 383 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 23 – 384 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 384 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 February 2012 23 – 385...
Page 385 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 23 – 386 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 386 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 February 2012 23 – 387...
Page 387 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 23 – 388 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 388 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 February 2012 23 – 389...
Page 389 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 23 – 390 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 390 X57 Pin RL11 RL12 RL13 RL14 RL15 RL16 RL17 RL18 RL19 RL20 RL21 RL22 RL23 X57: 50-pin terminal strip on the keyboard PCB of the TE 6xx Note The two keys left of the touchpad do not belong to the key matrix. When these keys are pressed, the signal is directly transmitted to the control via USB interface.
Page 391: Key Matrix Of The Screen Soft Keys
V soft key 2, etc. The arrow keys for the switching of the soft-key rows are logged. Any newly called soft-key row starts with soft key 0 or V soft key 0. 23 – 392 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 392: Machine Operating Panel
24 Machine operating panel 24.1 Introduction HEIDENHAIN machine operating panel MB 620 with axis axis-direction keys for up to six axes: Normally, the MB is installed below or already integrated in the TNC keyboard (as with TE 635 Q). On the MB 620 machine operating panel there are:...
Page 393 The descriptions for the MB 620 in this chapter also apply for the HSCI adapter PLB 6001. Signal paths Overview --> See ”Signal paths in the console and to the MC 62xx” on page 23 – 367. 24 – 394 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 394: Possible Error Causes
24.2 Possible error causes Heavy contamination. --> Key functions may be impaired. Jammed chips. --> Key gets stuck. Pressure contact defective. --> Key no longer reports actuation. Note Defective keys either do not contact any more or are in permanent contact. Defective switch (EMERGENCY STOP, CONTROL ON, NC START, NC STOP) Note If the NC STOP signal (low-active) between MB and control is interrupted, the machine cannot...
Page 395: Checking The Power Supply
In the window Hardware/firmware change detected, click reject and then call the HSCI bus diagnosis. --> See ”Bus diagnosis” on page 12 – 147. Check the status of the MB 620. 24 – 396 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 396: Checking The Keys
24.5 Checking the keys Correct operation? Ensure that the key really has to function in the selected operating mode. --> Consult the machine operator or the User's Manual! Visual inspection Start with a visual inspection: Is the key heavily contaminated (grease, dust, oil, etc.)? Are there any jammed chips? The key may thus get stuck.
Page 397 Press the keys or buttons. --> The associated inputs must change to 1. Exception: NC STOP --> Changes to 0 when actuated (failsafe!) Figure: Recording of NC START and NC STOP keys in the logic diagram 24 – 398 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 398: Checking The Outputs
24.6 Checking the outputs The MB 620 features 8 PLC outputs which serve, for example, to control the lamps of the buttons. These outputs are on the terminal strip X7. X7: Connecting terminals Assignment O0 (illumination for the NC Start key) O1 (illumination for the NC Stop key) O2 (illumination for the Control voltage ON key) +24 V NC...
Page 399: Corrective Action
If you have found that the HSCI interface of the MB 620 or the MC 62xx or of another control components component is defective, replace the control component. --> See ”Exchange of HEIDENHAIN components” on page 29 – 515. 24 – 400...
Page 400: Handwheel
25 Handwheel 25.1 Introduction Figure: HR 520 Portable An iTNC 530 HSCI can be equipped with the following handwheels: handwheels and HR 520 portable handwheel with display and potentiometers panel-mounted HR 410 portable handwheel handwheels HR 130 panel-mounted handwheel Cable adapter Portable handwheels with EMERGENCY stop button are connected to the MB 620 machine operating panel or HSCI adapter PLB 6001 via a cable adapter.
Page 401: Error Messages
The "threshold sensitivity“ of the handwheel encoder is entered in MP7660. Note Refer to the iTNC 530 HSCI User’s Manual for a detailed description on operating the electronic handwheels. Signal paths Overview --> See ”Signal paths in the console and to the MC 62xx” on page 23 – 367 25.2 Error messages...
Page 402 Figure: Error messages that may be displayed if a short circuit occurs in the handwheel during operation Figure: Error message displayed if a short circuit occurs in the handwheel during start-up of the control February 2012 25 – 403...
Page 403: Error Diagnosis Of Hr 520 Portable Handwheel With Display
Connect the test adapter between the handwheel and the connector X23 of the machine operating panel. (See ”Test adapter” on page 30 – 560.) Switch on the machine. Measure, whether there are +12 V between pin 2 (0 V) and pin 4 (+12 V). 25 – 404 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 404 Figure: Test adapter between MB 620 and HR 520 Note The MB 620 and the HSCI adapter PLB 6001 feature "polyfuses“. Polyfuses are electronic fuses that become highly resistive if an overload occurs and thus separate defective peripherals (e.g., handwheel) from the low voltages of the MB 620 or the HSCI adapter PLB 6001.
Page 405 Call the table with the PLC markers or the logic diagram. --> See ”Diagnosis tools in the PLC mode” on page 11 – 119. Press the handwheel keys. Check whether the corresponding markers are set (see table). 25 – 406 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 406 ↑ ↓ Handwheel active (M4660) – Rapid traverse (M4667) (M4666) (M4663) Spindle Actual NC start start position (M4661) (M4664) capture Spindle CTRL NC stop stop (M4668) (M4662) (M4665) All keys are evaluated by the NC. Certain keys are mapped to markers. Keys that are not mapped to markers can be checked easily by verifying whether a function is called by pressing the corresponding key or whether there is a reaction on the screen.
Page 407 Press the KBD (keyboard) soft key to activate the potentiometers of the keyboard. Press the HANDWHEEL key. --> The window Handwheel active on the control screen is closed, the handwheel is deselected. 25 – 408 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 408: Error Diagnosis Of Hr 410 Portable Handwheel
25.5 Error diagnosis of HR 410 portable handwheel Control impaired? If you suspect that a damaged handwheel or a handwheel into which liquid has penetrated impairs the function of the control: Disconnect the handwheel and observe the reaction. --> See ”Deselecting and disconnecting the portable handwheel” on page 25 – 412. Visual inspection Visually inspect the HR, EMERGENCY STOP button, keys, cable, contacts, etc.
Page 409 Polyfuses are electronic fuses that become highly resistive if an overload occurs and thus separate defective peripherals (e.g., handwheel) from the low voltages of the MB 620 or the HSCI adapter PLB 6001. Polyfuses have a self-resetting function ("self-healing effect"). 25 – 410 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 410 Checking the keys The function of the handwheel keys can be seen from the respective PLC inputs. Use the PLC diagnostic functions TABLE or LOGIC DIAGRAM for this purpose: Switch on the machine. Press the EMERGENCY STOP button. Call the table with the PLC inputs or the logic diagram. -->...
Page 411: Deselecting And Disconnecting The Portable Handwheel
The dummy plug for the handwheel adapter can be purchased from the machine manufacturer or from HEIDENHAIN (ID 271958-03). DANGER When you connect a new or repaired handwheel to the machine: You must absolutely check, whether the EMERGENCY STOP button on the handwheel functions properly! 25 – 412 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 412: Error Diagnosis Of Hr 130 Panel-Mounted Handwheel
25.7 Error diagnosis of HR 130 panel-mounted handwheel Control impaired? If you suspect that a damaged handwheel or a handwheel into which liquid has penetrated impairs the function of the control: Disconnect the handwheel and observe the reaction. Visual inspection Start with a visual inspection! Is there any damage, have liquids penetrated, etc.? Functional check...
Page 413: Corrective Action
If you have found that the handwheel interface on the MB 620 or the HSCI adapter PLB 6001 is components defective (connector X23), replace the component. --> See ”Exchange of HEIDENHAIN components” on page 29 – 515. 25 – 414 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 414: Touch Probes
26 Touch probes 26.1 Introduction Figure: TS 740 An iTNC 530 HSCI can be equipped with different touch probes (see following pages). February 2012 26 – 415...
Page 415 The TS 640 is equipped with an integrated cleaning blower. The TS 444 features an integrated air turbine generator and therefore is battery-free. Various styli can be inserted into the touch probes. The styli feature a rated break point. 26 – 416 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 416 TS with signal transmission via cable (e.g. TS 220) The machine operator inserts the touch probes into the spindle by hand. They serve to align workpieces, set datums and calibrate workpieces. Power supply and signal transmission via the cable. Various styli can be inserted into the touch probes. The styli feature a rated break point. TT tool touch probe TT with infrared transmission of the trigger signal (e.g.
Page 417 This laser system is used to measure tools (e.g., length, radius, individual teeth). Tools can be examined for breakage. Tool wear can be determined. DANGER Laser radiation! Do not stare into beam! Laser class 2. 26 – 418 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 418 You will find further information on touch probes in the… information iTNC 530 HSCI User's Manual corresponding mounting instructions brochure 3-D Touch Probes for Machine Tools These documents can be downloaded from the HEIDENHAIN website (www.heidenhain.de). February 2012 26 – 419...
Page 419: Error Messages
(e.g., touch probes) from the low voltages of the PLB 62xx or the UEC 11x. Polyfuses have a self-resetting function ("self-healing effect"). Figure: Error messages that may be displayed if a short circuit occurs in the touch probe during operation 26 – 420 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 420 Figure: Error messages that may be displayed if a short circuit occurs in the touch probe during start- up of the control Specifically for Battery flat (capacity below 10 %) --> In this case the message Exchange touch probe battery is output, when a probing operation is touch probes started.
Page 421: Error Diagnosis On Ts Touch Probes
Is the transmitter/receiver unit contaminated, etc.? Checking the LEDs Touch probe with infrared interface: Figure: Optical status indicator of the transceiver units SE 440, SE 640 and EA 632 with two multicolored LEDs 26 – 422 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 422 Figure: Optical status indicator of the SE 540 with one multicolored LED Note A detailed description of the optical status indicator, of the beam direction, of battery exchange, stylus exchange, centering, specifications, etc. can be found in the mounting instructions of the touch probe.
Page 423 + 5 V-NC (+/- 5%) TS start Do not assign 0 V-NC 0 V-NC + 24 V-NC Do not assign Do not assign Do not assign Do not assign Do not assign 26 – 424 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 424 Functional test by means of DriveDiag DANGER Ask the machine manufacturer and observe the machine manufacturers's safety precautions (set-up mode, etc.)! Switch on the machine. Insert the touch probe. Press the EMERGENCY STOP button as a precaution. Call DriveDiag. --> See ”DriveDiag” on page 9 – 91. Open the following page: Check the lamp at TS touch probe ready (X12).
Page 425 Check the marker 4050. If the probe is ready, this marker has the status zero. Deflect the stylus by hand. Check the marker 4051. If the stylus is deflected, this marker changes to one. 26 – 426 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 426: Error Diagnosis On Tt Touch Probes
26.5 Error diagnosis on TT touch probes Control impaired? If you suspect that a damaged touch probe or a touch probe into which humidity has penetrated impairs the function of the control: Disconnect the touch probe and observe the reaction. -->...
Page 427 + 5 V-NC (+/- 5%) Do not assign TT start 0 V-NC 0 V-NC + 24 V-NC TT ready Do not assign Do not assign Do not assign Do not assign 26 – 428 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 428 Functional test by means of DriveDiag DANGER Ask the machine manufacturer and observe the machine manufacturers's safety precautions (set-up mode, etc.)! Switch on the machine. Turn the feed-rate potentiometer to a small value. Call DriveDiag. --> See ”DriveDiag” on page 9 – 91. Open the following page: Start a probing cycle with the TT.
Page 429 Deflect the tool touch probe by hand. Check the marker 4051. If the touch probe is deflected, this marker changes to one. The message Stylus deflected appears in the machine display. 26 – 430 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 430: Error Diagnosis On The Laser Touch Probe
26.6 Error diagnosis on the laser touch probe Control impaired? If you suspect that a damaged laser system or a laser system into which liquid has penetrated impairs the function of the control: Disconnect the laser system and observe the reaction. -->...
Page 431 + 5 V-NC (+/- 5%) Do not assign TT start 0 V-NC 0 V-NC + 24 V-NC TT ready Do not assign Do not assign Do not assign Do not assign 26 – 432 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 432: Deselecting And Disconnecting The Touch Probe
26.7 Deselecting and disconnecting the touch probe You suspect a defective touch probe (short-circuit, etc.)? Now, you want to test the control function without touch probe connected. Proceed as follows: Close all active probing cycles. Remove the touch probe from the spindle (by hand or automatically). Press the EMERGENCY STOP button and shut down the control.
Page 433: Corrective Action
Check the accuracy of the touch probe system after exchanging the stylus, the contact plate, and of course after a collision. Perform a recalibration. For this purpose, consult the machine operator, the machine manufacturer or your HEIDENHAIN service agency. Note A detailed description of the visual status check, of the beam direction, of battery exchange, stylus exchange, centering, specifications, etc.
Page 434: Features Of Heidenhain Components
The picture is only an example as, of course, there is a great variety of different machine tools and machining centers. Furthermore, it does not claim to be complete! Note On the cover page of this Service Manual and in the PDF file the highlighted HEIDENHAIN components are clear to see. February 2012 27 – 435...
Page 435: Hardware Identification
Whenever possible, the ID label is located well visible on the front of a product. Otherwise, you may find it on the side or on the rear of the unit. ID labels are attached to the following mandatory and optional components of an iTNC 530 HSCI: Main computer...
Page 436 Storage medium SSDR hard disk (SSDR = solid state disk removable) Additionally required for MC 6222: SSDR hard disk of the iTNC 530 HSCI • Contains the NC software • Memory capacity 32 GB, of which 21.4 GB are for the TNC:\ partition and 1 GB for the PLC:\ partition;...
Page 437 2 SPI expansion slots Power supply through UV(R) power supply unit Available as: CC 6106 with 6 control loops CC 6108 with 8 control loops CC 6110 with 10 control loops 27 – 438 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 438 Controller unit with integrated inverter UEC 11x controller unit (UEC = Umrichtereinheit - inverter unit - with controller computer) Controller unit with integrated inverter and PLC for up to 5 control loops for providing line voltage. Compact unit for machines with limited number of axes and low power demands.
Page 439 PLA-H xx–xx–xx (PLA-H = PLC I/O module analog HSCI) Analog I/O module: PLA-H 08-04-04: Analog module with eight analog inputs ± 10 V, four analog outputs ± 10 V and four inputs for Pt 100 thermistors. 27 – 440 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 440 SPI expansion module Expansion module for analog axes/spindles in the HSCI system CMA-H 04-04-00 (CMA-H = controller module analog HSCI) Expansion module for analog axes/spindles in the HSCI system: CMA-H 04-04-00: Module for controlling analog axes or spindles. The CMA-H is inserted in one of the SPI slots on the bottom of the controller units.
Page 441 PSL 130 PSL 130 power supply unit for HSCI components with +24 V power supply when using a HEIDENHAIN inverter system The PSL 130 power supply unit was conceived in order to be able to provide the HSCI components of the iTNC 530 HSCI with +24 V NC voltage and +24 V PLC voltage.
Page 442 Visual display unit BF 250 15-inch design Resolution: 1024 x 768 pixels 8 horizontal soft keys, 6 vertical soft keys for PLC 3 soft keys for switching soft-key rows Key for screen layout and operating mode switching Additional USB interface (USB 2.0) on the front of the visual display unit Integrated USB hub with (USB 2.0) with 4 USB interfaces on the back of the display unit...
Page 443 The PLB 6001 is equipped with: HSCI interface Handwheel connection X23 64 PLC inputs, 32 PLC outputs for keys / key illumination Connection for spindle-speed and feed-rate override potentiometer Screw fastening or top-hat-rail mounting 27 – 444 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 444 Actual-position-capture key Three keys for machine functions (definable via PLC) • Spindle right/left/stop • NC start/stop, spindle start; for HEIDENHAIN basic PLC program Two permissive buttons (24 V) Emergency stop button (24 V) Magnetic holding pads HR 520 Portable electronic handwheel with snap-on (exchangeable) keys.
Page 445 TS 640, TS 740 TS 440, TS 444 TS 740 TS 640 TS 642 TS 440 TS 444 SE 640 transmitter-receiver unit SE 642 transmitter-receiver unit SE 540 transmitter-receiver unit SE 640 SE 540 27 – 446 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 446 TS 220 Triggering touch probe with signal transmission over cable connection for machines with manual tool change; for workpiece setup and measurement during machining TS 220 Adapter cable for connection to the system PL or the UEC TT 140 Tool touch probe Touch trigger probe with rated break point of the connection pin for the probe head and optical deflection display.
Page 447 8 horizontal soft keys 6 vertical soft keys 2 keys for switching the horizontal soft-key row Key for switching the vertical soft-key row Key for view change Key for changing screen layout 27 – 448 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 448 IPC 6120 package "IPC 6120 Advanced" package Main computer (with TE 630 and CFR) Separate TNC operating panel TE 630 or TE 620 15-inch screen "IPC 6120 Basic" package (with TE 620 and CFR) 3 USB connections Slot for CompactFlash memory card, types I and II Ethernet connection RS-232-C/V.24 data interface Power supply connection...
Page 449 For information on these components refer to the Service Manual "Inverter Systems and Motors". motors Interface boards for For information on these components refer to the Service Manual "Inverter Systems and Motors". the SIMODRIVE system 611D 27 – 450 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 450: Display Of Important System Information
27.3 Display of important system information When you consult your machine manufacturer or HEIDENHAIN in the event of an error or a malfunction of your machine, it is important that you know which NC and PLC software is installed on the iTNC 530 HSCI.
Page 451 340 421-xx iTNC 530 HSCI and HeROS 5 As the NC software of the iTNC 530 HSCI is subject to export licensing, HEIDENHAIN can also supply a special export version (until now all odd-numbered NC software versions). HEIDENHAIN releases a new program number for the NC software whenever it introduces extensive new functions.
Page 452: Connector Designations And Pin Layouts
28 Connector designations and pin layouts 28.1 Important note Attention Do not engage or disengage any connecting elements while the unit is under power! See “Safety precautions” on page 2 – 15. 28.2 MC main computer 28.2.1 Designations and positions of connectors MC 6222: Main computer for installation in the operating panel Positions of the connectors Connector...
Page 453 HDL interface for visual display unit X141 X121 MC 6x4x: Profibus (option) X143 X116 X144 X125 X500 X125 SIK (System Identification Key) X501 X601 X601 Reserved X600 X249 € Protective ground 28 – 454 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 454 28.2.2 Pin layouts Screen soft keys from X3 to TE via ribbon cable Connection for screen soft keys Screen soft keys BF 250 visual display unit TE 6xx keyboard unit D-sub connector, 15-pin Plug connector, 10-pin Plug connector, 50-pin X26, X116: Ethernet interface Connection...
Page 455 Face of the connector: Meanings of the LEDs on the Ethernet data interface: Condition Meaning Green Blinking Interface active Interface inactive Yellow 100 Mb network 10 Mb network 28 – 456 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 456 X27: Maximum cable length: 20 m RS-232-C/V.24 data interface 25-pin adapter block: MC 6xxx Connecting cable Adapter block Connecting cable 365 725-xx 310 085-01 274 545-xx Male Assignment Female Color Female Male Female Male Color Female Do not assign 1 White/ Brown Yellow 3...
Page 457: 2Pin Layouts
All signals on the PL 550 are electrically isolated. All signals are electrically isolated at X121 of the MC 6xxx main computer or the IPC 6xxx. The +5 V and GND pins supply the terminating resistor in the connector. 28 – 458 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 458 If USB components that are connected to one of the USB ports require more than 0.5 A, a separate power supply becomes necessary for these components. One possibility is the USB hub (USB 2.0) from HEIDENHAIN. If a USB hub is connected to one of the USB ports, the maximum permissible length of the USB cable is reduced to 20 m.
Page 459 Do not assign Do not assign HSCI connection X501, output 2 RJ45 connection (female) 8-pin Assignment TD1+ TD1– RD1+ Do not assign Do not assign RD1– Do not assign Do not assign 28 – 460 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 460: Cc Controller Unit
28.3 CC controller unit 28.3.1 Designations and positions of connectors CC 6106, controller unit with 6 control loops and HSCI interface Positions of the connectors Connector Function X15 to X20 Speed encoder X51 to X56 PWM output Supply bus X201 to X206 Position encoder X500 HSCI output...
Page 461 SPI slot 1 (on bottom, reserved for expansion modules) – SPI slot 2 (on bottom, reserved for expansion modules) Bridge for signal ground (= functional ground) (on bottom) € Protective ground 28 – 462 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 462 CC 6108 / CC 6110 controller unit with 8 / 10 control loops and HSCI interface Positions of the connectors Connector Function X15A - X18A Speed encoder Drive-control motherboard A X15A X15B X19B X15B - X20B Speed encoder Drive-control motherboard B X17A X17B X51A - X54A...
Page 463: Pin Layouts
CC 61xx of the respective supply bus. This bridge for the signal ground on all other CC 61xx units that are on a common supply bus (X69) must be disengaged in order to prevent ground loops. 28 – 464 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 464 Attention If you connect angle or linear encoders from HEIDENHAIN to the speed encoders (such as for torque motors), you must pay attention to the different connector layouts! HEIDENHAIN offers special cables and line-drop compensators for such applications. More information is in the Cable overviews.
Page 465 The interface complies with the requirements of EN 61800-5-1 for "protective extra-low voltage" (PELV). DANGER Only units that comply with the requirements of EN 61800-5-1 for "protective extra-low voltage (PELV)" may be connected. 28 – 466 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 466 Pin layout (for the LC or RCN): CC 61xx Adapter cable 336 376-xx Adapter cable 369 124-xx Adapter cable 369 129-xx Male Assignment Female Color Female Male Color +5 V (U Brown/Green Brown/Green 0 V (U White/Green White/Green Green/Black Green/Black A–...
Page 467 Do not assign Data Black Pink Temperature – Violet Hsg. Housing Hsg. External shield Hsg. Hsg. External shield Note The interface complies with the requirements of EN 61800-5-1 for "protective extra-low voltage" (PELV). 28 – 468 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 468 6a to 7b + 12 V RDY.PS +5 V (low-voltage separation) 0 V (low-voltage separation) ERR.ILEAK +15 V –15 V PF.PS.AC (only regenerative HEIDENHAIN inverters) UZAN Do not assign IZAN Do not assign RES.PS Do not assign PF.PS.ZK Reserved (SDA) ERR.UZ.GR Reserved (SLC) ERR.IZ.GR...
Page 469 Do not assign Violet Violet Do not assign Hsg. External shield Hsg. External shield Hsg. Hsg. External shield Note The interface complies with the requirements of EN50178 for "low voltage electrical separation." 28 – 470 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 470 X201 to X206: Pin layout: Position encoder with EnDat CC 61xx Adapter cable Connecting cable Adapter cable interface 332 115-xx 323 897-xx 313 791-xx Male Assignmt. Female Color Fem. Male Color Fem. Male Color Fem. Brown/ Brown/ Brown/ +5 V (U Green Green Green...
Page 471 Do not assign Do not assign HSCI connection X502, input RJ45 connection (female) 8-pin Assignment RD0+ RD0– TD0+ Do not assign Do not assign TD0– Do not assign Do not assign 28 – 472 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 472: Controller Unit With Integrated Uec Inverter
28.4 Controller unit with integrated UEC inverter 28.4.1 Designations and positions of connectors UEC 11x: Compact controller unit with integrated inverter and PLC I/Os Positions of the connectors Connector Function X4, X5 PLC inputs PLC outputs X15 to X19 Speed encoder X344 Supply voltage for UEC 11x (3 x 400 V ±...
Page 473: Pin Layouts
24 V supply of the outputs O0 to O7 0 V PLC 0 V for all I/Os –REF.SP Reserved, do not assign 0 V PLC 0 V for all I/Os 24 V inputs 24 V inputs 28 – 474 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 474 Connections on the front of the UEC 11x: Single-channel 20 single-channel PLC inputs are freely available: PLC inputs I18 to I37 Terminal Signal designation Assignm. / Function 24 V inputs –ES.A +24 V input for "Control is ready" acknowledgment –ES.B 24 V input "Drive enable"...
Page 475 If the integrated PLC outputs do not suffice for the machine, you can connect up to 7 additional external PL 61xx to the UEC 11x via the HSCI interface. X15 to X19: See “X15 to X20: 1 Vpp speed encoder” on page 28 – 465. Speed encoder 28 – 476 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 476 X31: UEC power supply Note EN 61800-5-1 requires a non-detachable connection to the line power supply. Note If the power supply is other than 400 V, an autotransformer is required. It must comply at least with the connection specifications of the UEC 11x. With a power supply of 400 V, the inverter voltage U is 565 Vdc, and with a power supply of 480 V it is 678 Vdc.
Page 477 Attention The +24 V pulse release voltage must not be linked with other voltages (e.g. +24 V NC or +24 V PLC) of the HEIDENHAIN control system. Attention A recovery diode is required in the proximity of inductive loads, e.g. relay or contactor coils.
Page 478 X112, X113: Triggering touch probe Note The touch probes are connected to the PLB 62xx PLC system module or UEC 11x controller unit at X112 (TS) and X113 (TT). Note For the PLB 62xx up to variant 02, please note: The touch probe adapter ID 667674-01 is required to connect a TT touch probe to the connector X113.
Page 479 X201 to X205: See “X201 to X206: Position encoder 1 Vpp” on page 28 – 470. Position encoder X500, X502: See “X500, X502: HSCI interfaces” on page 28 – 472. HSCI interfaces 28 – 480 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 480: Plb Basic Modules
28.5 PLB basic modules 28.5.1 Designations and positions of connectors PLB 62xx, PLC system module Connection overview Connector Function X500 HSCI output X502 HSCI input Safety-related PLC inputs/outputs X500 Reserved, do not assign X502 +24 V NC, +24 V PLC power supply X112 TS triggering touch probe X113...
Page 481 HSCI green (right) PL not ready for HSCI communication PL ready for HSCI communication HSCI yellow (left) No HSCI communication error Fast blinking No HSCI communication Blinking twice Error in HSCI communication 28 – 482 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 482: Pin Layouts
0.5 mm (only with Weidmüller PZ 6/5 crimping pliers) Note HEIDENHAIN recommends: Preferably use a conductor cross section of 0.34 mm if you use stranded wires with wire-end sleeves. This cross section can be clamped appropriately and ensures a reliable terminal connection.
Page 483 2 A outputs X112, X113: See “X112, X113: Triggering touch probe” on page 28 – 479. Triggering touch probe X500, X502: See “X500, X502: HSCI interfaces” on page 28 – 472. HSCI interfaces 28 – 484 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 484: Digital I/O Modules
28.6 Digital I/O modules 28.6.1 Designations and positions of connectors PLD-H 16-08-00 Positions of the Connector Function connectors PLC inputs, channel A PLC inputs, channel A PLC outputs, channel A Diagnosis (meanings of the LEDs): Red (X11/pin 1) status LED •...
Page 485: Pin Layouts
PLC for O0 to O4 to X22: PLC outputs on the PLD-H Assignment Terminal PL 6xxx Slot 1 O8 24 V 24 V PLC for PLC for O8 to O12 to 28 – 486 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 486: Analog I/O Modules
28.7 Analog I/O modules 28.7.1 Designations and positions of connectors PLA-H 08-04-04 Positions of the Connector Function connectors X66 to X67 Analog outputs +/- 10 V X46 to X49 Analog inputs +/- 10 V X81 to X82 Analog inputs Pt 100 The PLA-H 08-04-04 has analog inputs, analog outputs and inputs for PT 100 thermistors.
Page 487: Pin Layouts
–10 V to +10 V (input) 2a/2b 0 V (reference potential) 3a/3b Shield X66 to X67: Analog output Connecting terminals Assignment 1a/1b –10 V to +10 V (output) 2a/2b 0 V (reference potential) 3a/3b Shield 28 – 488 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 488 X81 to X82: Normally, the thermistor connection is configured as a "four-conductor circuit": Connection for PT 100 ’ Measuring input Measuring input ’ I– Pt100 Customer's cable 4 x 0.14 mm screened, max 30 m Connecting terminals Assignment 1a/1b I+ Constant current for PT 100 2a/2b U+ Measuring input for PT 100 3a/3b...
Page 489: Spi Expansion Module
The PL 6xxx provides PLC analog outputs. It is not possible to control interpolating axes; only spindles and auxiliary axes that are not interpolated together with other digital axes can be controlled. 28 – 490 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 490 0.5 mm (only with Weidmüller PZ 6/5 crimping pliers) Note HEIDENHAIN recommends: Preferably use a conductor cross section of 0.34 mm if you use stranded wires with wire-end sleeves. This cross section can be clamped appropriately and ensures a reliable terminal connection.
Page 491 3 a/b on the CMA-H and to the ground potential of the housing of the CC 61xx or UEC 11x. HEIDENHAIN recommends using EMC shielding terminals. The max. distance between the CMA-H and the ground point is 500 mm.
Page 492: Psl Low-Voltage Power Supply Unit
28.9 PSL low-voltage power supply unit 28.9.1 Designations and positions of connectors PSL 130 pin layout Connector Function Conductor bar Connection of DC-link voltage Uz B – Signal Signal ground (0 V signal of the +24 V NC ground signal connected internally to protective (= functional ground) ground)
Page 493: Pin Layouts
PSL 135 are available as soon as the machine’s main switch has been turned on. This is necessary to boot the control. Note HEIDENHAIN recommends connecting the PSL 135 power supply unit to the U DC-link voltage and the 400 V supply voltage (X31).
Page 494 PSL 130 are available as soon as the machine’s main switch has been turned on. This is necessary to boot the control. Note HEIDENHAIN recommends connecting the PSL 130 power supply unit to the U DC-link voltage and the 400 V supply voltage (X33).
Page 495 Power connection Note PSL 130: As of variant 04 the toroidal core is integrated in the unit. PSL 135: As of variant 02 the toroidal core is integrated in the unit. 28 – 496 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 496: Display Unit
Maximum absolute value: +28.8 V– Power consumption of the BF 250: 50 W Port for the HEIDENHAIN display link (HDL) connection to the MC 6xxx connector X249. HDL connection --> See ”X249: Visual display unit” on page 28 – 459.
Page 497: Keyboard Units
The TE keyboard units are supplied with power via the USB port. TE 635Q The TE 635Q is the same as the TE 630 with the operating panel keys of the MB 620 integrated. 28 – 498 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 498: Pin Layouts
28.11.2 Pin layouts See “X3: Connection for screen soft keys” on page 28 – 455. Connection of the screen soft keys X51: Connection for feed-rate override potentiometer Feed rate override potentiometer X52: Connection for spindle-speed override potentiometer Spindle override potentiometer X55: Connection for feed-rate override potentiometer;...
Page 499: Machine Operating Panel
PLC outputs Interface to keyboard and potentiometers Handwheel connection Connection for handwheel adapter (reserved for functional safety) Permissive key, NC Start, NC Stop X101 24 V NC power supply € Protective ground 28 – 500 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 500: Pin Layouts
28.12.2 Pin layouts PLC inputs Connecting terminals Assignment I2 (Control Voltage ON, CVO) Reserved (do not assign) Reserved (do not assign) a. With standard wiring DANGER Please note that the MB 620 is powered by +24 V NC. For the entire HSCI system, the +24 V NC power supply voltage is required to be safely separated voltage.
Page 501 X23: Handwheel input D-sub connector (female) 9-pin Assignment +12 V Do not assign Housing External shield Note The interface complies with the requirements of EN 61800-5-1 for "protective extra-low voltage" (PELV). 28 – 502 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 502 DANGER The connector for the handwheel on the machine operating panel, as well as the connector on the handwheel itself, may be removed only by trained and qualified personnel, even if it can be removed without using a tool. If the handwheel connector is removed, only basic insulation from line power (230 V) is provided! X30: Only for machine operating panels with FS (functional safety).
Page 503: Hsci Adapter Plb 6001
PLC inputs I56 to I63 X171 PLC outputs O0 to O7 X172 PLC outputs O8 to O15 X173 PLC outputs O16 to O23 X174 PLC outputs O24 to O31 € Protective ground 28 – 504 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 504: Pin Layouts
28.13.2 Pin layouts PLC inputs Connecting terminals Assignment I2 (Control Voltage ON, CVO) Reserved (do not assign) Reserved (do not assign) a. With standard wiring DANGER Please note that the PLB 6001 is supplied with +24 V NC. For the entire HSCI system, the +24 V NC power supply voltage is required to be safely separated voltage.
Page 505 If the handwheel connector is removed, only basic insulation from line power (230 V) is provided! 28 – 506 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 506 X31: NC Start / NC Stop Connecting terminals Assignment Reserved (do not assign) Reserved (do not assign) Reserved (do not assign) Reserved (do not assign) NC Start Reserved (do not assign) NC Start power supply (+24 V NC) NC Stop Reserved (do not assign) NC Stop power supply (+24 V NC) DANGER...
Page 507 The +24 V NC supply voltage must not, under any circumstances, be connected with the +24 V PLC supply voltage, because this removes the double basic insulation. X500, X502: Assignment --> See ”X500, X502: HSCI interfaces” on page 28 – 472. HSCI interfaces 28 – 508 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 508: Handwheels
28.14 Handwheels X23: Handwheels are connected to the MB 620 machine operating panel. --> See ”X23: Handwheel input” Handwheel input on page 28 – 502. 28.14.1 HR 4xx or HR 5xx portable handwheel Pin layout for the various extension cables, adapter cables, connecting cables, and the handwheel: Extension cable Adapter cable ID296466xx Connecting cable HR 4xx...
Page 509: Hr 130 Panel-Mounted Handwheel
HR 130, ID 254 040-xx D-sub cnnctr. (male) D-sub cnnctr. D-sub cnnctr. (male) 9-pin (female) 9-pin 9-pin Housing Shield Housing Housing Shield White White Brown Brown Yellow Yellow Green Green Gray 28 – 510 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 510: Touch Probes
Especially for machine retrofits, the use of adapters for encoder signal adjustment can be of interest. Encoder signals with 11 µA or TTL level can be adapted to the 1 V interface with HEIDENHAIN adapter connectors. February 2012 28 – 511...
Page 511 Do not assign Not assigned Not assigned a. The control assigns the EnDat clock to pin 14. Therefore, you must not assign any signals to this pin when using the TTL adapter connector. 28 – 512 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 512: Speed Encoders
Adapter Pin layout of D-sub connector (female) and D-sub connector (male): TTL (SIEMENS) 1 Vpp D-sub connector Assignment D-sub connection Assignment (female), 15-pin (male), 15-pin Not assigned Not assigned A– –U Not assigned Not assigned B– –U Not assigned Not assigned Not assigned Not assigned Not assigned...
Page 513: Inverters And Motors
For further information, refer to the Service Manual "Inverter Systems and Motors". 28.18 Interface boards for the SIMODRIVE 611D drive system The HEIDENHAIN interface boards for the SIMODRIVE system receive PWM signals from the control and convert them. --> See ”X51 to X56: PWM-output” on page 28 – 469.
Page 514: Exchange Of Heidenhain Components
DANGER Observe the safety precautions to avoid injury or damage to persons or machines. --> See ”Safety precautions” on page 2 – 15. Attention Always use original HEIDENHAIN components as replacements! Which components (Main computer) can be exchanged in the field?
Page 515 Export If an iTNC 530 HSCI operates with an NC software where more than four axes can interpolate restrictions with each other, (contouring with calculation of more than 4 axes), it is subject to export licensing. The NC software for path interpolation is stored on the data medium.
Page 516 The SIK (= System Identification Key) ... is located in a slot on the side of the MC 6222 housing (slot X125). is located in a slot on the bottom of the MC 6241 housing (slot X125). contains the NC software license (standard or export version). stores enabled control loops and software options (e.g, tilting operation, HSC milling, TCPM, cylindrical surface interpolation, synchronized axes, etc.) contains the Feature Content Level (of the NC software version).
Page 517 Some HEIDENHAIN units feature an electronic ID label. The product name, the ID number and the serial number are saved in this ID label. Prerequisite for the evaluation of the electronic ID labels of the iTNC 530 HSCI: Machine parameters...
Page 518 (motor encoder) or PWM outputs (interface to the power modules). MP7690 Evaluation of the electronic ID labels Input: %xxx Bit 0 – HEIDENHAIN power modules 0: Active 1: Inactive Bit 1 – HEIDENHAIN synchronous motors 0: Active 1: Inactive Bit 2 –...
Page 519 ESD protection ESD = Electrostatic discharge Attention When you exchange HEIDENHAIN components, you might come into direct or indirect contact with electronic components. Always assume that all electronic components and assemblies are endangered by electrostatic discharge (ESD) and may be damaged by incorrect handling.
Page 520 The following figure shows how a suitable working area could look in accordance with IEC 61340. € Wristband with 1 Mohm grounding cable for grounding the person Grounded connection for wristbands, floor mats, table mats etc. for equipotential bonding Dissipative shoes Dissipative flooring or floor mat An important part of the working area is a suitable working surface with a wristband with 1 Mohm grounding resistance for grounding the person:...
Page 521 HEIDENHAIN agency. Repair Many HEIDENHAIN units are not repaired on site but are exchanged or replaced. These devices are exclusively repaired by the specialists of the HEIDENHAIN workshops. The devices are also updated to the latest state-of-the-art and subjected to tests.
Page 522: Recognizing And Accepting Hardware Updates
29.2 Recognizing and accepting hardware updates The iTNC 530 HSCI automatically monitors and checks whether hardware changes (including different serial numbers of otherwise identical units) to control components were implemented. I.e., the control detects, if a hardware component was exchanged.
Page 523: Detecting And Loading Firmware Updates
These firmware updates cannot be repeated after a loading attempt has failed (e.g. interruption caused by power failure). The HSCI component requires servicing. This can happen with MC, CC units, etc. After startup, the control displays the following message: 29 – 524 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 524 If a message appears saying that the firmware of older HSCI devices could not be updated (See ”Special case: Firmware update cannot be loaded” on page 29 – 530.) --> Contact your OEM or a HEIDENHAIN service agency. Switch off the main switch of the machine.
Page 525 Accept these changes. --> The control will start up completely and display the following message (press the HELP key for this purpose): Acknowledge the message. Call the log. --> See ”Log” on page 8 – 79. 29 – 526 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 526 If you find the message Exchange the peripheral device in the log, or a similar message indicating that the firmware of older HSCI devices could not be updated --> Contact your OEM or a HEIDENHAIN service agency! Switch on the machine and test the functions.
Page 527 If a message appears saying that the firmware of older HSCI devices could not be updated (See ”Special case: Firmware update cannot be loaded” on page 29 – 530.) --> Contact your OEM or a HEIDENHAIN service agency. After the firmware updated was loaded automatically, the control displays this message: 29 –...
Page 528 If you find the message Exchange the peripheral device in the log, or a similar message indicating that the firmware of older HSCI devices could not be updated --> Contact your OEM or a HEIDENHAIN service agency! Switch on the machine and test the functions.
Page 529 Attention If this or a similar message appears, a firmware update cannot be performed for the older HSCI device. --> Contact your OEM or a HEIDENHAIN service agency. Note The message Exchange the peripheral device or similar messages indicating that a firmware update could not be loaded are also entered in the log of the control.
Page 530: Exchanging The Mc 6222
29.4 Exchanging the MC 6222 Preparing the If still possible: machine tool Move the machine to home position (axes, tool changer, tilting head, etc.) Ask the machine operator! Press EMERGENCY STOP. Backup of Back up the condition of non-volatile PLC markers and words from the RAM to the data medium. -->...
Page 531 The axis positions of EnDat encoders are saved to the RAM of the control when the machine is switched off. The actual axis positions of the machine are not identical with the values in the RAM of the exchange MC. 29 – 532 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 532 Please fill in this form and attach it to the housing of the MC 6222. Use the original packaging of the new MC 6222 to package the defective MC 6222. Return the defective MC 6222 to the machine manufacturer or to your HEIDENHAIN service agency. February 2012...
Page 533: Exchanging The Mc 6241
Switch on the power switch of the machine. Accepting After start-up, the control may display the window Hardware/firmware change detected. hardware updates Accept these changes. --> See ”Recognizing and accepting hardware updates” on page 29 – 523. 29 – 534 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 534 Running Firmware updates may be required for the exchange MC. The NC software automatically detects, firmware updates whether this is required. Run these firmware updates. --> See ”Detecting and loading firmware updates” on page 29 – 524. Restoring non- After restarting the control you must not acknowledge the Power interrupted message. volatile PLC Write the non-volatile PLC markers and words from the data medium to the RAM of the new control.
Page 535 Please fill in this form and attach it to the housing of the MC 6241. Use the original packaging of the new MC 6241 to package the defective MC 6241. Return the defective MC 6241 to the machine manufacturer or to your HEIDENHAIN service agency. 29 – 536...
Page 536: Exchanging The Ssdr
29.6 Exchanging the SSDR Attention The SSDR may only be exchanged in consultation with the machine manufacturer or by the machine manufacturer! SSDRs that you receive in exchange and new SSDRs are already partitioned and formatted. The HeROS operating system and the NC software are installed. The SSDRs are normally equipped with the most recent NC software.
Page 537 Insert the new SSDR and slide it left as far as it will go. new SSDR Tighten the two mounting screws. Close the console. Switch on the power switch of the machine. 29 – 538 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 538 Detecting The control may display the following window: hardware updates Note In the plant, the SSDR was configured with a hardware (e.g. an MC 63xx) your machine does not feature. The NC software now detects the changes to the hardware. Accept these changes.
Page 539 Open the program manager and delete the incomplete MPNAME.MP file. --> A suitable MPNAME.MP will be created automatically. Only now can you exit the Machine parameter programming mode; the Setup key word is accepted. 29 – 540 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 540 Setting date and Check the date and time of the control and reset it, if necessary. --> See ”Setting the system time” on page 13 – 173. time on the control Setting up the data Make the settings for Ethernet transmission on the control. -->...
Page 541 Attach a note with the error description to the SSDR. defective SSDR Use the original packaging of the new SSDR to package the defective SSDR. Return the defective SSDR to the machine tool builder or to your HEIDENHAIN service agency. 29 – 542 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 542: Replacing The Hdr
29.7 Replacing the HDR Attention The HDR may only be exchanged in consultation with the machine manufacturer or by the machine manufacturer! HDRs that you receive in exchange and new HDRs are already partitioned and formatted. The HeROS operating system and the NC software are installed. The HDRs are normally equipped with the most recent NC software.
Page 543 Press the handle in the HDR housing upwards to open the locking mechanism. Press the looking hook in the HDR housing upwards and remove the HDR. Attention Observe the ESD precautions. --> See ”Important information” on page 29 – 515! 29 – 544 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 544 Shipping brace Secure the HDR for transport! (The hard disk is mounted on a steel plate that is inserted into the guideways of the plastic housing. of the HDR --> See sticker "Locking the hard disk" on the HDR.) Figure: Sticker on the HDR housing informing on the shipping brace Installing the Loosen the shipping brace;...
Page 545 The current NC software on the new HDR detects that the firmware of HSCI devices needs to be updated. Run all firmware updates. --> See ”Detecting and loading firmware updates” on page 29 – 524. 29 – 546 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 546 Adapting Now the control may require entries in MPNAME.MP. MPNAME.MP Do not enter any data here. With the MOD key, you can open the code number window, set date and time, set up the Ethernet interface and load the appropriate backup for the machine. Continue as described! Defining the NC Check the currently active NC software version:...
Page 547 It is not recommended to protect the LIES_MP.A and READ_MP.A files on the control as protected files cannot be updated during an NC software update! Figure: Check marks for LIES_MP.A and READ_MP.A removed 29 – 548 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 548 Check whether the hard disk is secured by a shipping brace. Use the original packaging of the new HDR to package the defective HDR. Return the defective HDR to the machine manufacturer or to your HEIDENHAIN service agency. February 2012...
Page 549: Exchanging The Cc
Fill in this form and attach it to the housing of the CC. Use the original packaging of the new CC to package the defective CC. Return the defective CC to the machine manufacturer or to your HEIDENHAIN service agency. 29 – 550...
Page 550: Exchanging The Uec
Fill in this form and attach it to the housing of the UEC. Use the original packaging of the new UEC to package the defective UEC. Return the defective UEC to the machine manufacturer or to your HEIDENHAIN service agency. 29.10 Exchanging the buffer battery See ”Buffer battery”...
Page 551: Exchanging Other Heidenhain Components
Mounting Instructions and Mounting Information are also included in delivery. The HEIDENHAIN testing devices PWM 9 (See ”PWM 9 encoder diagnostic kit” on page 30 – 564) or PWT (See ”PWT 10/17/18 test unit” on page 30 – 566) are good aids for adjusting scanning heads.
Page 552: Exchanging Heidenhain Interface Boards In The Simodrive System
29.12 Exchanging HEIDENHAIN interface boards in the SIMODRIVE system Version with HEIDENHAIN interface boards for the SIMODRIVE system in the version with D-Sub connector are D-sub connector available with or without metallic isolation of HEIDENHAIN PWM signals to the Siemens interface.
Page 553 There is a grounding screw on the front panel. There is a transformer on the board. These boards have the ID number 324952-10 with index A, 11, 12, ... Transformer component on board 29 – 554 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 554 Grounding screw on front panel Attention The terminal X131 of the Siemens E/R module of boards with metallic isolation has to be connected to the central signal ground of the machine! The individual expansion boards must also be connected to the central signal ground of the machine via the grounding screw on the front panel.
Page 555 If a Siemens E/R module is used together with a "monitoring module" (UEB module), the terminal X131 of this module must be wired exactly like on the E/R module. Photo: Siemens UEB module with terminal X131 29 – 556 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 556 Version with ribbon HEIDENHAIN interface boards for the SIMODRIVE system in the version with ribbon cable feature cable connector metallic isolation of the HEIDENHAIN PWM signals to the Siemens interface. Thus, the terminal X131 must be available at the SIEMENS drive system! The individual expansion boards must also be connected to the central signal ground of the machine via the grounding screw on the front panel.
Page 557 Compatibility of SIEMENS has revised the SIMODRIVE power modules. HEIDENHAIN Among other things interference suppression circuits have been added. expansion boards In 2007, the HEIDENHAIN expansion boards for the modified SIMODRIVE power modules were to SIMODRIVE also revised: power modules Modified...
Page 558: Measuring, Testing And Inspection Equipment
30 Measuring, testing and inspection equipment 30.1 Important notes DANGER Observe the safety precautions in chapter 2 of this manual. --> See ”Safety precautions” on page 2 – 15! Attention The following inspection, measuring and testing equipment is only intended for testing machines! Attention Encoder cables, etc., are no longer continuously shielded when the test adapter is connected.
Page 559: Test Adapter
Brief description The test adapter ... currently has the ID 375830-01. can be connected to all D-Sub and ribbon-cable connectors of HEIDENHAIN devices. requires adapter cables. has numbered banana jacks to which, e.g., a multimeter can be connected. permits signal and voltage measurement during the operation of HEIDENHAIN devices.
Page 560 Adapter cable to Each ribbon cable and D-sub connector requires its own adapter cable. the test adapter Connecting cable, ribbon type 50, 40, 34-pin ID 375833-01 Connecting cable, ribbon type 26, 20, 16-pin ID 375833-02 A new and an old version of the D-sub adapter cables are available. The older version has some disadvantages: The oval-head screws on the D-sub connector reduce the insertion depth.
Page 561 D-sub adapter cable 15-pin ID 255482-01 New version D-sub adapter cable 15-pin ID 255482-01 Older version D-sub adapter cable 25-pin ID 255483-01 New version D-sub adapter cable 25-pin ID 255483-01 Older version 30 – 562 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 562 D-sub adapter cable 37-pin ID 255484-01 New version D-sub adapter cable 37-pin ID 255484-01 Older version February 2012 30 – 563...
Page 563: Pwm 9 Encoder Diagnostic Kit
Three BNC sockets (A/B/C) are available for checking the encoder signals on an oscilloscope (recommended by HEIDENHAIN). For inspecting and adjusting HEIDENHAIN measuring systems in the workshop the PWM 9 can also be used without subsequent electronics (e.g., control, position display).
Page 564 During our training courses on measuring systems or special PWM 9 trainings the PWM 9 is explained in detail. We recommend that you participate in a HEIDENHAIN service training course so that you can use the PWM 9 correctly and efficiently.
Page 565: Pwt 10/17/18 Test Unit
PWT 17 requires for evaluation. Sealed encoders do not feature such electronic conversion. For HEIDENHAIN motor encoders, the PWT 18 for 1 Vpp signals is used. The PWT cannot be connected in series between motor encoder and control. The encoder is connected to and powered by the PWT 18.
Page 566 A detailed explanation of the PWT is part of our training courses on measuring systems. We recommend that you participate in a HEIDENHAIN service training course so that you can use the PWT correctly and effectively. Contact HEIDENHAIN Traunreut or your regional agency.
Page 567: Ik 215 Adjusting And Testing Package
Software). The above package currently has the ID 547858-01. The IK 215 is an adapter card for PCs (PCI bus) for inspecting and testing absolute HEIDENHAIN encoders with EnDat or SSI interface. The incremental signals of linear and angle encoders are also displayed.
Page 568: Pwm 20 Encoder Diagnostic Kit
A detailed explanation of the PWM 20 encoder diagnostic kit is part of our training courses on measuring systems. We recommend that you participate in a HEIDENHAIN service training course so that you can use the PWM 20 correctly and efficiently.
Page 569 30 – 570 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 570: Machine Parameters
31 Machine parameters 31.1 Explanation A contouring control must have access to specific data (e.g., traverse distances, acceleration, shaft speeds) before it can execute its programmed instructions. You define these data in what are known as machine parameters. The list of machine parameters is structured according to topic groups. Machine parameters Topics 10 to 999...
Page 571: The Machine Parameter Editor
PLC! If necessary, ask the machine manufacturer which MP files or MP subfiles are active in which special mode of the machine, or which parameters are overwritten by the PLC! 31 – 572 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 572 Calling the Select the Programming and Editing operating mode. machine parameter editor If open: Close the program management by pressing the END button. Note Pressing the MOD key while the program manager is open calls screen where you can make the interface settings.
Page 573 The letter P (for "protected") is displayed in the status column of the program management. Of course, you can also back up important data on an external data medium beforeyou start servicing! 31 – 574 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 574 MP file for testing Load this file into the editor. Press the END key to activate the selected MP file. (The iTNC 530 HSCI may carry out a reset.) The original MP file is reactivated in the same way. Note In the program management, the active MP file is distinguished by the letter M in the status column.
Page 575 Press the END key. --> The machine parameter editor generates the deleted parameter again and asks you for information. Enter the correct value (if required, look it up in the original MP list). 31 – 576 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 576 The control is reset (e.g., changes to certain control-loop parameters). Note This behavior is defined by HEIDENHAIN and cannot be influenced! If you have reason to doubt that a changed parameter value was adopted, the control should be restarted manually.
Page 577 Call the program management. Place the cursor on the original MP list. Load this file into the editor. Press the END key. (The iTNC 530 HSCI activates the selected original MP file and performs a reset, if necessary.) Note In the program management, the active MP file is distinguished by the letter M in the status column.
Page 578: Meaning Of The Machine Parameters
Your can enter your own comments, beginning with a semicolon, in the MP list. For this purpose you need have write permission (enter correct code number). Text file If the machine manufacturer has removed the original HEIDENHAIN comments in full or in part: READ_MP.A Enter the PLC code number.
Page 579: List Of Machine Parameters
31.4 List of machine parameters (Excerpt from the iTNC 530 HSCI Technical Manual of May 2011) 31.4.1 Format: Encoders and machines Function and input Software version and behavior MP10 Active axes Input: %xxxxxxxxxxxxxxxxxx Input: Bits 0 to 17 represent axes 1 to 18...
Page 580 Function and input Software version and behavior MP111.x Position encoder input for the spindle/spindles Input: 0: No position encoder input 1 to 6: Position encoder inputs X1 to X6 35 to 38: Position encoder inputs X35 to X38 201 to 214: Position encoder inputs X201 to X214 MP111.0 Position encoder input for the first spindle MP111.1...
Page 581 MP711.x Height of peaks during circular movement (analog only) Input: –1.0000 to +1.0000 [mm] (digital: 0) MP712.x Compensation value per control loop cycle time Input: 0.000000 to 99.999999 [mm] (digital: 0) 31 – 582 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 582 Function and input Software version and behavior MP715.x Height of peaks during circular movement (analog only) with M105 Input: –1.0000 to +1.0000 [mm] (digital: 0) MP716.x Compensation value per control loop cycle time with M105 Input: 0.000000 to 99.999999 [mm] (digital: 0) MP720.x Linear axis error compensation Input: –1.000 to +1.000 [mm/m]...
Page 583 Simulated tool-change position for TOOL CALL during mid-program startup (block scan) Input: –99 999.9999 to +99 999.9999 [mm] or [°] MP960.x Machine datum Input: –1.79769313486E+308 to +1.79769313486E+308 [mm] or [°] Values with respect to the scale reference point 31 – 584 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 584: Positioning
31.4.2 Positioning Function and input Software version and behavior MP1010.x Rapid traverse Input: 10 to 1 000 000 [mm/min or °/ min] MP1011 Limit of rapid traverse on the path Input: 10 to 1 000 000 [mm/min or °/ min] MP1012.x Second axis-specific rapid traverse Input: 10 to 1 000 000 [mm/min or °/ min]...
Page 585 Minimum filter order for double filter (MP1095 = 1) OEM.SYS MP1110.x Standstill monitoring Input: 0.0010 to 30.0000 [mm] MP1120.x Standstill monitoring when determining the field angle Input: 0.0000 to 300.0000 [mm] or [°] 31 – 586 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 586 Function and input Software version and behavior MP1140.x Threshold above which the movement monitoring functions Input: Analog axes: 0.030 to 10.000 [V] Digital axes: 0.030 to 10.000 [1000 min] Recommended: 0.030 [1000 min] MP1144.x Motion monitor for position and speed Input: Analog axes: Without function Digital axes: 0 to 99 999.999 [mm] 0: No monitoring...
Page 587 Input: 0: Function inactive 1: Function active MP1320 Direction for traversing the reference marks Format: %xxxxxxxxxxxxxxxxxx Input: Bit 0 to Bit 17 represent axis 1 to 18 0: Positive 1: Negative 31 – 588 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 588 Function and input Software version and behavior MP1330.x Velocity for traversing the reference marks Input: 80 to 1 000 000 [mm/min] MP1331.x Velocity for leaving the reference mark end position for axes 1 to 18 (only for rotary encoders MP1350 = 2) Input: 10 to 1 000 000 [mm/min] MP1340.x Sequence for traversing the reference marks...
Page 589 Input: Bit 0 to Bit 17 represent axis 1 to 18 0: Operation with following error (lag) 1: Operation with velocity feedforward control MP1396.x Feedback control with velocity semifeedforward Input: 0.001 to 0.999 1: Velocity feedforward control 31 – 590 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 590: Operation With Velocity Feedforward Control
31.4.3 Operation with velocity feedforward control Function and input Software version and behavior MP1410.x Position monitoring for operation with velocity feedforward control (erasable) Input: 0.0010 to 30.0000 [mm] Recommended: 0.5 mm MP1420.x Position monitoring for operation with velocity feedforward control (emergency stop) Input: 0.0010 to 30.0000 [mm] Recommended: 2 mm MP1510.x...
Page 591: Operation With Following Error
M105 Input: 0.100 to 20.000 [(m/min)/mm] MP1820.x Multiplier for the k factor Input: 0.001 to 1.00000 MP1830.x Characteristic curve kink point Input: 0.000 to 100.000 [%] 31 – 592 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 592: Integrated Speed And Current Control
31.4.5 Integrated speed and current control Function and input Software version and behavior MP2000.x Performance of control loop (software option 49) RESET Input: 0: Single-speed axis 1: Double-speed axis MP2040 Axis groups (for drive enabling through MP4132) Format: %xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx (Bit 31 = spindle) Input: 0: Axis/spindle not assigned (switching only through emergency-stop inputs) 1: Axis/spindle assigned MP2040.0-7...
Page 593 Non-regenerative: 565 V Regenerative: 650 V MP2195 Handling of status signals from HEIDENHAIN power supply units. MP2195 can also be overwritten by the PLC and the LSV2 protocol. Input: Bit 0 – Status signals that are already active during control power-...
Page 594 Function and input Software version and behavior MP2204.x Overwrite "Counting direction" from the motor table RESET Input:*: Input from the motor table active +: Positive counting direction –: Negative counting direction MP2206.x Overwrite "Type of encoder" from the motor table RESET Input:*: Input from the motor table active 0: No speed encoder (volts-per-hertz control mode)
Page 595 1: Monitoring inactive Bit 1 – Monitoring the direction of rotation 0: Monitoring active 1: Monitoring inactive Bit 2 – Power limit of spindle with ERR.IZ.GR (only for HEIDENHAIN inverters, except UE 2xx) 0: Power limit active 1: Power limit inactive (All HEIDENHAIN inverters except UE 2xx) Bit 3 –...
Page 596 Function and input Software version and behavior MP2254.x Field-angle determination Input: 0: Field angle is determined during operation; soft key has no function (without plausibility test) 1: Reserved 2: Field angle determination via soft key, motor motion is permitted (with plausibility test) 3: Same as 2, but the drive no longer has to be be switched on by the PLC.
Page 597 Center/cutoff frequency for filter 2 Input: 0 to 30000.0 [Hz] MP2554.x Center/cutoff frequency for filter 3 Input: 0 to 30000.0 [Hz] MP2555.x Center/cutoff frequency for filter 4 Input: 0 to 30000.0 [Hz] 31 – 598 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 598 Function and input Software version and behavior MP2556.x Center/cutoff frequency for filter 5 Input: 0 to 30000.0 [Hz] MP2560.x Low-pass filter Input: 0: No low-pass filter 1: 1st-order low-pass filter 2: 2nd-order low-pass filter MP2560.x Filter order of the low-pass filter Input: 0 to 20 MP2561.x Maximum input frequency for motor encoders...
Page 599 0: No friction compensation (or axis is analog) MP2630.x Holding current Input: –100.000 to +100.000 [A] MP2640.x Torsion compensation between position encoder and speed encoder Input: 0.001 to 100.000 [µm/A] 0: Not active 31 – 600 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 600 Function and input Software version and behavior MP2900.x Tensioning torque between master and slave for master-slave torque control (entry for the slave axis) Input: –100.00 to +100.00 [Nm] MP2910.x P factor of the torque controller for master-slave torque control (entry for the slave axis) Input: 0.00 to 999.99 [1/(Nm ⋅...
Page 601: Spindle
Counting direction of spindle position encoder output signals Input: 0: Positive counting direction with M03 1: Negative counting direction with M03 MP3142 Line count of the rotary encoder on the spindle Input: 100 to 100 000 [lines] 31 – 602 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 602 Function and input Software version and behavior MP3143 Mounting configuration of the spindle position encoder Input: 0: Position encoder directly on the first spindle 1: Position encoder via transmission (ratio in MP3450.x and MP3451.x); X30 pin 1: reference pulse 2: Position encoder via transmission (ratio in MP3450 and MP3451); X30 pin 1: reference pulse release 3: Same as input value 1, except that the second reference pulse is evaluated.
Page 603 Minimum spindle speed as of which the monitoring in MP3540 becomes active Input: 0.001 to 0.999 0: Monitoring not active MP3550 Delay of emergency-stop reaction of spindles Input: 0.001 to 0.100 [s] 0: Delay not active 31 – 604 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 604: Integrated Plc
31.4.7 Integrated PLC Function and input Software version and behavior MP4000.0-63 Options for the conditional compilation of the PLC program MP4020 PLC functions RESET Format: %xxxxxxxxxxxxxx Input: Bit 0 to bit 4: Reserved Bit 5: Single or double spindle operation 0: Single-spindle operation 1: Double-spindle operation Bit 6 –...
Page 605 Setting a number in the PLC (Module 9032) Input: –99 999.9999 to +99 999.9999 MP4310.0-9 General parameters in the PLC (W976 to W994, M4300 to M4459) Format: Number, $xxxx [Hex], %xxxxxxxxxxxxxxxx [Bin] Input: 0 to 65535 31 – 606 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 606: Configuration Of The Data Interface
31.4.8 Configuration of the data interface Function and input Software version and behavior MP5000 Disable data interfaces Input: 0: No interface disabled 1: RS-232-C/V.24 interface disabled 2: RS-422/V.11 interface disabled 3: RS-232-C/V.24 and RS-422/V.11 interfaces disabled MP5020 Configuration of the data interface Format: %xxxxxxxx Input: Bit 0 –...
Page 607 5: 2400 bps 6: 4800 bps 7: 9600 bps 8: 19200 bps 9: 38400 bps 10: 57600 bps 11: 115200 bps MP5040.0 Operating mode EXT3 (PLC) MP5040.1 Operating mode EXT4 (PLC) 31 – 608 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 608: 3-D Touch Probe
31.4.9 3-D touch probe Function and input Software version and behavior MP6010 Selection of the touch probe Input: 0: Touch probe with cable transmission (TS 120, TS 220) CN123 1: Touch probe with infrared transmission (TS 632) 2: Touch probe with infrared transmission (TS 440, TS 640) 3: Battery-free TS 444 touch probe MP6120 Probing feed rate (triggering touch probe)
Page 609 Input: 0 to +99 999.9999 [mm] MP6182.0 X coordinate MP6182.1 Y coordinate MP6182.2 Z coordinate MP6185 Distance of probing point below ring top surface during calibration Input: +0.001 to +99 999.9999 [mm] CN123 31 – 610 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 610: Tool Measurement With Tt
31.4.10 Tool measurement with TT Function and input Software version and behavior MP6500 Tool measurement with TT 130 Format: %xxxxxxxxxxxxxxx Input: Bit 0 – Cycles for tool measurement 0: Disabled 1: Not disabled Bit 1 – 0: Tool radius measurement allowed. Tool length measurement with rotating spindle 1: Tool radius measurement and individual tooth measurement disabled Bit 2 –...
Page 611 M function before and after tool measurement cycle (TT cycle) 349 490-06 Input: –1: Function inactive 0 to 999: Number of the M function CN123 MP6562.0 M function before the cycle start MP6562.1 M function after cycle end 31 – 612 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 612 Function and input Software version and behavior MP6570 Max. permissible surface cutting speed at the tooth edge Input: 1.0000 to 129.0000 [m/min] CN123 MP6572 Maximum permissible speed during tool measurement –1 Input: 1 to 1000 [min –1 0: 1000 [min CN123 MP6580.0-2 Coordinates of the TT 130 probe contact center with respect to the machine datum...
Page 613: Tapping
1: Spindle operated with position feedback control Bit 3 – Acceleration feedforward control 0: Active 1: Not active Bit 4 – 0: Tool axis tracks the spindle 1: Tool axis and spindle interpolated 31 – 614 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 614: Display And Operation
Lock specific file types Input: 0: Do not disable 1: Disable CN123 Bit 0 – HEIDENHAIN programs *.H Bit 1 – ISO programs *.I Bit 2 – Tool tables *.T Bit 3 – Datum tables *.D Bit 4 – Pallet tables *.P Bit 5 –...
Page 615 14, 15, 16 and 17 only in connection with BF 150 MP7230.0 NC conversational language, soft keys for OEM cycles, operating-system language MP7230.1 PLC conversational language (user parameters) MP7230.2 PLC error messages MP7230.3 Help files 31 – 616 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 616 Function and input Software version and behavior MP7237 Display and reset the operating times MP7237.0 Display PLC operating times Input: Bits 0 to 12 represent PLC operating times 1 to 13 0: Do not display 1: Display MP7237.1 Reset PLC operating times with code number 857282 Input: Bits 0 to 12 represent PLC operating times 1 to 13 0: Do not reset 1: Reset...
Page 617 The settings of bits 4 and 5 also apply to the index entries if bit 6 is set. 0: Deletion always impossible 1: Deletion possible depending on settings in bits 4 and 5 31 – 618 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 618 Function and input Software version and behavior MP7266 Elements of the tool table CN123 MP7266 can also be overwritten by the PLC and the LSV2 protocol. Input: 0: No display 1 to 99: Position in the tool table MP7266.0 16-character alphanumeric tool name (NAME) MP7266.1 Tool length L MP7266.2...
Page 619 2: All blocks line by line; complete block when editing MP7285 Tool length offset in the tool-axis position display Input: 0: Tool length is not offset 1: Tool length is offset CN123 31 – 620 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 620 Function and input Software version and behavior MP7289 Position display step for the spindle Input: 0: 0.1° 1: 0.05° CN123 2: 0.01° 3: 0.005° 4: 0.001° 5: 0.0005° 6: 0.0001° MP7290.0-8 Position display step for axes 1 to 18 Input: 0: 0.1 mm or 0.1° 1: 0.05 mm or 0.05°...
Page 621 Specification of user parameters 1 to 16 Input: 0 to 9999.00 (no. of the user parameter) MP7340.0-15 Dialog messages for user parameters 1 to 16 Input: 0 to 4095 (line number of the PLC dialog message file) 31 – 622 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 622: Colors
31.4.13 Colors Function and input Software version and behavior MP7350 Window frames MP7351 Error messages MP7351.0 Priority 0 (error) MP7351.1 Priority 1 (warning) MP7351.2 Priority 2 (information) MP7352 "Machine" operating mode display MP7352.0 Background MP7352.1 Text for operating mode MP7352.2 Dialog MP7353 "Programming"...
Page 623 Colors 1 to 7 (Color 8: MP7350) MP7367.8-14 Colors 9 to 15 MP7368 Calculator MP7368.0 Background MP7368.1 Background of displays and keys MP7368.2 Key texts ("os" in "cos") MP7368.3 Key symbols 31 – 624 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 624 Function and input Software version and behavior MP7369 Directory tree in PGM MGT MP7369.0 Text background MP7369.1 Text MP7369.2 Text background of the active folder MP7369.3 Line color of the tree structure MP7369.4 Folders MP7369.5 Drives MP7369.6 Text background of the heading in the browser window MP7370 Small PLC window MP7370.0...
Page 625: Machining And Program Run
Input: 0.001 to 1.414 CN123 MP7431 Arc end-point tolerance Input: 0.0001 to 0.016 [mm] CN123 MP7432 Limit-switch tolerance for M140 / M150 Input: 0.0001 to 1.0000 [mm] 0: Limit-switch tolerance not active 31 – 626 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 626 Function and input Software version and behavior MP7440 Output of M functions Format: %xxxxxxx Input: Bit 0 – Program stop with M06 CN123 0: Program stop with M06 1: No program stop with M06 Bit 1 – Modal cycle call M89 0: Normal code transfer of M89 at beginning of block 1: Modal cycle call M89 at end of block Bit 2 –...
Page 627 Tool from magazine 5 to be returned MP7481.5 Tool from magazine 6 to be returned MP7481.6 Tool from magazine 7 to be returned MP7481.7 Tool from magazine 8 to be returned 31 – 628 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 628 Function and input Software version and behavior MP7482 Pocket coding of the tool magazines Format: %xxxxxxxx 0: Variable pocket coding 1: Fixed pocket coding Input: Bit 0: Magazine 1 Bit 1: Magazine 2 Bit 2: Magazine 3 Bit 3: Magazine 4 Bit 4: Magazine 5 Bit 5: Magazine 6 Bit 6: Magazine 7...
Page 629 MP7520 Reserved (only possible via the old kinematics table) MP7530 Reserved (only possible via the old kinematics table) MP7550 Reserved (only possible via the old kinematics table) 31 – 630 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 630: Hardware
31.4.15 Hardware Function and input Software version and behavior MP7602 PLC cycle time Input: 0 to 60 [ms] 0 to 12: 12 ms MP7610.x Reserved MP7620 Feed-rate override and spindle speed override Format: %xxxxxxx Input: Bit 0 – Feed-rate override if rapid traverse key is pressed in Program Run mode.
Page 631 Bit 9 – PLC soft keys with active HR 420/HR 5xx 0: PLC soft keys are not active when HR is active 1: PLC soft keys are active when HR is active 31 – 632 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 632 Function and input Software version and behavior MP7645 Initializing parameter for handwheel MP7645.0 Assignment of the keys on handwheel HR 410 Input: 0: Evaluation of the keys by NC, including LEDs 1: Evaluation of the keys by PLC MP7645.0 Assignment of a third handwheel via axis selector switch S2, when MP7645.2 = 0 Input: 0: Switch position 1 (at the left stop) 3rd handwheel axis Z...
Page 633 Bit 7 – Inserting a defined rounding arc or spline 0: Defined rounding arcs are always inserted 1: Defined rounding arcs are always inserted if the acceleration from MP1060.x or MP1070 was exceeded 31 – 634 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 634 Function and input Software version and behavior MP7680 Machine parameter with multiple function Bit 8 – Insertion of rounding arc or cubic spline 0: Rounding arc is inserted 1: A cubic spline is inserted instead of a rounding arc Bit 9 – Constant jerk on spline (bit 8 = 1) 0: No constant jerk 1: Constant jerk Bit 10 –...
Page 635 Bit 14 – No insertion of the tool if TIME2 has expired 0: Tool is inserted even if TIME2 has expired 1: TOOL CALL for a tool where TIME2 has expired leads to an error message and NC stop 31 – 636 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 636 Function and input Software version and behavior MP7683 Executing pallet tables and NC programs Format: %xxxxxxxxx Input: Bit 0 – No function Bit 1 – Program Run, Full Sequence mode 0: NC start executes a complete NC program. 1: NC start executes all NC programs up to the next pallett. Bit 2 –...
Page 637 Bit 0 – HEIDENHAIN power modules 0: Active 1: Inactive Bit 1 – HEIDENHAIN synchronous motors 0: Active 1: Inactive Bit 2 – HEIDENHAIN power supply units 0: Active 1: Inactive 31 – 638 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 638: Spindle, Second
31.4.16 Spindle, second Function and input Software version and behavior MP13010 to Machine parameter block for the second spindle MP13530 Input: Function and input range are identical with MP3010 to MP3530. February 2012 31 – 639...
Page 639 31 – 640 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 640: Annex: Principle Of Function Of The Itnc 530 Hsci Control
This relieves the prior controller. The respective outer control loop protects the inner control loop by limiting the command variable. The position, speed and current controllers are integrated in the iTNC 530 HSCI control. The power output stage is driven over PWM signals.
Page 641 Nominal and actual values for the controllers Figure: CC 61xx: Nominal values, actual values and connected devices Figure: UEC 11x: Nominal values, actual values and connected devices 1 – 642 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 642 Figure: Cycle times Look ahead In order to adapt the feed rate to the machining process, the iTNC 530 HSCI calculates the geometry ahead of time. This way changes in directions (corners, curvatures, and changes in curvatures) are detected in time, and the participating NC axes can be braked or accelerated accordingly.
Page 643 Position controller With the iTNC 530 HSCI the user can choose between two types of feedback control: Feedback control with following error (servo lag) Feedback control with velocity feedforward Machine Following Velocity For the operating modes parameter error feedforward MP1391.0...
Page 644 factor for The control loop gain - the k factor - defines the amplification of the position control loop. feedback control The k factor is defined by the machine tool builder. with following error For axes that are interpolated with each other, the k factors must be equal to prevent contour deviations.
Page 645 MP1391 bit x = 1 MP1392 bit x = 0 MP1392 bit x = 1 MP1392 bit x = 1 MP1396.x = nonfunctional MP1396.x = 0.001 MP1396.x = 0.999 MP1396.x = 1 1 – 646 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 646 Speed controller Up to 20 digital speed controllers for the axes and spindles are integrated in the iTNC 530 HSCI. The actual speed values are measured directly at the motors with HEIDENHAIN rotary encoders. The position controller provides the nominal speed value. The speed controller is driven by the difference between nominal and actual speed values.
Page 647: The Hsci Bus
Connection of The main computer (MC 62xx), the controller unit (CC 61xx, UEC 11x) and other control components HEIDENHAIN (PLB 6xxx, MB 620) are connected to each other via the HSCI, the HEIDENHAIN Serial Controller components Interface. Figure: Example of HSCI connections The HSCI components are connected via special shielded HSCI cables adapted for the increased demands of machine tool environments.
Page 648 Maximum number The following table shows the maximum permissible number of individual HSCI participants for the of devices iTNC 530 HSCI: HSCI component Maximum quantity in the system MC (HSCI master) 1 in the system CC, UEC, UMC (HSCI slave)
Page 649 The momentary configuration is compared with the nominal configuration. If there is a deviation, the machine operator is prompted to check the configuration. 1 – 650 HEIDENHAIN Service Manual iTNC 530 HSCI...
Page 650 Ethernet ... 181, 183, 209 Counting direction, position encoder signals ... 317 Ethernet cable, crossed ... 209 current ... 327 Exchange of HEIDENHAIN components ... 515 Current controller ... 227, 327, 349, 643, 647 Expansion PL ... 440 Current-controller software ... 452 Export restrictions ...
Page 651 HDR, replacement ... 543 LED, inverter system ... 226 HEIDENHAIN components ... 435 LED, MC 62xx ... 255 HEIDENHAIN expansion boards, compatibility ... 558 LED, PLB 62xx ... 272 HEIDENHAIN interface boards, exchange ... 553 LED, PLD-H ... 120, 123, 276 HELP Key ...
Page 652 Process of interchange, motor outputs ... 341 Opto bridge ... 192, 210, 211 Process of interchange, position encoders ... 281 Original HEIDENHAIN components ... 515 Process of interchange, PWM outputs ... 341 Original parts ... 11 Process of interchange, speed encoders ... 304 Oscilloscope ...
Page 653 inspections ... 522 Table of power stages ... 334 Replacement units ... 522 Tachometer adjustment ... 358 Replacing instructions ... 552 TCP/IP protocol ... 186 Restore ... 207 Temperature ... 74 Restoring ... 207 Temperature sensor lines ... 301 ReturnLine (RL) ... 366 Temperature, CPU ...

Save PDF