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iTNC 530 HSCI
HEIDENHAIN iTNC 530 HSCI Service Manual
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February
2012
Ser
vice
Manual
iTNC 530
HSCI
2
Table of Contents
Default Chapter
2
Table of Contents
2
1 How to Use the Itnc 530 HSCI Service Manual
10
Target Group
10
About this Manual
10
Other Service Manuals
11
Other Documentation
11
Support
11
Service Training
12
Meaning of the Symbols Used in this Manual
12
Safety
12
2 Safety Precautions
14
Introduction
14
Overview
14
3 Code Numbers
16
Introduction
16
Overview
16
Input of Code Numbers
17
4 Error Messages
20
Introduction
20
HELP Key
23
ERR Key
24
CE Key
25
List of NC Error Messages
26
5 Errors
50
Introduction
50
Overview of Possible Errors
50
6 Procedures and Tips for Error Diagnosis in the Field
54
Introduction
54
Power off and on
54
Sequence for Finding Serious Electrical Errors
55
Sequence for Finding Errors in the Control Loop
57
Error Localization by Process of Interchange
60
Error Localization by Process of Exclusion
62
Observing Essential Values with the Integrated Oscilloscope
64
Finding Position Differences of Direct and Indirect Encoders
66
Error Localization by Switching from Direct to Indirect Position Measurement
68
Notes and Tips for the Field Service
70
7 Creating and Reading out Service Files
74
Introduction
74
Automatic Generation of Service Files
75
Manual Generation of Service Files
75
Generating Service Files with Tncremont
76
Evaluation of the Service Files
77
8 Log
78
Introduction
78
Calling the Log
79
Reading out the Log with Tncremont and Filtering by Event Types
80
Overview of Log Entries
82
Log Entries at Program Termination
88
9 Drivediag
90
Introduction
90
Activation and Operation
90
Troubleshooting with Drivediag
92
10 Integrated Oscilloscope
94
Introduction
94
Activation and Settings
95
Recording and Adjusting the Signals
100
Saving and Loading Recordings
105
For Error Diagnosis
106
Triggering on Error Marker
106
Circular Interpolation Test
108
Finding Compensation Values
110
Working with Delta Triggers
112
Descriptions in this Manual
113
11 PLC Diagnosis
114
Introduction
114
Error Messages
117
Possible Error Causes
117
Diagnosis Tools in the PLC Mode
118
The ABLE Function
118
The LOGIC Diagram
123
The TRACE Function
126
The WATCH LIST Function
127
The I/O-FORCE LIST
130
Non-Volatile PLC Markers and Words
133
Overviews
135
Specifications
143
PLC Inputs
143
Analog Inputs
143
Inputs for Pt 100 Thermistors
143
PLC Outputs
144
Analog Outputs
145
Assignment of the Inputs and Outputs
145
12 Bus Diagnosis
146
HSCI Bus
146
Introduction
146
Possible Error Causes
146
Calling and Operating the HSCI Bus Diagnosis
147
Identification of the PLC Operands
148
Read-Back Outputs
149
Master, Slaves and Clients
151
For Error Diagnosis
152
Profibus
161
Introduction
161
Possible Error Causes
161
Calling and Operating the PROFIBUS Diagnosis
162
Identification of the PLC Operands
163
Troubleshooting with Drivediag
163
Log Files
164
13 Data Media and File Management of the Itnc 530 HSCI
166
Introduction
166
Structure of the Data Medium
167
Possible Error Causes
167
Test of the Data Medium
168
Setting the System Time
172
Settings in the Program Manager
173
File Management in the TNC Partition
174
File Management in the PLC Partition
176
14 Data Backup
180
Introduction
180
Connection Setup
182
Via Ethernet
182
Via RS-232-C/V.24 Serial Interface
191
Via USB
194
Reading in and out Individual Files and Directories
195
Backup on an External Data Medium
201
Extracting Files from the Backup File
205
Restoring Data
206
Cable Overview
208
Ethernet Interface RJ45 Connection
208
Rs-232-C (V.24)
209
Operating Modes of the Data Interfaces
212
Drive Symbols
213
15 Reloading the Currently Used NC Software
214
Introduction
214
Preparations
214
Procedure
215
16 Loading Service Packs
218
Introduction
218
Preparations
219
Procedure
220
17 Checking the Enables on the Itnc 530 HSCI
224
Introduction
224
Examination
227
Control Is Ready" Output and Input (EMERGENCY STOP Chain)
227
Axis-Specific Drive Enable Via Axis Groups
231
Readiness of the Inverter System
232
PLC Modules, Markers and Words for Drive Enabling
237
EMERGENCY STOP Test During Switch-On
239
18 Power Supply
242
Introduction
242
Supply Voltages in the HSCI System
242
PSL 130 Low-Voltage Power Supply Unit
245
PSL 135 Low-Voltage Power Supply Unit
249
Power Supply for the MC 62Xx Computer Unit
254
Buffer Battery
256
Information Menu
260
Power Supply of the CC 61Xx Feedback Control Unit
261
Power Supply of the UEC 11X Feedback Control Unit
266
Power Supply of the MB 620 Machine Operating Panel
267
Power Supply of the BF 250 Visual Display Unit
268
Power Supply of the te 6Xx Keyboard Unit
269
Power Supply for the Control-Is-Ready Signal
270
Power Supply of the PLB 62Xx System Module
271
Supply Voltage for PLC Outputs
273
Introduction
273
Supply Voltage for PLC Outputs on the UEC 11X
274
Supply Voltage for PLC Outputs on the MB 620
274
Supply Voltage for PLC Outputs on the PLB 62Xx
274
Supply Voltage for PLC Outputs on the PLD-H XX-XX-XX
275
19 Encoder Interface
276
Position Encoders
276
Introduction
276
Machine Parameters
278
Error Messages
279
Possible Error Causes
280
Troubleshooting
280
Possibilities with Drivediag
288
Possibilities with the Integrated Oscilloscope
289
Corrective Action
292
Determining the Field Angle on Linear Motors, Torque Motors and Synchronous Spindles
293
Resetting the Machine Datum
294
Restoring the Spindle Orientation
298
Speed Encoders
299
Introduction
299
Machine Parameters
301
Error Messages
302
Possible Error Causes
302
Troubleshooting
303
Possibilities with Drivediag
305
Possibilities with the Integrated Oscilloscope
306
Corrective Action
309
Readjusting the Trip Dog for Reference End Position
310
Resetting the Machine Datum
311
Restoring the Spindle Orientation
311
Error Codes for Encoders with Endat Interface
312
Further Examination of Position and Speed Encoders
313
Position Measurement Via Motor Encoder (Indirect Position Measurement)
316
Switching over the Position Display for Servicing
320
20 Reference Run
322
Definition
322
Traversing the Reference Marks
323
Error Messages
323
Possible Error Causes
323
Troubleshooting
324
Corrective Action
325
Deselecting Axes Referencing
325
21 Interfaces to the Drives
326
Digital PWM Interface
326
Introduction
326
Machine Parameters
329
Tables for Power Supply Modules, Power Stages and Motors
331
Reading out Power Module Data
337
Error Messages
338
Possible Error Causes
339
Sequence for Finding Errors in the Control Loop
339
Error Finding: Axes Swapping
340
Error Finding: Swapping Power Modules or Output Stages of the same Type
342
Error Finding: Swapping the HEIDENHAIN Expansion Boards for the SIMODRIVE 611 System
346
Corrective Action
347
Analog Speed Value Interface
348
Introduction
348
Machine Parameters
349
Error Messages
349
Possible Error Causes
350
Sequence for Finding Errors in the Control Loop
350
Checking the Analog Speed Value Interface
351
Adjusting the Electrical Offset (Drift Adjustment)
354
Speed Adjustment at the Servo Amplifier (Tachometer Adjustment)
357
Corrective Action
359
22 Visual Display Unit
360
Introduction
360
Possible Error Causes
361
Troubleshooting
362
Corrective Action
363
23 Keyboard Unit
364
Introduction
364
Signal Paths in the Console and to the MC 62Xx
366
Possible Error Causes
368
Checking the Keys
369
Checking the Potentiometers
375
Checking the Touchpad
379
Corrective Action
380
Key Matrix of the Keyboard Units
381
Key Matrix of the Screen Soft Keys
391
24 Machine Operating Panel
392
Introduction
392
Possible Error Causes
394
Checking the Power Supply
395
Checking the HSCI Connection
395
Checking the Keys
396
Checking the Outputs
398
Corrective Action
399
25 Handwheel
400
Introduction
400
Error Messages
401
Possible Error Causes
401
Error Diagnosis of HR 520 Portable Handwheel with Display
403
Error Diagnosis of HR 410 Portable Handwheel
408
Deselecting and Disconnecting the Portable Handwheel
411
Error Diagnosis of HR 130 Panel-Mounted Handwheel
412
Corrective Action
413
26 Touch Probes
414
Introduction
414
Error Messages
419
Possible Error Causes
419
Error Diagnosis on TS Touch Probes
421
Error Diagnosis on TT Touch Probes
426
Error Diagnosis on the Laser Touch Probe
430
Deselecting and Disconnecting the Touch Probe
432
Corrective Action
433
27 Features of HEIDENHAIN Components
434
HEIDENHAIN Components in a Machine too
434
Hardware Identification
435
Display of Important System Information
450
28 Connector Designations and Pin Layouts
452
Important Note
452
MC Main Computer
452
Designations and Positions of Connectors
452
2Pin Layouts
457
CC Controller Unit
460
Designations and Positions of Connectors
460
Pin Layouts
463
Controller Unit with Integrated UEC Inverter
472
Designations and Positions of Connectors
472
Pin Layouts
473
PLB Basic Modules
480
Designations and Positions of Connectors
480
Pin Layouts
482
Digital I/O Modules
484
Designations and Positions of Connectors
484
Pin Layouts
485
Analog I/O Modules
486
Designations and Positions of Connectors
486
Pin Layouts
487
SPI Expansion Module
489
Designations and Positions of Connectors
489
Pin Layouts
489
PSL Low-Voltage Power Supply Unit
492
Designations and Positions of Connectors
492
Pin Layouts
493
Display Unit
496
Designations and Positions of Connectors
496
Pin Layouts
496
Keyboard Units
497
Designations and Positions of Connectors
497
Pin Layouts
498
Machine Operating Panel
499
Designations and Positions of Connectors
499
Pin Layouts
500
HSCI Adapter PLB 6001
503
Designations and Positions of Connectors
503
Pin Layouts
504
Handwheels
508
HR 4Xx or HR 5Xx Portable Handwheel
508
HR 130 Panel-Mounted Handwheel
509
Touch Probes
510
Encoders
510
Position Encoders
510
Speed Encoders
512
Inverters and Motors
513
Interface Boards for the SIMODRIVE 611D Drive System
513
29 Exchange of HEIDENHAIN Components
514
Important Information
514
Recognizing and Accepting Hardware Updates
522
Detecting and Loading Firmware Updates
523
Exchanging the MC 6222
530
Exchanging the MC 6241
533
Exchanging the SSDR
536
Replacing the HDR
542
Exchanging the CC
549
Exchanging the UEC
550
Exchanging the Buffer Battery
550
Exchanging Other HEIDENHAIN Components
551
Exchanging HEIDENHAIN Interface Boards in the SIMODRIVE System
552
30 Measuring, Testing and Inspection Equipment
558
Important Notes
558
Test Adapter
559
PWM 9 Encoder Diagnostic Kit
563
PWT 10/17/18 Test Unit
565
IK 215 Adjusting and Testing Package
567
PWM 20 Encoder Diagnostic Kit
568
31 Machine Parameters
570
Explanation
570
The Machine Parameter Editor
571
Meaning of the Machine Parameters
578
List of Machine Parameters
579
Format: Encoders and Machines
579
Positioning
584
Operation with Velocity Feedforward Control
590
Operation with Following Error
591
Integrated Speed and Current Control
592
Spindle
601
Integrated PLC
604
Configuration of the Data Interface
606
3-D Touch Probe
608
Tool Measurement with TT
610
Tapping
613
Display and Operation
614
Colors
622
Machining and Program Run
625
Hardware
630
Spindle, Second
638
Annex: Principle of Function of the Itnc 530 HSCI Control
640
Introduction
640
The Control Loop
640
The HSCI Bus
647
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HEIDENHAIN iTNC 530 HSCI Specifications
General
Brand
HEIDENHAIN
Model
iTNC 530 HSCI
Category
Control Systems
Language
English
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