Page 2 July 2002 HEIDENHAIN iTNC 530 Service Manual...
Page 3: Table Of Contents
5 Overview of Components ....................93 5.1 Standard Components....................93 5.2 Accessories ........................96 6 Important Features of HEIDENHAIN Components ............97 6.1 Hardware Identification ....................97 6.2 Display of System Information ..................100 7 Connector Designation and Layout.................. 103 7.1 MC and CC ........................
Page 4 8.2 Basic Circuit Diagrams ....................155 8.3 Block diagram ......................160 9 Power Supply ........................165 9.1 Power Supply for the iTNC 530 ................... 165 9.2 Power Supply for Control-Is-Ready Signal ..............170 9.3 Buffer Battery ......................171 9.4 Info Menu ........................172 9.5 Power Supply for PLC Outputs ...................
Page 5 22 Transfer of Files via Data Interface................. 273 22.1 The Data Transfer Menu.................... 273 22.2 Downloading Files from the iTNC via Data Interface..........274 22.3 Uploading Files onto the iTNC via Data Interface ............277 July 2002 HEIDENHAIN Service Manual iTNC 530...
Page 6 24.1 Universal Measuring Adapter (Id.Nr. 255 480 01) ............. 297 24.2 Encoder Diagnostic Set PWM 8 (Id.Nr. 309 956-xx) ..........299 25 Machine Parameter List ....................301 25.1 Excerpt from the iTNC 530 Technical Manual ............301 25.1.1 Encoders and machines .................. 301 25.1.2 Positioning ....................... 306 25.1.3 Operation with velocity feedforward control ...........
Page 7: Using The Service Manual
However, support will also be provided by the service department of HEIDENHAIN Traunreut or by the nearest HEIDENHAIN agent. You will find the necessary telephone and fax numbers, as well as relevant e-mail addresses, on the back cover of the Service Manual, or on the HEIDENHAIN home page at http://www.heidenhain.de. Note It is extremely important to read also the general safety precautions on the following page, see page 1- 6.
Page 8: Safety Precautions
Improper treatment or use may cause considerable damage or injury to property or persons. HEIDENHAIN can accept no responsibility for direct or indirect damage or injury caused to property or persons through improper use or incorrect operation of the machine.
Page 9: Integral Monitoring System
Integral Monitoring System Introduction iTNC 530 features a comprehensive integral monitoring system for the prevention of input or operation errors, as well as for identification and diagnosis of technical errors on the control and the connected units. The monitoring system is an integral component of the iTNC hardware and software and is active as long as the control is switched on.
Page 10: Monitoring Functions
Position monitoring in operation with velocity feedforward control (erasable) MP1420.x Position monitoring in operation with velocity feedforward control (EMERGENCY STOP) MP1710.x Position monitoring for operation with following error (erasable) MP1720.x Position monitoring for operation with following error (EMERGENCY STOP) 2 – 8 HEIDENHAIN Service Manual iTNC 530...
Page 11: Nominal Speed Value Monitoring
2.2.2 Nominal speed value monitoring For the axes, the nominal speed value monitoring is effective only in operation with velocity feedforward. For the spindle, it is effective in operation with following error as long as the position control loop is closed (orientation). If the nominal speed value calculated by the position controller is greater than the maximum possible nominal value, the blinking error message NOMINAL SPEED VALUE TOO HIGH <AXIS>...
Page 12: Standstill Monitoring
On contours that can be machined with constant surface speed, W1026 is not set. Reset W1026 Axes in position Bits 0 to 8 correspond to axes 1 to 9 0: Axis not in positioning window 1: Axis in positioning window 2 – 10 HEIDENHAIN Service Manual iTNC 530...
Page 13 Axes in motion During axis movement, the NC sets the corresponding bits in W1028. Reset W1028 Axes in motion Bits 0 to 8 correspond to axes 1 to 9 0: Axis not in motion 1: Axis in motion July 2002 2 –...
Page 14: Monitoring Of The Power Supply Unit
Since the AC fail is reported to the control before the power fail, the control has more time to react to the subsequent dc-link voltage failure. Note Only the regenerative HEIDENHAIN inverter units provide the AC-fail signal. If a power fail is triggered on the control, all drives are brought to a controlled stop.
Page 15: Temperature Monitoring
2.2.7 Temperature monitoring Temperature of The internal temperature of the MC 422 is continuously being monitored. At approx. 55 °C the the MC 422 message TNC temperature warning is displayed. If the temperature does not fall below 55 °C any more, the warning is reactivated after two minutes. As of approx. 60 °C the error message TNC temperature too high <temperature>...
Page 16: I 2 T Monitoring
In the oscilloscope you can display the current values of the I -t monitoring of motor and power module as well as the current utilization of the drive. MP2302.x Reference value for I t monitoring 2 – 14 HEIDENHAIN Service Manual iTNC 530...
Page 17: Read Actual Utilization Of Drive Motors
Ask your machine tool builder, how he evaluates this PLC module and how this information is displayed. 2.2.10 Status of HEIDENHAIN inverters Status information of the HEIDENHAIN inverters can be read with PLC module 9066: DC-link voltage too high (ERR.UZ.GR) Heat sink temperature too high (ERR.TEMP )
Page 18 After switching on again, the machine control voltage can be switched off, and then the control operates normally. After detecting a fault, the Blinking error message control switches off the control- is-ready output (X41/34). 2 – 16 HEIDENHAIN Service Manual iTNC 530...
Page 19: Error Messages
Reset error message with END BLOCK key or main On/Off switch All axes must be referenced Operating-system error message (white letters on black background) with Reset Error message: HEIDENHAIN OPERATING SYSTEM - FATAL ERROR MESSAGE Deceleration of axes at current limit iTNC keyboard disabled...
Page 20 Press <NO ENT> to delete value digitizing cycle 16.0 MEANDER or for 'DIST'. The TNC enters a value 18.0 LINE is smaller than the automatically. minimum permissible distance that the TNC calculates from the machine data. 2 – 18 HEIDENHAIN Service Manual iTNC 530...
Page 21 Error message Error Cause of error Corrective action number Current to axis 2657 The axis motor is receiving current, Inform your service agency. although its inverter was switched %.1s not equal 0 off. Axis %.1.s: MP112/ 2200 MP112 / MP113 for the displayed Inform your service agency.
Page 22 GOTO + block number, then was changed program had been changed. continue the run. During a return jump from a sub- program, the control found that the calling program had been changed. 2 – 20 HEIDENHAIN Service Manual iTNC 530...
Page 23 Error message Error Cause of error Corrective action number Start position Digitizing with contour lines: Check the axes defined in the Incorrect starting position selected. Contour Lines cycle. incorrect Radius comp. entry 1142 M120 with LA greater than 0 Edit the part program. permitted only during active tool is missing radius compensation.
Page 24 (empty CC block, ISO: G29). Path comp wrongly You tried to program an APPR block APPR block is permitted only when with tool radius compensation no tool radius compensation is started active. active. 2 – 22 HEIDENHAIN Service Manual iTNC 530...
Page 25 Error message Error Cause of error Corrective action number Path comp You attempted to begin a tool Tool radius compensation can only radius compensation on a circular be activated with a line. incorrectly begun: path. NC block must be a line Path comp wrongly You attempted to end a tool radius...
Page 26 Measure the temperature sensor Incorrect or defective temperature (2000[Ohm] at 25[°C]) sensor was installed. C340 Unknown Hardware defective. Inform your service agency. counter compnt Incorrect software version. Check software version. Exchange drive control board. 2 – 24 HEIDENHAIN Service Manual iTNC 530...
Page 27 Error message Error Cause of error Corrective action number C350 Axis module No pulse release for the power Inform your service agency. supply unit. not ready Check the control and cabling of Uz too high. the pulse release. 5-V power supply too weak. Check Uz.
Page 28 Edit the part program. connecting circle (CT) immediately permitted after an APPR block. CYCL 210 not 2045 Cycle 210 cannot be run in the Use another fixed cycle. CIRCULAR PATTERN or LINEAR permitted PATTERN cycles. 2 – 26 HEIDENHAIN Service Manual iTNC 530...
Page 29 Error message Error Cause of error Corrective action number CYCL 211 not 2046 Cycle 211 cannot be run in the Use another fixed cycle. CIRCULAR PATTERN or LINEAR permitted PATTERN cycles. CYCL CALL PAT 3189 You have used Cycle 12 (ISO: G39) CYCL CALL PAT in connection to declare a program containing with cycle 12 (ISO: G39) is not...
Page 30 1216 Reserved xxxx Faulty range data Range cycle: Max. value is smaller Check the data in the Range cycle. than min. value. Range extends past software limit switch. No Range cycle defined. 2 – 28 HEIDENHAIN Service Manual iTNC 530...
Page 31 Error message Error Cause of error Corrective action number DEP LCT after You programmed a DEP LCT block Edit the part program. for departing a contour immediately HELIX not after a helix. permitted DEP not permitted You programmed a DEP block in the Edit the part program.
Page 32 C (ISO: G2, G3) defined if the starting point and end point do not have the same two axes or those axes are not parallel to the axes of the circle center (CC, ISO: I,J;K). 2 – 30 HEIDENHAIN Service Manual iTNC 530...
Page 33 Error message Error Cause of error Corrective action number Plane wrongly Radius compensation in a rounding Edit the part program. block is not possible (RND, ISO: defined G25) if two mutually parallel linear axes are programmed in the preceding positioning block (e.g.
Page 34 The encoder with EnDat interface is Inform your service agency. defective. The error codes have the %d %.1s following meanings: 001 Light source defective 010 Signal amplitude too low 100 Position value incorrect 2 – 32 HEIDENHAIN Service Manual iTNC 530...
Page 35 Error message Error Cause of error Corrective action number EnDat defective When you were downloading the Exchange the encoder cable. xxxxx axis current position value from the EnDat Exchange the encoder. encoder (only following switch-on of Use another encoder input on the machine), an error was detected in TNC.
Page 36 Enter the correct speed. speed. Refer to your machine manual. Incorrect entry in 1149 The permissible input range of a Check the input range of the machine parameter was exceeded. marked machine parameter. MP%.4u 2 – 34 HEIDENHAIN Service Manual iTNC 530...
Page 37 Error message Error Cause of error Corrective action number Incorrect entry in 1182 An incorrect value was entered in a Edit your entry. machine parameter. MP%.4u.%u Incorrect entry in 2746 Input value of the machine Edit MP2180: PWM frequency. parameter MP2180 (PWM MP%u frequency) is incorrect.
Page 38 You programmed in sequence a Enter a chamfer no earlier than positioning block without radius after two compensated part- permitted compensation, a positioning block program blocks. with radius compensation and a chamfer (CHF, ISO: G24). 2 – 36 HEIDENHAIN Service Manual iTNC 530...
Page 39 Error message Error Cause of error Corrective action number Chamfer not You programmed in sequence a Enter a chamfer only between positioning block without radius radius-compensated blocks. permitted compensation, a chamfer (CHF, ISO: G24) and a positioning block with radius compensation. Chamfer not You programmed in sequence a Enter a chamfer only between...
Page 40 Error in contour The length of the path to be Check the input values. traversed in the contour pocket or pocket/train Contour Train cycle is too large to be represented as a number. 2 – 38 HEIDENHAIN Service Manual iTNC 530...
Page 41 Error message Error Cause of error Corrective action number Pos. control cyc. 2893 MCU is outputting erroneous cycle Inform your service agency. time for CCU position controller. time err. Check machine parameter 7600.0. Hardware error. Exchange drive control board. Cutout channels 2936 Machine key depressed (ZT.HR, Inform your service agency.
Page 42 Incorrect include 2831 An include file was called that has Check the software version. differing version numbers in the file version Inform your service agency. MCU and CCU. Software error. 2 – 40 HEIDENHAIN Service Manual iTNC 530...
Page 43 Error message Error Cause of error Corrective action number Incorrect 2373 Erroneous data in compensation Inform your service agency. table. compensation values Program data This is a general error message Edit the part program. which informs that there is some erroneous error in the program data (e.g.
Page 44 TNC is no longer accessing the network), although the TNC is still device. accessing the device. Protected file! You cannot edit or erase this Cancel file protection. program until the protection has been removed. 2 – 42 HEIDENHAIN Service Manual iTNC 530...
Page 45 Error message Error Cause of error Corrective action number Locked axis was You programmed a locked axis in a If necessary, activate the axis. part program block. programmed Delete the axis from the part- A traverse was calculated for a program block.
Page 46 Exchange the motor drive control board. No rotary axis was The axis recognized as main axis in Edit the contour subprogram. Cycle 27 (Cylinder Surface, ISO: programmed G127) is not a rotary axis. 2 – 44 HEIDENHAIN Service Manual iTNC 530...
Page 47 Error message Error Cause of error Corrective action number All elements 2384 While editing the structure of a Insert at least one element. freely definable table you erased all deleted! the elements. No chamfer as last In the definition of a contour, a Edit the part program.
Page 48 Contour A contour starting point lies on a Change the contour starting point contour intersection: The TNC in a contour subprogram. programming error cannot recognize how you wish to combine the contours. 2 – 46 HEIDENHAIN Service Manual iTNC 530...
Page 49 Error message Error Cause of error Corrective action number Contour Two successive contour elements Check the arc end-point are circles with the same center but coordinates. programming error different radii. Contour A contour subprogram contains Add data to the contour only one point.
Page 50 IMAX = peak current Power stage %.1s: 2192 U-IMAX of the power stage for the Inform your service agency. displayed axis is incorrect U-Imax incorrect U-IMAX = voltage of the current sensor 2 – 48 HEIDENHAIN Service Manual iTNC 530...
Page 51 Error message Error Cause of error Corrective action number Power stage in axis 2188 Power stage for displayed axis is Inform your service agency. too weak. %.1s too weak LN: Oriented stop 2691 The tool direction given in the LN Have the CAD system recalculate block (TX, TY, TZ) cannot be realized the tool direction.
Page 52 %.1s Inform your service agency. position encoder is greater than the value from MP640.x. MCU command 2880 Internal software error. Inform your service agency. invalid Check the software version. 2 – 50 HEIDENHAIN Service Manual iTNC 530...
Page 53 Error message Error Cause of error Corrective action number MCU command 2869 Internal software error. Inform your service agency. unknown Check the software version. ME: Tape end The cassette in the ME magnetic Turn the cassette over or insert tape unit has reached the end of the a new one.
Page 54 Motor defective. Incorrect motor selected (MP2200). Assignment of PWM outputs entered incorrectly in MP120. Assignment of encoder inputs entered incorrectly in MP112. Motor power cables crossed. Motor encoder cables crossed. Motor connection defective. 2 – 52 HEIDENHAIN Service Manual iTNC 530...
Page 55 Error message Error Cause of error Corrective action number Motor %.2s not 2920 Motor cables were crossed Check the motor cabling. (e.g. X with Y). controllable Inform your service agency. Motor encoder cables crossed. Check motor and motor encoder Phases connected incorrectly to cabling.
Page 56 Edit machine parameter list. A machine parameter has not been defined. The line is generated automatically. MP: Saving not Machine parameter input error: Inform your service agency. A machine parameter cannot be possible stored. 2 – 54 HEIDENHAIN Service Manual iTNC 530...
Page 57 Error message Error Cause of error Corrective action number MP: Line w/o Machine parameter input error: Edit machine parameter list. A line was found without a machine number parameter number (not an empty line or comment). MP75XX not 2213 M128 without machine geometry Inform your service agency.
Page 58 PGM not found During execution of a blockwise Load the part program. transferred part program (DNC mode) the control found that a called subprogram does not exist in NC memory. 2 – 56 HEIDENHAIN Service Manual iTNC 530...
Page 59 Error message Error Cause of error Corrective action number PGM section During graphic simulation of a The TNC cannot graphically simulate traverse in the A, B, C, cannot be shown positioning block one of the following U, V, and W axes. errors occurred: Enlarge the BLK FORM.
Page 60 Edit the PLC program. module from the main file as main file GLOBAL. Only modules from files that are linked with the USES statement can be made accessible for other files through the GLOBAL statement. 2 – 58 HEIDENHAIN Service Manual iTNC 530...
Page 61 Error message Error Cause of error Corrective action number PLC: Global/ PLC syntax error: You wrote the Edit the PLC program. GLOBAL or EXTERN commands external incorrect behind other program code in the file. These commands must always appear before the program code. PLC: Global label PLC syntax error: You defined the Edit the PLC program.
Page 62 PLC: Program too PLC syntax error: The complete Edit the PLC program. length of the program code to be long generated exceeds the storage space available in the control. 2 – 60 HEIDENHAIN Service Manual iTNC 530...
Page 63 Error message Error Cause of error Corrective action number PLC: Jump PLC syntax error: An unconditional Edit the PLC program. jump was programmed although incorrectly the assignment chain begun programmed beforehand had not yet been assigned. PLC: Jump PLC syntax error: A jump statement Edit the PLC program.
Page 64 1,000 global labels were global labels defined within the associated files. PLC: Too many An attempt was made to nest more Edit the PLC program. than 16 parenthetical expressions in parentheses each other. 2 – 62 HEIDENHAIN Service Manual iTNC 530...
Page 65 Error message Error Cause of error Corrective action number PLC: Too many PLC syntax error: More than 1,000 Edit the PLC program. labels assigned in one file. All LBL, local labels KFIELD and EXTERN statements are added together along with the (hidden) labels created through structured commands.
Page 66 Q222 must be 2048 Stud finishing cycle: Workpiece Correct the workpiece blank blank diameter Q222 must be diameter in the fixed cycle. greater than Q223 greater than the finished part diameter Q223. 2 – 64 HEIDENHAIN Service Manual iTNC 530...
Page 67 Error message Error Cause of error Corrective action number Q223 must be 2238 In the Circular Pocket Finishing Edit Q222 in the cycle definition. cycle (Cycle 212, ISO: G212), you greater than Q222 entered a finished-part diameter (Q223) smaller than the workpiece- blank diameter (Q222).
Page 68 (the minimum and limits were switched). Rotor time constant 2899 The rotor time constant calculated Inform your service agency. from the rotor table is invalid. err. %.2s Check the motor table. 2 – 66 HEIDENHAIN Service Manual iTNC 530...
Page 69 Error message Error Cause of error Corrective action number RND radius = 0 not In the definition of a contour, a Edit the part program. contour pocket or a contour train, permitted you programmed a rounding arc (RND, ISO: G25) with radius 0. RND after chamfer In the definition of a contour, a Edit the part program.
Page 70 %s detected a disagreement between The TNC will restart. the geometry and the machine in the data of the active spindle (S), the traverse range (R), or the PLC datum shift (P). 2 – 68 HEIDENHAIN Service Manual iTNC 530...
Page 71 Error message Error Cause of error Corrective action number Triggering touch 1171 You have attempted to start a Edit machine parameters 6200. digitizing cycle for a measuring probe selected touch probe, although a triggering touch probe is defined in machine parameter 6200.
Page 72 Software error Check the wiring. Check the software version. 0 pitch not You have programmed a thread Edit the part program. pitch of 0 in the Rigid Tapping cycle permitted or Tapping cycle. 2 – 70 HEIDENHAIN Service Manual iTNC 530...
Page 73 Update the system 1845 The system files on your hard disk Ask your machine tool builder or are no longer up-to-date. HEIDENHAIN for a SETUP disk for data! your present software. System memory 1810 This error occurs when the TNC...
Page 74 Text not found The ASCII editor could not find the Search for another text (note upper desired text in a file. and lower case). 2 – 72 HEIDENHAIN Service Manual iTNC 530...
Page 75 Error message Error Cause of error Corrective action number Tmax of motor table 2903 Incorrect temperature entry in Inform your service agency. motor table. %.2s Check the motor table. TNC program block FK programming: Conventional Resolve the FK contour completely. blocks may follow an FK block not permitted until only if the FK block led to a...
Page 76 RDY=0 condition. Inverter for spindle 2654 The power supply for a spindle is Inform your service agency. ready for operation although it RDY=1 ought to be switched off. 2 – 74 HEIDENHAIN Service Manual iTNC 530...
Page 77 Error message Error Cause of error Corrective action number Unknown computer 2917 Hardware defective. Inform your service agency. compnt. %.2s Incorrect software version. Check the software version. Exchange drive control board. Unknown G code You have programmed an Check the highlighted block. unknown G code.
Page 78 7680 that a spline be inserted as connecting element at radius-compensated outside corners. Feed rate is missing 161 You did not program a feed rate. Edit part program, FMAX only effective for block programming. 2 – 76 HEIDENHAIN Service Manual iTNC 530...
Page 79 Error message Error Cause of error Corrective action number Reciprocation feed 1856 In the Rough-Out cycle, the Define the feed rate. reciprocation feed rate has not yet rate missing been defined. Feed rate too fast The feed rate is too high for the Select another screen layout.
Page 80 Edit the part program. than the tool diameter large Tool radius too Rectangular pocket cycle: The Edit the part program. pocket width is less than or equal large to the tool diameter. 2 – 78 HEIDENHAIN Service Manual iTNC 530...
Page 81 Error message Error Cause of error Corrective action number Tool radius too Rectangular pocket cycle: Edit the part program. The corner rounding radius is large smaller than the cutter radius. Tool radius too Circular pocket cycle: Edit the part program. The pocket radius is smaller than large the cutter radius.
Page 82 Tool definition not You programmed a tool definition Delete the TOOL DEF block (G99 (TOOL DEF, ISO: G99), although block). permitted the central tool file is active. Deactivate the tool table (machine parameter 7260). 2 – 80 HEIDENHAIN Service Manual iTNC 530...
Page 83 Error message Error Cause of error Corrective action number Tool number 0 A tool definition with the number Edit the part program. "0" is not permitted. not permitted Tool number 1099 The number used in the tool Use numbers greater than 99 for definition in the program is already the tool definition in the program.
Page 84 The union of cycles results in too Use a smaller tool. many subcontours. subcontours Too many Calculation of the tool path results Use a smaller tool. in more than 12 subcontours. subcontours Decrease the number of programmed subcontours. 2 – 82 HEIDENHAIN Service Manual iTNC 530...
Page 85 Error message Error Cause of error Corrective action number Too many Calculation of the equidistant Use a smaller tool. results in too many subcontours. subcontours Too many Calculation of the equidistant Use a smaller tool. results in too many subcontours. subcontours Too many A contour subprogram contains...
Page 86 DEL. To interrupt the delete DEL. sequence, press END. Cylinder surface not You called the Cylinder Surface Delete the cyclindrical interpolation cycle while the working plane cycle from the part program. tiltable was tilted. 2 – 84 HEIDENHAIN Service Manual iTNC 530...
Page 87: Log
General The log serves as a troubleshooting aid. There are 4 MB of memory available for this purpose. All entries in the log are marked with the current date and time. Note The following error messages are not entered in the log: *** POWER FAIL *** File system error x Overview of log...
Page 88 Log in with LSV2 protocol REMO A_LO Log out with LSV2 protocol REMO C_LK LSV2 protocol: Locking and releasing the keyboard; the key codes between locking and releasing are sent via LSV2 protocol. 2 – 86 HEIDENHAIN Service Manual iTNC 530...
Page 89 Example of a log The following example shows possible entries in the log: entry INFO: MAIN START 21.11.2001 07:30:51 iTNC 530 INFO: MAIN START 21.11.2001 07:30:51 NC SOFTWARE = 340420 01 INFO: MAIN CYCLES 21.11.2001 07:30:55 CYCLE data are up to date...
Page 90 Ensure correct spelling when making any changes in the log window. Then start reading out the log by pressing the "EXECUTE" soft key. A log file is now created and displayed on the screen. 2 – 88 HEIDENHAIN Service Manual iTNC 530...
Page 91: Errors And Error Analysis On The Machine Or Control
Check the grounding of your terminal X131 of power supply machine according to the current controller mode, accompanied by module (Simodrive 611D) not HEIDENHAIN grounding diagram loud noises (initial operation). properly wired. after consultation with the machine tool builder, see page 154.
Page 92 3 – 90 HEIDENHAIN Service Manual iTNC 530...
Page 93: Reserved
Reserved July 2002 4 – 91...
Page 94 4 – 92 HEIDENHAIN Service Manual iTNC 530...
Page 95: Overview Of Components
Overview of Components Standard Components Controller unit CC 422 (CC = Controller Computer) Main computer MC 422 (MC = Main Computer) July 2002 5 – 93...
Page 96 TE 420 Operating panel TE 530 Operating panel Picture to be added 5 – 94 HEIDENHAIN Service Manual iTNC 530...
Page 97 BF 120 Visual display unit Color VDU TFT interface (thin film transistor) Connection to iTNC: Female 62-pin D-sub connector X49 BF 150 Visual display unit Color VDU TFT interface (thin film transistor) Connection to iTNC: Female 44-pin D-sub connector X149 July 2002 5 –...
Page 98: Accessories
Accessories PL 410 B PL 405 B PLC input/ output unit MB 420 Machine operating panel HR 410 Handwheel 5 – 96 HEIDENHAIN Service Manual iTNC 530...
Page 99: Important Features Of Heidenhain Components
Important Features of HEIDENHAIN Components Hardware Identification ID plate (example) Note The location of the ID plate with unit designation, ID number and series number is shown below. Each unit can be identified through its own numbers. For the service the most important number is the ID number.
Page 100 BF 120 (unit rear side) BF 150 (unit rear side) 6 – 98 HEIDENHAIN Service Manual iTNC 530...
Page 101 TE 420 (unit rear side) TE 530 Picture to be added July 2002 6 – 99...
Page 102: Display Of System Information
Display of System Information General When consulting your machine manufacturer or HEIDENHAIN in case of error or malfunction of your machine, it is important to know which software is installed on the iTNC.  Display on iTNC Press the following keys to display the currently active NC software on the iTNC screen: ...
Page 103 Option Identifier of binary format 0000111100000111 Options enabled in the SIK (e.g. auxiliary axes, tilting operation, HSC milling etc.) DSP software 246275 Program number of DSP software Version of DSP software Note The DSP software designates the operating system for the digital signal processors (DSP). This is a part of the SETUP and is only active with digital axes/spindle.
Page 104 6 – 102 HEIDENHAIN Service Manual iTNC 530...
Page 105: Connector Designation And Layout
Connector Designation and Layout MC and CC 7.1.1 Designation and position of connectors MC 422 M with 5 position encoder inputs and CC 422 with 6 speed control loops X1 to X5 Position encoder 1 V X35 to X38 Vacant X15 to X20 Speed encoder 1 VPP X51 to X60...
Page 106 Axis-specific drive release 1 to 6 X151 Axis-specific drive release 7 to 10 Signal ground Equipment ground (YL/GN) Caution Do not engage or disengage any connecting elements while the unit is under power! 7 – 104 HEIDENHAIN Service Manual iTNC 530...
Page 107: Pin Layouts
7.1.2 Pin layouts X1 to X6, X35 to X38: Position encoder MC 422 AK 309 783-xx Encoder AK 310 197-xx Male Assignment Female Color Female Male Color +5 V (U Brown/Green Brown/Green 0 V (U White/Green White/Green Brown Brown A– Green Green Do not assign...
Page 108 White line) Free Black Internal Internal Internal Internal shield shield shield shield Clock Violet Violet Violet Clock Yellow Yellow Yellow External Externa External Hsg. Housing Hsg. shield Hsg. l shield Hsg. shield 7 – 106 HEIDENHAIN Service Manual iTNC 530...
Page 109 Analog outputs 1 to 6 MC 422 Connecting cable D-sub Assignment D-sub Color connctn. connctr. (female) (male) 15-pin 15-pin Analog output 1: ±10 V Brown Do not assign Brown/Green Analog output 2: ±10 V Yellow Analog output 5: ±10 V Red/Blue Analog output 3: ±10 V Pink...
Page 110 Stylus at rest means logic level HIGH. Two EA 652 can be connected to the MC 422 via the APE 652. This is necessary for example on large machines or on machines with swivel heads. 7 – 108 HEIDENHAIN Service Manual iTNC 530...
Page 111 Pin layout for TS 632 with two EA 652 via the APE 652: MC 422 Adapter APE 652 VB 336 157-xx EA 652 TS 632 cable 354 656-xx 346 323-xx 310 197-xx Male Female Male Color Female Male Color White/ White/ Brown Brown...
Page 112 0 V (U White White R– Black Black Green Green C– Brown Brown Gray Gray D– Pink Pink Do not assign Temperature– Violet Violet Hsg. Housing Hsg. External shield Hsg. Hsg. External shield Hsg. 7 – 110 HEIDENHAIN Service Manual iTNC 530...
Page 113 X15 to X20, X80 to X85: Speed encoder with EnDat interface CC 422 AK 336 376-xx VB 340 302-xx Male Assignment Female Color Female Male Color Female +5 V (U Brown/Green Brown/Green 0 V (U White/Green White/Green Green/Black Green/Black A– Yellow/Black Yellow/Black Blue/Black...
Page 114 Brown Brown Signal GND Black Black Violet Violet Gray Gray White/ White/ Green Green Do not assign Green Green External Hsg. Hsg. Hsg. External Hsg. Hsg. External shield Hsg. shield Hsg. shield 7 – 112 HEIDENHAIN Service Manual iTNC 530...
Page 115 Hsg. External shield Hsg. shield Hsg. X30: Reference signal for spindle Connecting terminal Assignment +24 V X34: Power supply for control-is-ready Connecting terminal Assignment Connection when using a signal HEIDENHAIN inverter +24 V X72/1 X72/2 July 2002 7 – 113...
Page 116 Gray/Brown Yellow/Brown White/Yellow Gray/White Pink/Blue Pink/Red 32, 33 Do not assign Brown/Blue, Pink/Green Control is ready Brown 35, 36, 37 Do not assign Yellow/Pink, Violet, White Housing External shield Housing External shield 7 – 114 HEIDENHAIN Service Manual iTNC 530...
Page 117 X42: PLC inputs on the MC 422 MC 422 Connecting cable Id. Nr. 244 005-xx, Id. Nr. 263,954-xx D-sub connctn. Assignment D-sub connctn. (female) 37-pin (male) 37-pin Gray/Red Brown/Black White/Black I3 Control-is-ready signal Green/Black acknowledgement Brown/Red White/Red White/Green Red/Blue Yellow/Red Gray/Pink Black Pink/Brown...
Page 118 RL14 Yellow RL15 RL16 Gray RL17 Blue RL18 Pink White/Gray Yellow/Gray Green/Red White/Pink Gray/Green Yellow/ Brown Gray/Brown Yellow/Black 27 RL19 White/Yellow 28 RL20 Gray/Blue Do not assign Pink/Blue RL21 Pink/Red RL22 Brown/Blue 7 – 116 HEIDENHAIN Service Manual iTNC 530...
Page 119 MC 422 Connecting cable Id. Nr. 263 954-xx TE 420 313 038-xx D-sub connctn. Assignment D-sub D-sub X2: D-sub (female) cnnctr. cnnctr. connctn. 37-pin (male) (female) (male) 37-pin 37-pin 37-pin RL23 Pink/Green Spindle override Brown (wiper) Feed-rate override Yellow/Pink (wiper) +5 V override Violet potentiometer...
Page 120 Via X4 34, 35 0 V (PLC) 34, 35 Brown, Yellow/Pink 34, 35 34, 35 36, 37 +24 V (PLC) Violet, white 36, 37 36,37 Housing Ext. shield Housing External shield Housing Housing 7 – 118 HEIDENHAIN Service Manual iTNC 530...
Page 121 X47: PLC expansion on the MC 422 MC 422 Conn. cable 1. PL 410 B/PL405 B Id. Nr. 289 111-xx / Id. Nr. 317 788-xx D-sub Assignment D-sub D-sub X1 D-sub Assignment connctn. connector connctr. connctn. (male) (female) (male) (female) 25-pin 25-pin 25-pin...
Page 122 (female) (male) (female) (male) 62-pin 62-pin 62-pin 62-pin Gray/Black CLK.P Brown/Black HSYNC Green/Black BLANK Orange/Black VSYNC Blue/Black Green/White Orange/White Brown/White Gray/White Blue/White Violet/White Violet/Brown Violet/Green Violet/Orange Violet/Blue Red/Gray Red/Brown Yellow/Gray Yellow/Brown Yellow/Green 7 – 120 HEIDENHAIN Service Manual iTNC 530...
Page 123 MC 422, X49 Connecting cable Id. Nr. 340 300-xx BF 120, X2 D-sub Assignmt. D-sub D-sub D-sub connctn. connctr. connector connctn. (female) (male) (female) (male) 62-pin 62-pin 62-pin 62-pin Free Black/Gray CLP.P Black/Brown HSYNC Black/Green BLANK Black/Orange VSYNC Black/Blue White/Green White/Orange White/Brown White/Gray...
Page 124 -15 V PF.PS.AC (only UV 120, UV 140, UV 150, UR 2xx) 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 RES.LE ERR.TMP 7 – 122 HEIDENHAIN Service Manual iTNC 530...
Page 125 X149: BF 150 flat-panel display MC 422, X149 Connecting cable Id. Nr. 35 545-xx BF 150, X2 D-sub (female) Assignmt. D-sub (male), D-sub (female), D-sub (male) 44-pin 44-pin 44-pin 44-pin White/Brown 2 White/Green Red/Gray CLKM Red/Blue White/Orange 7 Red/Brown Red/Green LVDSGND Red/Orange HWK_GND...
Page 126 Reserved, do not assign Reserved, do not assign Reserved, do not assign Reserved, do not assign Reserved, do not assign Reserved, do not assign Reserved, do not assign a. Maximum current consumption 10 mA. 7 – 124 HEIDENHAIN Service Manual iTNC 530...
Page 127: Plc Expansion Boards
PLC Expansion Boards 7.2.1 Designation and position of connectors PL 405 B +24V SUPPLY +24V +24V +24V +24V July 2002 7 – 125...
Page 128 PL 410 B +24V SUPPLY +24V +24V +24V +24V +24V SUPPLY ANALOG 7 – 126 HEIDENHAIN Service Manual iTNC 530...
Page 129: Pin Layouts
7.2.2 Pin layouts Pin layout of MC, connecting cable, and PL: PLC expansion on the MC Connecting cable Id. Nr. 289 111-xx 1. PL 4xx B D-sub Assignment D-sub D-sub D-sub Assignment (male) cnnctr. cnnctr. cnnctn. 25-pin, (female) (male) (female) 25-pin 25-pin 25-pin...
Page 130 Serial OUT Serial OUT White/Pink Serial OUT Address 4 Black Address 4 Address 2 Gray Address 2 Address 0 White Address 0 Housing External shield Housing External shield Housing Housing External shield 7 – 128 HEIDENHAIN Service Manual iTNC 530...
Page 131 X3: PLC input Terminal Assignment 1. PL 2. PL 3. PL 4. PL I192 I256 I320 I193 I257 I321 I194 I258 I322 I195 I259 I323 I196 I260 I324 I197 I261 I325 I198 I262 I326 I199 I263 I327 I200 I264 I328 I201 I265 I329...
Page 132 I120 I248 I312 I376 I121 I249 I313 I377 I122 I250 I314 I378 I123 I251 I315 I379 I124 I252 I316 I380 I125 I253 I317 I381 I126 I254 I318 I382 I127 I255 I319 I383 7 – 130 HEIDENHAIN Service Manual iTNC 530...
Page 133 X7: PLC output Terminal Assignment 1. PL 2. PL 3. PL 4. PL O128 O160 O129 O161 O130 O162 O131 O163 O132 O164 O133 O165 O134 O166 O135 O167 O136 O168 O137 O169 O138 O170 O139 O171 O140 O172 O141 O173 O142 O174...
Page 134 U – Measuring input for Pt 100 I – Constant current for Pt 100 Shield X23: Terminal Assignment Power supply for +24 V as per EN 50 178, 5.88 the analog inputs +0 V on the PL 410B 7 – 132 HEIDENHAIN Service Manual iTNC 530...
Page 135: Itnc Operating Panel
iTNC Operating Panel 7.3.1 Designation and position of connectors TE 420 7.3.2 Pin layouts Pin layout of the iTNC operating panel: Connection of soft Connecting element (male) 9-pin Assignment keys on the visual display unit with the iTNC operating panel Do not assign RL15 RL14...
Page 136 RL21 Pink/Red RL22 Brown/Blue RL23 Pink/Green Spindle override Brown (wiper) Feed-rate override Yellow/Pink (wiper) +5 V override Violet potentiometer 0 V override White potentiometer Housing External shield Housing External Housing Housing shield 7 – 134 HEIDENHAIN Service Manual iTNC 530...
Page 137: Visual Display Units
Visual Display Units 7.4.1 BF 120 Connection layouts Connecting terminal X1 Assignment +24 V Power supply July 2002 7 – 135...
Page 138 Orange/Red HWK0 White/Blue HWK1 Blue/White HWK2 White/Gray HWK3 Gray/White Brown/White Green/White Gray/Red CLKP Blue/Red Orange/White Brown/Red Green/Red Not assigned Not assigned Not assigned Not assigned Not assigned Not assigned LVDSGND LVDSGND LVDSGND 7 – 136 HEIDENHAIN Service Manual iTNC 530...
Page 139 MC 422, X149 Connecting cable Id. Nr. 353 545-xx BF 150, D-sub Assignment D-sub D-sub D-sub connctn. connctr. connctr. connctn. (female) (male), (female), (male) 44-pin 44-pin 44-pin 44-pin LVDSGND LVDSGND LVDSGND LVDSGND LVDSGND LVDSGND Not assigned Not assigned Not assigned Not assigned Not assigned Housing...
Page 140: Bf 150
Connecting cable Id. Nr. 353 545-xx BF 150, D-sub Assignment D-sub D-sub D-sub connctn. connctr. connctr. connctn. (female) (male), (female), (male) 44-pin 44-pin 44-pin 44-pin White/Brown White/Green Red/Gray CLKM Red/Blue White/Orange Red/Brown Red/Green LVDSGND Red/Orange 7 – 138 HEIDENHAIN Service Manual iTNC 530...
Page 141 MC 422, X149 Connecting cable Id. Nr. 353 545-xx BF 150, D-sub Assignment D-sub D-sub D-sub connctn. connctr. connctr. connctn. (female) (male), (female), (male) 44-pin 44-pin 44-pin 44-pin HWK_GND Orange/Red HWK0 White/Blue HWK1 Blue/White HWK2 White/Gray HWK3 Gray/White Brown/White Green/White Gray/Red CLKP Blue/Red...
Page 142: Interface Card For Simodrive 611D
With PLC module 9161, the iTNC sets the axis-specific internal current and speed controller (X111 or X112 Pin 4a high). Speed and current controller are not active? Clamping axis clamped? No M function active for spindle? 7 – 140 HEIDENHAIN Service Manual iTNC 530...
Page 143: Interface Card Id.nr. 31 437-Xx
7.5.2 Interface card Id.Nr. 31 437-xx Overview Designation Operating element LEDs and Enabling connector connectors Equipment ground Pulse release disabled (red) Pulse release disabled (red) READY Ready for operation (green) Pulse release disabled (red) Pulse release disabled (red) X111 PWM, axis/spindle X112 PWM, axis/spindle X351...
Page 144: Interface Card Id.nr. 324 952-1X
No controller enable for axis by iTNC. X2 (red) Path for PWM signals not enabled. With PLC module 9161, the iTNC sets the axis-specific internal current and speed controller (X2 pin 5 high). 7 – 142 HEIDENHAIN Service Manual iTNC 530...
Page 145: Interface Card Id.nr. 324 952-0X
7.5.4 Interface card Id.Nr. 324 952-0x Overview Designation Element LEDs and Connection of CC connectors Not ready: Monitoring of U , temperature, Power supply Pulse release Normally closed contact 1 Normally closed contact 2 K663 Safety relay for pulse release Power supply for safety relay (from SIMODRIVE unit bus) Connection of CC...
Page 146: Machine Operating Panel
Spindle off I145 Blue Coolant I146 Pink NC start I147 White/Gray NC stop I148 Yellow/Gray Rapid trav. I149 Green/Red Retract axis I150 White/Pink Rinse water I151 Gray/Green Via X3 I152 Yellow/Brown Via X3 7 – 144 HEIDENHAIN Service Manual iTNC 530...
Page 147 MC 422 Connecting cable Id. Nr. 263 954-xx MB 420 D-sub Assignment D-sub D-sub D-sub connctn. connctr. connctn. connctn. (female) (male) (female) (male) 37-pin 37-pin 37-pin 37-pin Gray/Brown Via X4 Yellow/Black Via X4 White/Yellow Via X4 Gray/Blue Via X4 Pink/Blue Via X4 Pink/Red Via X4...
Page 148: Handwheels
HR 130 Id. Nr. 254 040-xx D-sub cnnctr. Color D-sub connctr. D-sub cnnctr. Color (male) 9-pin (female) (male) 9-pin 9-pin Housing Shield Housing Housing Shield White White Brown Brown Yellow Yellow Green Green Gray 7 – 146 HEIDENHAIN Service Manual iTNC 530...
Page 149: Hr 410 (Portable Handwheel)
7.7.2 HR 410 (Portable handwheel) Pin layouts X23: Pin layout of the logic unit: Handwheel input D-sub connection (female) 9-pin Assignment +12 V Do not assign Housing External shield July 2002 7 – 147...
Page 150 Gray Green 8 Green C Green C Blue Contact 1 + 2 Contact 2 (left) permissive button Contact 1 (right) Contact 1 Contact 1 EMERGENCY STOP YL/BK 3 Contact 2 Contact 2 7 – 148 HEIDENHAIN Service Manual iTNC 530...
Page 151: Hra 110 (Multi-Axis Handwheel)
7.7.3 HRA 110 (Multi-axis handwheel) Pin layout X1, X2, X3: Pin layout on the HRA 110 for the HR 150: Inputs for HR 150 HRA 110 handwheels 261 097-xx Connection (female) 9-pin Assignment – – – +5 V Internal shield Housing External shield X23:...
Page 152: Touch Probe Systems
Trigger signal Green Green Trigger signal Yellow Yellow 11 to 15 Do not assign 11 to 15 External Hsg. External shield Hsg. shield Hsg. a. Stylus at rest means logic level HIGH. 7 – 150 HEIDENHAIN Service Manual iTNC 530...
Page 153 7.8.2 TS 632 Pin layout MC 422 AK 310 197-xx EA 632 TS 632 346 322-xx Female Assignment Male Color Female Male Color 0 V (internal shield) White/ White/ Brown Brown Do not assign Ready Gray Gray Start Yellow + 15 V ± 10% (U ), max.
Page 154: Ts 632
White/ White/ Brown Brown Gray Gray Yellow For the layout see Brown Brown TS632 with EA632 on page 108 Blue Blue White White Green Green External Hsg. Hsg. Hsg. shield Hsg. Hsg. 7 – 152 HEIDENHAIN Service Manual iTNC 530...
Page 155: Tt 130
7.8.3 TT 130 Pin layout Pin layout on adapter cable and touch probe: MC 422 TT 130 335 332-xx 296 537-xx Female Assignment Male Color Female Male Color Ready Pink 0 V (U White/Green 1 White Do not assign +15 V ± 5% (U Brown/Green 2 Brown Do not assign...
Page 156: Grounding Diagrams And Block Diagrams
8 Grounding Diagrams and Block Diagrams Grounding Diagram In preparation 8– 154 HEIDENHAIN Service Manual iTNC 530...
Page 157: Basic Circuit Diagrams
8.2 Basic Circuit Diagrams iTNC 530 with Modular Non-Regenerative HEIDENHAIN Inverter System July 2002 8 – 155...
Page 158 530 with Modular Regenerative HEIDENHAIN Inverter System 8– 156 HEIDENHAIN Service Manual iTNC 530...
Page 159 530 with UE 2xxB Non-Regenerative HEIDENHAIN Compact Inverter July 2002 8 – 157...
Page 160 530 with UR 2xx Regenerative HEIDENHAIN Compact Inverter 8– 158 HEIDENHAIN Service Manual iTNC 530...
Page 161 530 with SIMODRIVE Inverter System July 2002 8 – 159...
Page 162: Block Diagram
Block diagram 8– 160 HEIDENHAIN Service Manual iTNC 530...
Page 163 Digital axis/spindle Machine iTNC 530 Acceleration Velocity feedforward feedforward Feed motor with rotary encoder Machine slide for rotor speed with linear Position Digital speed Current Power stage and position encoder controller control controller Nominal position Nominal Nominal speed current Actual position...
Page 164 Block diagram of the speed controller Power Machine Speed Current stage Motor slide controller controller Nominal Nominal current value Actual current Actual rpm Block diagram of position feedback control with servo lag Noml Noml Actl 8– 162 HEIDENHAIN Service Manual iTNC 530...
Page 165 Block diagram of position feedback control with velocity feedforward control ∆ S Noml ∆ t Noml Noml – Actl MP1510.x MP1080.x July 2002 8 – 163...
Page 166 8– 164 HEIDENHAIN Service Manual iTNC 530...
Page 167: Power Supply
Power Supply Power Supply for the iTNC 530 The iTNC 530 is powered via a compact inverter, via the UV 1x0 power supply units or via the UV 105 power supply unit. Power is supplied through the 50-pin ribbon-cable connector X69 and in addition through a 5 V terminal on the CC 422.
Page 168 Power supply for CC 422 (to X69 on CC 422) Status signals from UV 1x0 Power supply Caution Do not engage or disengage any connecting elements while the unit is under power! 9 – 166 HEIDENHAIN Service Manual iTNC 530...
Page 169 The UV 105 is powered with dc-link voltage U through UV 105 with U The conductor bars (for HEIDENHAIN inverter systems). A cable which is connected instead of the conductor bar (for non-HEIDENHAIN inverter systems). The dc-link voltage is monitored by the control. Service diagnosis...
Page 170 If not, check the fuses on the protective PCB (see below!). Note Operation with a non-HEIDENHAIN inverter (e.g. Simodrive 611): The power supply from the dc link is usually lead via a protective PCB. This is secured to the conductor bar on the non-HEIDENHAIN inverter.
Page 171 Fuses in  Switch off the main switch of the machine. UV 105  Dismantle the UV 105 power supply unit.  Ensure that the unit is not under power.  Remove the side plate. Caution: One screw is located under the cover of the connector of the conductor bar. ...
Page 172: Power Supply For Control-Is-Ready Signal
 Switch off the main switch of the machine.  Dismount the MC.  Check the fine-wire fuses on the board in the area of connector X34 and replace these if necessary. 9 – 170 HEIDENHAIN Service Manual iTNC 530...
Page 173: Buffer Battery
Buffer Battery General If the machine is switched off, the power for the RAM is supplied by the buffer battery. The rated voltage is 3 V. For safeguarding the RAM, an additional capacitor (Gold cap) was integrated onto the PCB of the iTNC.
Page 174: Info Menu
° TEMP Temperature inside the iTNC ° T[CPU1] 63 Temperature of CPU1 Note The values are updated internally every minute; the display is only updated each time the Info menu is called. 9 – 172 HEIDENHAIN Service Manual iTNC 530...
Page 175: Power Supply For Plc Outputs
Power Supply for PLC Outputs 9.5.1 General The PLC of the iTNC 530 as well as the PL 410 B/PL 405 B are powered by the 24 Vdc control voltage of the machine (in accordance with VDE 0551). Minimum absolute value 19.2 Vdc...
Page 176: Supply Voltage For Plc Outputs On The Pl 4Xx B
+24 Vdc O48 – O80 – O144 – O176 – Power supply O151 O183 for outputs +24 Vdc O56 – O88 – O152 – O184 – Power supply O158 O190 for outputs 9 – 174 HEIDENHAIN Service Manual iTNC 530...
Page 177 Pin layout on the PL 405 B: Terminal Assignment PL 1 PL 2 PL 3 PL 4 +24 Vdc logic power supply and for control-is-ready signal +24 Vdc O48 – O80 – O144 – O176 – Power supply O151 O183 for outputs +24 Vdc O56 –...
Page 178: Power Supply For The Display Units
Power Supply for the Display Units Power supply with basic insulation in accordance with EN 50 178: Connecting terminal X1 Assignment +24 V Power consumption:BF 120: 15 W BF 150: 25 W 9 – 176 HEIDENHAIN Service Manual iTNC 530...
Page 179: Te 420 And Te 530 Keyboard Units
10 TE 420 and TE 530 Keyboard Units 10.1 Front View of the Keyboard Units 10.1.1 TE 420 July 2002 10 – 177...
Page 180: Te 530
10.1.2 TE 530 10 – 178 HEIDENHAIN Service Manual iTNC 530...
Page 181: Checking The Keyboard Unit
10.2 Checking the Keyboard Unit Checking a When checking a defective key, proceed as follows: defective key  Activate a key which according to the key matrix has the same SL line as the defective key. If this key does not react, the SL line is interrupted. If the key reacts, proceed as follows: ...
Page 182 Measuring circuit Logic-Unit X 45 Measuring adapter Multimeter 10 – 180 HEIDENHAIN Service Manual iTNC 530...
Page 183: Key Matrix Of The Te 420 Keyboard Unit
10.3 Key Matrix of the TE 420 Keyboard Unit 10.3.1 TE 420 X2 PIN 17 18 19 28 29 31 32 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 SL0 July 2002 10 – 181...
Page 184 X2 PIN 17 18 19 28 29 31 32 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 SL0 10 – 182 HEIDENHAIN Service Manual iTNC 530...
Page 185 X2 PIN 17 18 19 28 29 31 32 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 SL0 July 2002 10 – 183...
Page 186 X2 PIN 17 18 19 28 29 31 32 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 SL0 10 – 184 HEIDENHAIN Service Manual iTNC 530...
Page 187 X2 PIN 17 18 19 28 29 31 32 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 SL0 July 2002 10 – 185...
Page 188: Te 530
10.3.2 TE 530 X2 PIN HOME BREAK SCROL 10 – 186 HEIDENHAIN Service Manual iTNC 530...
Page 189 X2 PIN & July 2002 10 – 187...
Page 190 X2 PIN 10 – 188 HEIDENHAIN Service Manual iTNC 530...
Page 191 X2 PIN CAPS LOCK July 2002 10 – 189...
Page 192 X2 PIN SHIFT " links 10 – 190 HEIDENHAIN Service Manual iTNC 530...
Page 193 X2 PIN < > SHIFT GOTO CTRL rechts links links July 2002 10 – 191...
Page 194 X2 PIN SPACE Kont links rechts 10 – 192 HEIDENHAIN Service Manual iTNC 530...
Page 195 X2 PIN APPR C H F R N D CALC HELP July 2002 10 – 193...
Page 196 X2 PIN TO UCH CYCL CYCL STOP PROBE CALL CALL 10 – 194 HEIDENHAIN Service Manual iTNC 530...
Page 197 X2 PIN TO O L TO O L PG M CALL CALL July 2002 10 – 195...
Page 198: Keys On The Vdus
Connection for ribbon cable display unit=> keyboard unit (plug-type connector) Connection for cable keyboard unit => MC (D-Sub 37-pin) SK = Soft key (SK1..SK8 from left to right) BF 150 X1 pin X2 pin RL12 RL13 RL14 RL15 10 – 196 HEIDENHAIN Service Manual iTNC 530...
Page 199 X1 pin X2 pin RL12 RL13 RL14 RL15 a. Connector on the keyboard unit b. Key on visual display unit Connection for ribbon cable display unit=> keyboard unit (plug-type connector) Connection for cable keyboard unit => MC (D-Sub 37-pin) SK = Horizontal soft keys (SK1..SK8 from left to right) MF = Vertical soft keys (MF1..MF6 from top to bottom) July 2002...
Page 200: Mb 420 Machine Operating Panel
For this purpose you require the universal test adapter (Id. Nr. 255480-01,See section “Inspection, Measuring and Test Equipment” on page 297. Note Use the TABLE function in the PLC mode for assistance. Assignment of PLC inputs to the keys of the MB 420: 10 – 198 HEIDENHAIN Service Manual iTNC 530...
Page 201: Visual Display Units
11 Visual Display Units 11.1 Checking the BC 120F Visual Display Unit Fault diagnosis If the machine is switched on, but the screen remains black:  Is the fan running?  Check the 24 V voltage at the 2-pin connector of the visual display unit. Note If the power supply is in order, then a further inspection of the flat-panel display is not possible without special test equipment.
Page 202: Checking The Bc 150 Visual Display Unit
If you have a dimensionally identical control:  Test the BF 150 with this control. Note If required you can display the control monitor by means of the programs TNCremo, TNCremoNT or TeleService. 11 – 200 HEIDENHAIN Service Manual iTNC 530...
Page 203: File Management Of Itnc
PLC error tables, compensation value tables and OEM cycles are stored here. The PLC partition only becomes visible when you enter the code number 807667. System-specific files (system files, NC dialogs, HEIDENHAIN cycles, etc.) A daily password is required to open the SYS partition. Caution Changes to the SYS partition can result in a malfunction of your TNC.
Page 204 Structure of the iTNC hard disk TNC Partition USER Data PLC Partition OEM Data SYS Partition HEIDENHAIN NC Software Setup HEROS Operating System 12 – 202 HEIDENHAIN Service Manual iTNC 530...
Page 205: Tnc Partition (Tnc:\)
12.3 TNC Partition (TNC:\)  Calling the Press the following key combination to call the TNC partition: TNC partition  Select Programming and Editing operating mode  Call the program management The directory structure is displayed on the left side of the screen. You can move to the corresponding subdirectories using the UP and DOWN arrow keys.
Page 206 The file is selected in a Program Run mode Protected file, i.e. cannot be deleted or edited Date Date on which file was last changed Time Time at which file was last changed 12 – 204 HEIDENHAIN Service Manual iTNC 530...
Page 207: Plc Partition (Plc:\)
12.4 PLC Partition (PLC:\)  Calling the PLC Press the following key combination to call the PLC partition: partition  Select Programming and Editing operating mode.  Prepare iTNC for entry of code number.  Enter code number and acknowledge. After the code number has been entered, the PLC basic menu is displayed.
Page 208 The file is selected in a Program Run mode Protected file, i.e. cannot be deleted or edited Date Date on which file was last changed Time Time at which file was last changed 12 – 206 HEIDENHAIN Service Manual iTNC 530...
Page 209: Machine Parameter Editor
12.5 Machine Parameter Editor  Call the Press the following key combination to call the active machine parameter list: active machine  Select Programming and Editing operating mode. parameter list  Call input field for code number.  Enter code number and acknowledge. Caution Machine parameters may only be changed after consultation with the machine manufacturer.
Page 210 When you press the END key, the iTNC carries out a reset and activates the backup copy of the machine parameter list file. The original file is activated in the same way. 12 – 208 HEIDENHAIN Service Manual iTNC 530...
Page 211: Switching The Position Display For Service Purposes
12.6 Switching the Position Display for Service Purposes  Activation Press the following key combination to switch the position display:  Select MACHINE mode (manual, program run/full sequence, etc.).  Activate MOD function.  Press GOTO to open a list box. Description of Possible position displays: the settings...
Page 212 12 – 210 HEIDENHAIN Service Manual iTNC 530...
Page 213: Encoder Interface
13 Encoder Interface 13.1 Position Encoders Circuit Position encoder On the MC there are the following inputs: inputs X1 to X6 and - depending on the expansion stage - X35 to X38. The monitoring functions for the position encoders are activated in MP 20.x. MP 100 contains the information which axis is the first, the second, the third axis etc.
Page 214 Does the error message move from X to Y? Error at position encoder input of Error in position encoder or encoder control cable If necessary, you may also exchange MP 115.0 and MP 115.2. 13 – 212 HEIDENHAIN Service Manual iTNC 530...
Page 215: Speed Encoders Circuit
13.2 Speed Encoders Circuit Speed encoder On the CC there are the following inputs: inputs X15 to X20 and - depending on the expansion stage of the auxiliary drive-control board - X80 to X83. MP 100 contains the information which axis is the first, the second, the third axis etc. The allocation of speed encoder inputs to the axes can be found in the machine parameters MP 112.x The allocation of speed encoder inputs to the spindles can be found in the machine parameters...
Page 216 MP 112.0 and MP 112.1 Does the error message move from X to Y? Error at speed encoder input of Error in speed encoder or encoder control cable 13 – 214 HEIDENHAIN Service Manual iTNC 530...
Page 217: Checking Position And Speed Encoders
Adapter Various adapters have been developed to permit PWM8 measurement of the different encoder signals(11 µApp, 1 VPP, TTL) at iTNC 530. You will find a connection diagram of the adapters and ID numbers in the PWM8 operating manual. Internal...
Page 218: Traverse With Indirect Distance Measurement (Emergency Operation)
Now you can traverse the axis with indirect distance measurement. Note If an error message is generated immediately (in most cases "Standstill monitoring" or "Movement monitoring" or similar), invert MP 210 (counting direction of position encoder). 13 – 216 HEIDENHAIN Service Manual iTNC 530...
Page 219: Reference Marks
Reference marks HEIDENHAIN linear encoders are designed with one or more reference marks. The reference marks identify an axis position at a known distance from the machine datum. The position of the freely selectable datum is defined with respect to the machine datum.
Page 220: Heidenhain Service Manual Itnc
Direction for traversing the reference marks Format: %xxxxxxxxxxxxxx Input: Bits 0 to 13 correspond to axes 1 to 14. 0: Positive 1: Negative MP1330.x Velocity for traversing the reference marks Input: 80 to 300,000 [mm/min] 14 – 218 HEIDENHAIN Service Manual iTNC 530...
Page 221 MP1331.x Velocity for leaving the reference mark end position for axes 1 to 9 (only for rotary encoders MP1350 = 2) Input: 10 to 300,000 [mm/min] MP1340.x Sequence for traversing the reference marks Input: 0: No evaluation of reference marks 1 to 14: Axes 1 to 14 MP1350.x Type of reference mark traverse...
Page 222 Two successive reference marks are traversed Is the machine outside the software limit switch range? Machine moves to software limit switch Machine stops 14 – 220 HEIDENHAIN Service Manual iTNC 530...
Page 223 Function when MP1350.x = 0. This setting is used only to ensure compatibility. Do not use for new installations. Reference marks "Reference end closed postion" trip dog open Traverse direction MP1320 Press external START key Trip dog "Reference end position" closed? Traverse direction from Invert traverse direction...
Page 224 "Reference end position" is closed before two successive reference marks are traversed Reference mark is passed over Is the machine outside the software limit switch range? Machine moves to software limit switch Machine stops 14 – 222 HEIDENHAIN Service Manual iTNC 530...
Page 225 Linear Function when MP1350.x = 2 measurement For linear measurement using a rotary encoder, a reference pulse is produced on each revolution through rotary of the encoder. Ensure that during referencing the same reference pulse is always evaluated. encoder This can be realized with the trip dog for reference end position. Measuring length Reference pulse Desired reference pulse...
Page 226 14 – 224 HEIDENHAIN Service Manual iTNC 530...
Page 227: Checking The Enables On The Itnc
MP 2040 contains the information whether this drive enabling for axis groups is used and how the axis groups are assigned.  HEIDENHAIN inverter system ready. The green READY LEDs at the drive module (of a modular inverter system) or at the output stage (of a compact inverter) must be lit.
Page 228 1: Emergency stop for all axes that are not excepted with Module 9169 2: I32 and Module 9169 are without functionality MP2170 Waiting time between the switch-on of the drive and the drive’s standby signal Input: 0.001 to 4.999 [s] 0: 2 [s] 15 – 226 HEIDENHAIN Service Manual iTNC 530...
Page 229: Examination
15.2 Examination 15.2.1 Examination of the control-is-ready output (X41/pin 34) and the control-is-ready signal acknowledgment input I3 (X42/pin 4). If the message "Relay external DC voltage missing" remains on the screen after the control has been switched on, carry out the following fault diagnosis: ...
Page 230: Checking The Drive Enabling For The Axis Groups Via Connector X150 (If Wired)
Insert a bridge between X41/Pin34 and X42/Pin4 (unclamp wires). Note If 24 V is supplied to the control-is-ready output from the HEIDENHAIN inverter system via connector X34, potential differences between the 24 V machine voltage and the 24 V from the inverter can result in compensating currents.
Page 231: Checking The Readiness Of The Inverter System
 Check, whether the green READY LED (at the compact inverter, at the UM axis module or at the HEIDENHAIN interface card for the SIMODRIVE system) of the axis to be traversed is lit. Note The SH1 signal (safe stop 1) indicated by a red LED at the inverter, is generated by the computer of the iTNC.
Page 232: Checking Plc Modules, Markers And Words
= 1+2+4+8 = F), the second HEX digit has the value 4, i.e. the 7th axis is enabled (2 = 4). In binary format this would be: 0100 1111 And in decimal format: 79. 15 – 230 HEIDENHAIN Service Manual iTNC 530...
Page 233: Interface To Servo Amplifier
Assignment nominal value output 1. spindle MP 121.1 Assignment nominal value output 2. spindle iTNC 530 Input values in machine parameter MP 120.x and 121.x: 0 = No nominal value output via control 1 = Analog nominal speed value ( ±10 V) at connection X8 channel 1 2 = Analog nominal speed value ( ±10 V) at connection X8 channel 2...
Page 234: Overview Of Test Routines For Error Diagnosis
Two-axis module SIMODRIVE 611 D and servo motors, Test routine 5 if no error at the iTNC HEIDENHAIN UE 2xxB compact inverters Test routine 6 Note Also use the HEIDENHAIN tool TNCdiag for error diagnosis. 16 – 232 HEIDENHAIN Service Manual iTNC 530...
Page 235: Test Routine 1, Checking The Analog Speed Command Interface
16.2.1 Test routine 1, Checking the analog speed command interface General The control outputs an analog voltage of 0V to ±10V, in proportion to the traversing speed (See MP1050.x page 306, analog voltage for rapid traverse). This voltage can be measured directly at the MC or at the connecting terminals of the servo amplifier with a multimeter via the universal measuring adapter.
Page 236 Voltage range: = +10 V ± 100 mV amax = -10 V ± 100 mV amin Resolution: 14 bit = 16.384 steps Smallest step: ------------------- 0,610 mV 16384 16 – 234 HEIDENHAIN Service Manual iTNC 530...
Page 237: Test Routine 2
= 0 (2. spindle not active) Caution Please contact your HEIDENHAIN agency, if you want to execute this routine and different values are entered in the parameters MP2180.x. Only encoders within the groups X51 to X56 (main controller board) and X57 to X60 (aux.
Page 238 S ervo am plifier, servo drive etc. are The defect is probably w orking properly. The defect is probably outside the C C . located in the C C (PW M output). (sevor am plifier, m otor, etc.) 16 – 236 HEIDENHAIN Service Manual iTNC 530...
Page 239: Test Routine 3
= 0 (2. spindle not active) Caution Please contact your HEIDENHAIN agency, if you want to execute this routine and different values are entered in the parameters MP2180.x. Only encoders within the groups X51 to X56 (main controller board) and X57 to X60 (aux.
Page 240: Test Routine 4
= 0 (2. spindle not active) Caution Please contact your HEIDENHAIN agency, if you want to execute this routine and different values are entered in the parameters MP2180.x. Only encoders within the groups X51 to X56 (main controller board) and X57 to X60 (aux.
Page 241: Test Routine 5
= 0 (2. spindle not active) Caution Please contact your HEIDENHAIN agency, if you want to execute this routine and different values are entered in the parameters MP2180.x. Only encoders within the groups X51 to X56 (main controller board) and X57 to X60 (aux.
Page 242: Test Routine 6
= 0 (2. spindle not active) Caution Please contact your HEIDENHAIN agency, if you want to execute this routine and different values are entered in the parameters MP2180.x. Only encoders within the groups X51 to X56 (main controller board) and X57 to X60 (aux.
Page 243: Speed Adjustment At Servo Amplifier
16.3 Speed Adjustment at Servo Amplifier General Speed adjustment at servo amplifier needs to be carried out if You have updated the mechanical design of an axis (e.g. guideway, bearing, drive spindle, etc.) You have exchanged the servo amplifier or the motor. Servo lag at constant traverse is impermissibly high.
Page 244: Adjusting The Electrical Offset
Adjust the offset at the servo amplifier until the individual axes either display the value 0 or oscillate around 0 (approximate value ± 3-5 µm).  Reset the original values in machine parameters and in the position display. 16 – 242 HEIDENHAIN Service Manual iTNC 530...
Page 245 Offset adjusting via Procedure: code number  Select the Programming and Editing mode.  Prepare iTNC for entry of code number.  Enter the code number.  Confirm.  Press one of the following soft keys. Carry out an offset compensation. The values are stored in the nonvolatile memory.
Page 246 16 – 244 HEIDENHAIN Service Manual iTNC 530...
Page 247: Integrated Oscilloscope
17 Integrated Oscilloscope The iTNC features an integrated oscilloscope. The oscilloscope can be called via code number 688379. With this oscilloscope you can record the following signals in up to six channels: Signal Explanation No recording in this channel Saved The signal last recorded is saved Actual pos Actual position [mm]...
Page 248 When the internal oscilloscope is activated again, "Ramp" output is automatically selected. Feed rate:  Enter the height of the step for the nominal velocity value (in mm/min). This entry has no effect for ramp output. 17 – 246 HEIDENHAIN Service Manual iTNC 530...
Page 249 Sample time:  Set the time interval for recording the signals. Entry: 0.6 ms; 1.8 ms and 3.6 ms 4096 samples are stored. The signals are therefore stored for the following duration: 0.6 ms ⋅ 4096 = 2.4576 s 1.8 ms ⋅ 4096 = 7.3728 s 3.6 ms ⋅...
Page 250 The time [s] and the value of the second cursor is shown with respect to the time point of the first cursor. With this function you can measure the acceleration time of an axis, for example. 17 – 248 HEIDENHAIN Service Manual iTNC 530...
Page 251 Meaning of the soft keys: Meaning of the soft keys: Select one of the six channels using the cursor keys (arrow keys around the GOTO key). Press the arrow keys on the VDU to switch the soft-key row and display the following symbols: Soft-key row 1: Back to setup menu.
Page 252 TNCscope software. The TNCscope software has been developed as external oscilloscope for TNC410. With iTNC 530 it does not work online. You can use TNCscope to open and edit your oscilloscope files (*.DTA files) on your computer.
Page 253: Plc Interface
18 PLC Interface 18.1 Specifications PLC inputs Voltage ranges MC 422 PL 4xx B “1” signal: U 13 V to 30.2 V “0” signal: U -20 V to 3.2 V Current ranges: “1” signal: I 3.8 mA to 8.9 mA 2.5 mA to 6 mA “0”...
Page 254: Monitoring The Plc Inputs And Outputs
PL 405B/510B I/O unit is defective.  Press the END key twice to end the TABLE function and exit the Programming and Editing mode. 18 – 252 HEIDENHAIN Service Manual iTNC 530...
Page 255 PLC outputs When checking the PLC outputs, proceed as follows:  Switch off the main switch of the machine.  Connect the universal measuring adapter to connector X41 or X46 between the MC and the connecting cable. Note The voltage levels for the PLC inputs or the output current for the PLC outputs on the PL 405B/410B must be measured directly at the corresponding terminal.
Page 256 Always switch off the main electrical disconnect switch of the machine before connecting or disconnecting any plugs or terminals. Otherwise damage or injury to property or persons may result. X41: PLC output X42: PLC input X46: Machine operating panel 18 – 254 HEIDENHAIN Service Manual iTNC 530...
Page 257: Service Diagnosis In Plc Mode
18.3 Service Diagnosis in PLC mode 18.3.1 TRACE function The TRACE function allows the monitoring of logic states such as Markers Inputs Outputs Timers Counters as well as the inspection of the contents of Bytes Words Double words  The TRACE function is called via the TRACE soft key. Call The statement list (STL) of the converted program is displayed.
Page 258: Logic Diagram
Only a maximum 1024 PLC scans are traced.  Soft key for storing a completed trace on the hard disk.  Soft key for loading a saved trace into the logic diagram. 18 – 256 HEIDENHAIN Service Manual iTNC 530...
Page 259 Selection of  Press the following key combination: operands and start  Display selection table. of recording A table appears in which the desired operands can be selected. The individual positions in the table are interrogated using dialog. Incorrect entries can be deleted with DEL key. A trigger condition can be set for each operand.
Page 260: Table Function
The logic states of the markers, inputs, outputs, counters and timers are shown dynamically. The display mode for byte, word and doubleword tables can be switched between HEX and DECIMAL. Positions can be selected within the tables using the cursor keys or the GOTO key. 18 – 258 HEIDENHAIN Service Manual iTNC 530...
Page 261: Re-Compile The Plc Program
18.4 Re-Compile the PLC program Main screen  Prepare compilation. Compile PLC program  Compilation of the main PLC program and the PLC error table.  Compilation of the main PLC program.  Compilation of the PLC error table.  After pressing this soft key, the program manager is opened.
Page 262: Calling The Plc Error Table (.Pet) For Diagnosis Purposes
A priority from 0 to 2 can be entered for the error message. 0 is the highest priority. The active PLC error messages are displayed in order of priority. MType Message type: E = Error, W = Warning, I = Info  Exit PET table 18 – 260 HEIDENHAIN Service Manual iTNC 530...
Page 263: Nonvolatile Plc Markers And Words
18.6 Nonvolatile PLC Markers and Words Saving on hard disk For storing certain states of the PLC program, it is possible to save the nonvolatile PLC memory range on the hard disk and then load it again for testing purposes. ...
Page 264 The default setting offered by the iTNC is PLC:\PLCMEM.A.  The stored states of the PLC markers and words are restored in the RAM.  Exit PLC operating mode. 18 – 262 HEIDENHAIN Service Manual iTNC 530...
Page 265: Serial Handwheels
19 Serial Handwheels 19.1 HR 130 Handwheel HR130 Checking data The HR 332 serial handwheel with auxiliary keys can be checked using an oscilloscope. transmission The following signals can be measured at handwheel input X23 of the MC. The signals must correspond to the following diagram: Pin 6 DTR Pin 8 RxD...
Page 266: Hr 410 Handwheel
Pin 6 DTR Pin 8 RxD t = 6 ms Note Power is supplied to the handwheel via the MC. (X23 Pin 2 = 0 V, Pin 4 = + 12 V) 19 – 264 HEIDENHAIN Service Manual iTNC 530...
Page 267 Checking the keys Set machine parameter MP7640 = 6. MP7645.0 determines whether the handwheel keys are evaluated by the NC or the PLC. MP7645.0 = 0 MP7645.0 = 1 Evaluation of keys via NC Evaluation of keys via PLC With the exception of the function keys A, B and All keys are evaluated by the PLC.
Page 268 19 – 266 HEIDENHAIN Service Manual iTNC 530...
Page 269: Touch Probe Systems
20 Touch Probe Systems 20.1 Overview 20.1.1 Touch probes for workpiece measurement TS 220 With cable connection TS 632 20.1.2 Touch probe for tool measurement TT 130 July 2002 20 – 267...
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Page 271: Data Interfaces
21 Data Interfaces 21.1 Cable Overview Please note: Max. cable length with Ethernet is 400 m (shielded), 100 m (unshielded). Maximum cable length with RS-232-C/V.24 is 20 meters. Maximum cable length with RS-422-C/V.11 is 1000 meters. 21.1.1 Ethernet interface RJ45 port ...
Page 272: Rs-422/V.11
21.1.3 RS-422/V.11 Note The RS-422-/V.11 data interface has the same pin layout at the iTNC (connector X28) and at the V.11 adapter block. 21 – 270 HEIDENHAIN Service Manual iTNC 530...
Page 273: Data Interface Operating Modes
21.2.1 Overview of operating modes The iTNC can be set for data transfer according to the following interface operating modes: For connection of the HEIDENHAIN floppy-disk unit FE 401B or other peripheral units. This operating mode is supported by TNCremo/TNCremoNT.
Page 274: Interface Configuration And Assignment Of Mode
Press the ENT key repeatedly until the value you require is displayed (or press MOD to call the menu).  To exit MOD function RS 232/RS 422, press the END soft key. 21 – 272 HEIDENHAIN Service Manual iTNC 530...
Page 275: Transfer Of Files Via Data Interface
22 Transfer of Files via Data Interface 22.1 The Data Transfer Menu When you call program management in the Programming and Editing mode, the different drives are displayed. RS 232:\ V.24 data interface (X27) RS 422:\ V.11 data interface (X28) TNC:\ TNC partition (user data) PLC:\...
Page 276: Downloading Files From The Itnc Via Data Interface
22.2 Downloading Files from the iTNC via Data Interface Note The following procedures describe the downloading and uploading of files using the HEIDENHAIN data transfer software TNCremoNT 2.0 from revision 237. Connection setup If your PC or laptop has a functioning ethernet card, proceed as follows: via Ethernet ...
Page 277 Connect a crossed serial connecting cable (RS232 or RS422) to your laptop and to the RS 422/V.11 serial D-Sub connector of the electrical cabinet (HEIDENHAIN adapter block). interface For possible configurations - also for direct connection of the laptop to the iTNC - please refer to the chapter “Data Interfaces”...
Page 278 You may also transfer the file with "drag & drop". For this purpose click the file to be transferred and hold the right mouse button. Now you can drag the file to its destination. 22 – 276 HEIDENHAIN Service Manual iTNC 530...
Page 279: Uploading Files Onto The Itnc Via Data Interface
22.3 Uploading Files onto the iTNC via Data Interface Note The following procedures describe the downloading and uploading of files using the HEIDENHAIN data transfer software TNCremoNT 2.0 from revision 237. Connection setup See previous pages. Uploading files  Select the target directory from the lower screen window (contents of iTNC) onto iTNC ...
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Page 281: Replacing Instructions
The ID number of the CC can be found on the underside of the base plate of the housing. Required PC or laptop with serial interface and/or Ethernet adapter and HEIDENHAIN data transfer software TNCremoNT, version 2.0, from revision 237.
Page 282 Caution When exchanging MC, CC or hard disk take the necessary preventive measures (EMC). There should be no contact between EMC-sensitive components with a statically loaded object (packaging, storing, warehousing). 23 – 280 HEIDENHAIN Service Manual iTNC 530...
Page 283: Nc Software Update For Pgm No. 340420/421
NC software. Normally the NC software is only exchanged by or upon consultation with the machine tool manufacturer. The new software can only be downloaded from the HEIDENHAIN website after entering a user name and a password. Information about...
Page 284 Press the EMERGENCY STOP button of your machine.  Press the following key combination:  Select Programming and Editing operating mode.  Prepare iTNC for entry of code number.  Enter the code number. 23 – 282 HEIDENHAIN Service Manual iTNC 530...
Page 285  Confirm.  Call submenu.  Call further submenu. Note: It is not necessary to enter the directory that is shown on the iTNC screen.  The files on the hard disk are converted in turn into ASCII format. During the conversion a progress window is displayed. The following type assignment exists between the binary files and the converted ASCII files: Binary file Extension of converted file...
Page 286 Contact the machine manufacturer for more information. See also "iTNC 530 READ_MP.A" in NC Info on the HEIDENHAIN file base on the internet. If required you can add comments on the function of the new parameters in the MP list.
Page 287 A log for the conversion process is stored in the file TNC:\CVREPORT.A. Copy sample files  With the COPY SAMPLE FILES soft key, the HEIDENHAIN standard tables for cutting data, the tables for tilting-axis geometry, and the table of M-function macros can be copied into the corresponding directories.
Page 288: Activating An Existing Nc Software In The Control
Otherwise enter values for the new parameters into the active machine parameter list. Contact the machine manufacturer for more information. See also "iTNC 530 READ_MP.A" in NC Info on the HEIDENHAIN file base on the internet. Deactive non-required parameters by leading semicolons.
Page 289: Backup/Restoring Hard-Disk Data
Note The following procedures describe the downloading and uploading of files using the HEIDENHAIN data transfer software TNCremoNT 2.0 from revision 237. The machine must not work while the hard disk data are being backed up or restored. We recommend to leave the control at the "Power interrupted" message.
Page 290 If the data transfer has been completed successfully, there should now be two files on your laptop: *.BCK backup file with the original files in compressed format *.LST reference list containing the directories and the files 23 – 288 HEIDENHAIN Service Manual iTNC 530...
Page 291: Extracting Files From The Backup File
23.4.2 Extracting files from the backup file General If you want to create a backup e.g. of the PLC partition, all related files are stored in one *.bck file using a compression algorithm. To view individual files (MP list, OEM.SYS, etc.) you can extract them from the *.bck file by means of TNCremoNT.
Page 292: Restoring The Data
Confirm the message regarding automatic reset of control with Yes and continue data transfer.  After restoring the machine backup the control needs to be rebooted. Now the machine operates as usual. 23 – 290 HEIDENHAIN Service Manual iTNC 530...
Page 293 Note The following problem may arise after restoring the machine backup and subsequent rebooting of the control: In the original MP list the control requires additional parameters (e.g. as of index xxx.5). Background: In the OEM.SYS there may be the entry AXISNUMBER. This serves to specify the number of axes for which indices are to be created in the MP file (e.g.
Page 294: Exchanging The Mc
On the hard disk of the new MC there is the operating system and the current NC software. If you require an older software version, you will have to install it now.  Restore your backup. 23 – 292 HEIDENHAIN Service Manual iTNC 530...
Page 295 Note The following problem may arise after restoring the machine backup and subsequent rebooting of the control: In the original MP list the control requires additional parameters (e.g. as of index xxx.5). Background: In the OEM.SYS there may be the entry AXISNUMBER. This serves to specify the number of axes for which indices are to be created in the MP file (e.g.
Page 296: Exchanging The Cc
Mount the new CC together with the MC in the electrical cabinet.  Re-establish all of the connections on the CC and the MC. Caution Do not confuse any of the connectors! 23 – 294 HEIDENHAIN Service Manual iTNC 530...
Page 297: Exchanging The Hard Disk
23.7 Exchanging the Hard Disk Preparing the machine Note Carry out the preparations described, if the hard disk is still functional.  Move the swivel head to a defined position or basic position. Contact your machine manufacturer for more information. ...
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Page 299: Inspection, Measuring And Test Equipment
24 Inspection, Measuring and Test Equipment 24.1 Universal Measuring Adapter (Id.Nr. 255 480 01) Measuring adapter The measuring adapter is used for checking the inputs or outputs on 9 - 37-pin D-sub connections. Messadapter Measuring Adapter Accessories Each connector size requires its own cable adapter. Adapter cable, 9-pin Id.Nr.
Page 300 Adapter cable, 25-pin. Id.Nr. 255 483 01 Adapter cable, 37-pin Id.Nr. 255 484 01 24 – 298 HEIDENHAIN Service Manual iTNC 530...
Page 301: Encoder Diagnostic Set Pwm 8 (Id.nr. 309 956-Xx)
24.2 Encoder Diagnostic Set PWM 8 (Id.Nr. 309 956-xx) General The PWM 8 phase angle measuring unit is a universal encoder for inspecting and setting HEIDENHAIN linear and angle encoders. Main functions The main functions of the PWM 8 are:...
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Page 303: Machine Parameter List
25 Machine Parameter List 25.1 Excerpt from the iTNC 530 Technical Manual 25.1.1 Encoders and machines Function and input Software version and behavior MP10 Active axes Format: %xxxxxxxxxxxxxx Input: Bits 0 to 13 correspond to axes 1 to 14 0: Axis not active...
Page 304 Bit 6 to bit 9: Position encoder inputs X35 to X38 Bit 10: Nonfunctional With 1 V : 0: 50 kHz; 1: 350 kHz With 11 µA : 0: 50 kHz; 1: 150 kHz 25 – 302 HEIDENHAIN Service Manual iTNC 530...
Page 305 Function and input Software version and behavior MP120.x Nominal speed command outputs of the axes Input: 0: No servo-controlled axis 1 to 6: Analog outputs 1 to 6 at terminal X8 7 to 12: Analog outputs 7 to 13 at terminal X9 51 to 60: Digital output X51 to X60 MP121.0 Nominal speed command output of the first spindle...
Page 306 Backlash compensation time Input: 0 to 1000 [ms] MP810.x Display mode for rotary axes and PLC auxiliary axes Input: 0.0000 to 99,999.9999 [°] 0: Display +/–99 999.9999 1: Modulo value for display 25 – 304 HEIDENHAIN Service Manual iTNC 530...
Page 307 Function and input Software version and behavior MP812 Activate software limit switches for tilting axes with RESET modulo display, M94 and encoders with EnDat interface Format: %xxxxxxxxxxxxxx Input: Bits 0 to 3 correspond to axes 1 to 14: 0: Software limit switch not active 1: Software limit switch active MP850.x Synchronized axes...
Page 308: Positioning
0.1 to 1000.0 [m/s or 1000°/s] MP1090.0 With machining feed rate MP1090.1 Beginning with feed rate from MP1092 MP1092 Feed rate threshold from which MP1090.1 becomes effective Input: 10 to 300,000 [mm/min] 25 – 306 HEIDENHAIN Service Manual iTNC 530...
Page 309 Function and input Software version and behavior MP1094 HSC filter 280 474-07 Input: 0: HSC filter inactive 0.1 to 166.0: Cutoff frequency for HSC filter MP1095 Nominal position value filter Input: 0: Single filter 1: Double filter MP1095.0 In the Program Run, Full Sequence; Program Run, Single Block;...
Page 310 Bits 0 to 13 correspond to axes 1 to 14 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 25 – 308 HEIDENHAIN Service Manual iTNC 530...
Page 311: Operation With Velocity Feedforward Control
25.1.3 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...
Page 312: Operation With Following Error (Servo Lag)
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 [%] 25 – 310 HEIDENHAIN Service Manual iTNC 530...
Page 313: Integrated Speed And Current Control
0.001 to 4.999 [s] 0: 2 [s] MP2180.x PWM frequency RESET Input: 0: f = 5000 Hz (for HEIDENHAIN inverters) 3200 to 4000: f = 3330 Hz 4001 to 4999: f = 4166 Hz 5000 to 6000: f = 5000 Hz...
Page 314 1: Monitoring inactive Bit 2 – Monitoring the ERR-IZ signal 0: Monitoring inactive (Non-HEIDENHAIN inverters, UE 2xx) 1: Monitoring active (All HEIDENHAIN inverters except UE 2xx) MP2302.x Reference value for I t monitoring Input: 0 to 1 000.000 [⋅ rated current of motor]...
Page 315 Function and input Software version and behavior MP2550.x Band-rejection filter for center frequency Input: 0.0 to 999.9 [Hz] MP2560.x Low-pass filter Input: 0: No low-pass filter 1: 1st-order low-pass filter 2: 2nd-order low-pass filter MP2590.x Braking ramp in an emergency stop Input: 0.1 to 999.9 [rpm/ms] 0: Function inactive...
Page 316: Spindle
Bit 1: Zero spindle speed when switching to another gear range 0: Reduce speed to 0 1: Do not reduce speed to 0 MP3120 Zero speed permitted Input: 0: S = 0 allowed 1: S = 0 not allowed 25 – 314 HEIDENHAIN Service Manual iTNC 530...
Page 317 Function and input Software version and behavior MP3130 Polarity of the nominal spindle speed Input: 0: M03 positive, M04 negative 1: M03 negative, M04 positive 2: M03 and M04 positive 4: M03 and M04 negative MP3140 Counting direction of spindle position encoder output signals Input: 0: Positive counting direction with M03...
Page 318 Maximum spindle speed for gear ranges 1 to 8 Input: 0 to 99 999.999 [rpm] MP3520.0 Speed activation through marker M4011 Input: 0 to 99 999.999 [rpm] MP3520.1 Spindle speed for oriented stop Input: 0 to 99 999.999 [rpm] 25 – 316 HEIDENHAIN Service Manual iTNC 530...
Page 319: Integral Plc
25.1.7 Integral PLC Function and input Software version and behavior MP4000.0-15 Options for the conditional compilation of the PLC program MP4020 PLC Functions RESET Format: %xxxxxxxxxxxxx Input: Bit 0 to bit 4: Reserved Bit 5: Single or double spindle operation 0: Single-spindle operation 1: Double-spindle operation Bit 6 - Reserved...
Page 320 -99,999.9999 to +99,999.9999 MP4231.0-31 Setting a number in the PLC (Module 9032) Input: -99,999.9999 to +99,999.9999 MP4310.0-6 Setting a number in the PLC (W976 to W988, M4300 to M4411) Input: 10 to 30,000 25 – 318 HEIDENHAIN Service Manual iTNC 530...
Page 321: Configuration Of The Data Interface
25.1.8 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 MP5020 Configuration of the data interface Format: %xxxxxxxx Input: Bit 0 – CN123 0: 7 data bits 1: 8 data bits...
Page 322: 3-D Touch Probe
MP6170 Number of measurements in a programmed measurement (touch probe block) Input: 1 to 3 CN123 MP6171 Confidence range for programmed measurement (MP6170 > 1) Input: 0.002 to 0.999 [mm] CN123 25 – 320 HEIDENHAIN Service Manual iTNC 530...
Page 323 Function and input Software version and behavior MP6180 Coordinates of the ring gauge center for Probing Cycle 2 with respect to the machine datum (traverse range 1) CN123 Input: 0 to +99,999.9999 [mm] MP6180.0 X coordinate MP6180.1 Y coordinate MP6180.2 Z coordinate MP6181 Coordinates of the ring gauge center for Probing Cycle 2...
Page 324: Tool Measurement With Tt
0: The NC program is not stopped when the breakage tolerance is exceeded 1: If the breakage tolerance is exceeded, the NC program is stopped and the error message Touch point inaccessible is displayed. 25 – 322 HEIDENHAIN Service Manual iTNC 530...
Page 325 Function and input Software version and behavior MP6500 Tool measurement with TT 130 Format: %xxxxxxxxxxxxxxx Input: Bit 7 – Reserved Bit 8 – Probing routine 0: Probe contact is probed from several directions 1: Probe contact is probed from one direction Bit 9 –...
Page 326 M function for spindle orientation during individual tooth measurement Input: -1: Spindle orientation directly by NC CN123 0: Function inactive 1 to 999: Number of the M function for spindle orientation by PLC 25 – 324 HEIDENHAIN Service Manual iTNC 530...
Page 327 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 Input: 1 to 1000 [rpm] 0: 1000 [rpm] CN123 MP6580.0-2 Coordinates of the TT 130 probe contact center with respect to the machine datum (traverse range 1) Input:...
Page 328: Tapping
Bit 2 – Spindle in position feedback control 0: Spindle operated without position feedback control 1: Spindle operated with position feedback control Bit 3 – IPC and acceleration feedforward control 0: Active 1: Not active 25 – 326 HEIDENHAIN Service Manual iTNC 530...
Page 329: Display And Operation
%xxxxxxxx Input: 0: Do not disable CN123 1: Disable 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 – Text files .A Bit 6 –...
Page 330 NC conversational language, soft keys for OEM cycles MP7230.1 PLC conversational language (user parameters) MP7230.2 PLC error messages MP7230.3 Help files MP7235 Time difference to time set in BIOS Input: -23 to +23 [hours] CN123 25 – 328 HEIDENHAIN Service Manual iTNC 530...
Page 331 Function and input Software version and behavior MP7237 Displaying and resetting the operating times MP7237.0 Display PLC operating times Input: Bits 0 to 7 represent PLC operating times 1 to 8 0: Do not display 1: Display MP7237.1 Resetting PLC operating times with the code number 857282 Input: Bits 0 to 7 represent PLC operating times 1 to 8...
Page 332 1 to 99: Position in the pocket table MP7267.0 Tool number (T) MP7267.1 Special tool (ST) MP7267.2 Fixed pocket (F) MP7267.3 Locked pocket (L) MP7267.4 PLC status (PLC) MP7267.5 Tool name (TNAME) MP7267.6 Comment on the tool (DOC) 25 – 330 HEIDENHAIN Service Manual iTNC 530...
Page 333 Function and input Software version and behavior MP7267.7 Tool type for pocket table (PTYP) 340 420-02 MP7267.8 Value 1 (P1) MP7267.9 Value 2 (P2) MP7267.10 Value 3 (P3) MP7267.11 Value 4 (P4) MP7267.12 Value 5 (P5) MP7267.13 Reserve pocket (RSV) MP7267.14 Pocket above locked (LOCKED_ABOVE) MP7267.15...
Page 334 6: Erase the status display when a program is selected and in the event of M02, M30, END PGM. 7: Erase the status display when a program is selected and in the event of M02, M30, END PGM. 25 – 332 HEIDENHAIN Service Manual iTNC 530...
Page 335 Function and input Software version and behavior MP7310 Graphic display mode Format: %xxxxxxxx Input: Bit 0 – Projection in three planes: CN123 0: German-preferred projection 1: US-preferred projection Bit 1 - Rotating the coordinate system in the working plane by 90°: 0: No rotation 1: Rotation by +90°...
Page 336: Colors
MP7360.1 Top surface MP7360.2 3-D: Front face MP7360.3 Text display in the graphics window MP7360.4 3-D: Lateral face MP7360.5 Lowest point of blank form MP7360.6 Highest point of blank form (below surface) 25 – 334 HEIDENHAIN Service Manual iTNC 530...
Page 337 Function and input Software version and behavior MP7361 Graphics: Projection in three planes MP7361.0 Background MP7361.1 Top view MP7361.2 Front and side view MP7361.3 Axis cross and text in the graphic display MP7361.4 Cursor MP7362 Additional status display in the graphics window MP7362.0 Background of graphic window MP7362.1...
Page 338 Line color of the tree structure MP7369.4 Folders MP7369.5 Drives MP7369.6 Text background of the heading in the browser window MP7392 Screen saver Input: 1 to 99 [min] 0: No screen saver CN123 25 – 336 HEIDENHAIN Service Manual iTNC 530...
Page 339: Machining And Program Run
25.1.14 Machining and program run Function and input Software version and behavior MP7410 Scaling cycle in two or three axes Input: 0: Scaling cycle is effective in all three principle axes CN123 1: Scaling cycle is effective only in the working plane MP7411 Tool data in the touch probe block...
Page 340 Bits 0 to 3 correspond to axes 1 to 14: 0: Do not offset 1: Offset MP7451.0-8 Feed rate for returning to the contour for axes 1 to 9 Input: 10 to 300,000 [mm/min] 25 – 338 HEIDENHAIN Service Manual iTNC 530...
Page 341 Function and input Software version and behavior MP7470 Maximum contouring tool feed rate at 100% override Input: 0 to 300,000 [mm/min] 0: No limitation CN123 MP7471 Maximum velocity of the principle axes during compensating movements through M128 Input: 0 to 300,000 [mm/min] CN123 MP7475 Reference for datum table...
Page 342 1: The 0° position is assumed for the first rotary axis Bit 4 – 0: Compensate mechanical offset during exchange of the spindle head when calling M128, M114 or “tilted working plane” 1: Compensate mechanical offset during PLC datum shift 25 – 340 HEIDENHAIN Service Manual iTNC 530...
Page 343 Function and input Software version and behavior MP7500 Tilting working plane Format: %xxxxxxxxx Bit 5 – 0: The current tilting-axis position is taken into account with respect to the machine datum 1: The tilting-axis position that was entered with the 3-D ROT soft key applies. Bit 6 –...
Page 344 -99,999.9999 to +99,999.9999 0: Free tilting axis MP7530.0-14 Transformation 1 to transformation 15 MP7550 Home position of the tilting element Input: -99,999.9999 to +99,999.9999 MP7550.0 A Axis MP7550.1 B Axis MP7550.2 C Axis 25 – 342 HEIDENHAIN Service Manual iTNC 530...
Page 345: Hardware
25.1.15 Hardware Function and input Software version and behavior Position controller cycle time = MP7600.0 ⋅ 0.6 ms MP7600.0 RESET Input: 1 to 20 Proposed input value: 3 (= 1.8 ms) PLC cycle time = position controller cycle time ⋅ MP7600.1 MP7600.1 Input: 1 to 20...
Page 346 Interpolation factor for handwheel Input: 0 to 10 MP7670.0 Interpolation factor for low speed MP7670.1 Interpolation factor for medium speed (only HR 410) MP7670.2 Interpolation factor for high speed (only HR 410) 25 – 344 HEIDENHAIN Service Manual iTNC 530...
Page 347 Function and input Software version and behavior MP7671 Handwheel feed rate in the Handwheel operating mode with HR 410 Input: 0 to 1000 [% of MP1020] MP7671.0 Low speed MP7671.1 Medium speed (only HR 410) MP7671.2 High speed (only HR 410) MP7680 Machine parameter with multiple function Format:...
Page 348 1: Transfer S or G code to the PLC after block scan. Bit 3 – 0: Transfer FN19 outputs to the PLC during block scan. 1: Transfer last FN19 outputs to the PLC after block scan. 25 – 346 HEIDENHAIN Service Manual iTNC 530...
Page 349 Function and input Software version and behavior MP7682 Machine parameter with multiple function Format: %xxxxx Input: Bit 0 – Incremental block after TOOL CALL 0: with length compensation 1: without length compensation Bit 1 – Reference value for calculating the preset during datum setting 0: Actual value is calculated 1: Nominal value is calculated...
Page 350: Second Spindle
Bit 2 – Test the hard disk 25.1.16 Second spindle Function and input Software version and behavior MP13010 to Machine parameter block for the second spindle MP13520 Input: Function and input range are identical with MP3010 to MP3520. 25 – 348 HEIDENHAIN Service Manual iTNC 530...
Page 351 HEIDENHAIN DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Straße 5 D-83301 Traunreut Technische Unterstützung / Technical support TNC-Steuerungen Phone: +49 (0) 8669 / 31-3101 TNC controls mailto:service.nc-support@heidenhain.de PLC-Programmierung / Phone: +49 (0) 8669 / 31-3102 PLC programming: mailto:service.plc@heidenhain.de NC-Programmierung / Phone: +49 (0) 8669 / 31-3103 NC programming: mailto:service.nc-pgm@heidenhain.de...
Page 352 July 2002 HEIDENHAIN iTNC 530 Service Manual...

HEIDENHAIN iTNC 530 Service Manual

1 Using the Service Manual

2 Integral Monitoring System

3 Errors and Error Analysis on the Machine or Control

4 Reserved

5 Overview of Components

6 Important Features of HEIDENHAIN Components

7 Connector Designation and Layout

8 Grounding Diagrams and Block Diagrams

9 Power Supply

10 TE 420 and te 530 Keyboard Units

11 Visual Display Units

12 File Management of Itnc

13 Encoder Interface

14 Reference Marks

15 Checking the Enables on the Itnc

16 Interface to Servo Amplifier

17 Integrated Oscilloscope

18 PLC Interface

19 Serial Handwheels

20 Touch Probe Systems

21 Data Interfaces

22 Transfer of Files Via Data Interface

23 Replacing Instructions

24 Inspection, Measuring and Test Equipment

25 Machine Parameter List

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