HEIDENHAIN ITNC 530 - CONVERSATIONAL PROGRAMMING User manual

July2010
Service Manual
iTNC 530

638142_00_a_01.pdf 2 11.12.2007 08:07:01

July2010 HEIDENHAIN Service Manual iTNC 530
1 How to Use this Service Manual ........................................................................................ 11
1.1 Target Group.................................................................................................................. 11
1.2 About this Manual ......................................................................................................... 11
1.3 Other Service Manuals.................................................................................................. 12
1.4 Other Documentation.................................................................................................... 12
1.5 Support.......................................................................................................................... 12
1.6 Service Training ............................................................................................................. 12
1.7 Meaning of the Symbols Used in this Manual............................................................... 13
1.8 Safety ............................................................................................................................ 13
2 Safety Precautions............................................................................................................... 15
2.1 Overview ....................................................................................................................... 15
3 Code Numbers ..................................................................................................................... 17
3.1 Introduction ................................................................................................................... 17
3.2 Overview ....................................................................................................................... 17
3.3 Input of Code Numbers ................................................................................................ 18
4 Error Messages .................................................................................................................... 21
4.1 Introduction ................................................................................................................... 21
4.2 HELP Key....................................................................................................................... 25
4.3 ERR Key ........................................................................................................................ 26
4.4 CE Key .......................................................................................................................... 28
4.5 List of NC Error Messages ............................................................................................ 29
5 Errors Patterns ..................................................................................................................... 55
5.1 Introduction ................................................................................................................... 55
5.2 Overview of Possible Error Patterns ............................................................................. 55
6 Procedures and Tips for Error Diagnosis ........................................................................... 59
6.1 Introduction ................................................................................................................... 59
6.2 Power Off and On ......................................................................................................... 59
6.3 Sequence for Finding Serious Electrical Errors.............................................................. 60
6.4 Sequence for Finding Errors in the Control Loop .......................................................... 62
6.5 Error Localization by Process of Interchange ................................................................ 65
6.6 Error Localization by Process of Exclusion .................................................................... 66
6.7 Finding Position Differences of Direct and Indirect Encoder......................................... 68
6.8 Error Localization by Switching from Direct to Indirect Position Measurement............ 70
6.9 Notes and Tips............................................................................................................... 72
7 Creating and Downloading of Service Files ...................................................................... 77
7.1 Introduction ................................................................................................................... 77
7.2 Automatic Generation of Service Files .......................................................................... 78
7.3 Automatic Generation of Service Files .......................................................................... 78
7.4 Downloading of Service Files ........................................................................................ 79
8 Log......................................................................................................................................... 81
8.1 Introduction ................................................................................................................... 81
8.2 Calling the Log............................................................................................................... 82
8.3 Overview of Log Entries................................................................................................ 83
8.4 Log Entries at Program Cancelation .............................................................................. 87
9 Integrated Diagnostic Functions and DriveDiag ............................................................... 89
9.1 Introduction ................................................................................................................... 89
9.2 Activation and Operation ............................................................................................... 90
9.3 For Error Diagnosis........................................................................................................ 98
10 Integrated Oscilloscope..................................................................................................... 99
10.1 Introduction ................................................................................................................. 99
10.2 Activation and Settings.............................................................................................. 100
10.3 Recording and Adjusting the Signals......................................................................... 105
10.4 Saving and Loading Recordings................................................................................. 110

HEIDENHAIN Service Manual iTNC 530
10.5 For Error Diagnosis.................................................................................................... 111
10.5.1 Triggering on error marker ............................................................................... 111
10.5.2 Circular interpolation test ................................................................................. 113
10.5.3 Descriptions in this manual ............................................................................. 114
11 PLC Diagnosis................................................................................................................... 115
11.1 Introduction ............................................................................................................... 115
11.2 Possible Causes of Errors ......................................................................................... 118
11.3 Diagnosis Tools in the PLC Mode ............................................................................. 119
11.3.1 The TABLE function ......................................................................................... 119
11.3.2 The LOGIC diagram ......................................................................................... 125
11.3.3 The TRACE function ....................................................................................... 128
11.3.4 The WATCH LIST function .............................................................................. 129
11.3.5 The I / O - FORCE LIST .................................................................................... 131
11.3.6 PROFIBUS diagnosis ....................................................................................... 133
11.4 Non-Volatile PLC Markers and Words ....................................................................... 136
11.5 Overviews ................................................................................................................. 138
11.6 Specifications ............................................................................................................ 147
11.6.1 PLC inputs ....................................................................................................... 147
11.6.2 Analog inputs ................................................................................................... 148
11.6.3 Inputs for thermistors ...................................................................................... 148
11.6.4 PLC outputs ..................................................................................................... 149
12 Hard Disk and File Manager of the iTNC 530 ................................................................ 151
12.1 Introduction ............................................................................................................... 151
12.2 Structure of the Hard Disk......................................................................................... 152
12.3 Possible Causes of Error ........................................................................................... 152
12.4 Test of Hard Disk ..................................................................................................... 153
12.5 Setting the System Time........................................................................................... 159
12.6 Setting the Program Manager .................................................................................. 162
12.7 File Management of TNC Partition ........................................................................... 163
12.8 File Management of PLC Partition ............................................................................ 165
13 Data Backup ..................................................................................................................... 169
13.1 Introduction ............................................................................................................... 169
13.2 Connection Setup...................................................................................................... 172
13.2.1 Via Ethernet ..................................................................................................... 172
13.2.2 Via serial interface RS-232-C or RS-422 ........................................................... 182
13.2.3 Via USB ............................................................................................................ 185
13.3 Reading In and Out of Individual Files or Directories ................................................ 186
13.4 Backup on an External Data Medium........................................................................ 192
13.5 Extracting Files from the Backup File........................................................................ 196
13.6 Restoring Data........................................................................................................... 197
13.7 Cable Overview ......................................................................................................... 200
13.7.1 Ethernet interface RJ45 connection ................................................................ 200
13.7.2 RS-232-C (V.24) ............................................................................................... 201
13.7.3 RS-422 (V.11) .................................................................................................. 204
13.8 Operating Modes of the Data Interfaces................................................................... 205
13.8.1 Overview of operating modes ......................................................................... 205
13.8.2 Interface configuration and assignment of mode ............................................ 206
13.9 Drive Symbols ........................................................................................................... 207
14 Reloading the NC Software Used .................................................................................. 209
14.1 Introduction ............................................................................................................... 209
14.2 Preparations .............................................................................................................. 209
14.3 Proceeding up to NC Software 34049x-02 (Single-Processor Version) ..................... 210
14.4 Proceeding as of NC Software 34049x-02 (Single-Processor Version)...................... 212
14.5 Proceeding for the Dual-Processor Version............................................................... 215

July2010 HEIDENHAIN Service Manual iTNC 530
15 Loading of Service Packs ................................................................................................ 219
15.1 Introduction ............................................................................................................... 219
15.2 Preparations............................................................................................................... 220
15.3 Execution up to NC Software 34049x-01 (Single and Dual Processor Version) ........ 221
15.4 Execution as of NC Software 34049x-02 (Single-Processor Version)........................ 223
15.5 Execution as of NC Software 34049x-02 (Dual-Processor Version) .......................... 226
16 Checking the Enables on the iTNC 530.......................................................................... 229
16.1 Introduction ............................................................................................................... 229
16.2 Examination............................................................................................................... 232
16.2.1 Checking the "Control is ready" output and input
(EMERGENCY STOP chain) ....................................................................................... 233
16.2.2 Checking the global drive enable I32, connector X42 / pin 33 ......................... 239
16.2.3 Checking the drive enabling for the axis groups via connector
X150 and X151 (if wired) ............................................................................................ 242
16.2.4 Checking the readiness of the inverter system ............................................... 243
16.2.5 Checking PLC modules, markers and words ................................................... 248
17 Power Supply ................................................................................................................... 251
17.1 Power Supply for the iTNC 530 ................................................................................. 251
17.1.1 Introduction ...................................................................................................... 251
17.1.2 UV 105, UV 105 B ............................................................................................ 256
17.1.3 UV 106, UV 106 B ............................................................................................ 260
17.2 Power Supply for "Control-Is-Ready Signal"............................................................... 262
17.3 Buffer Battery............................................................................................................ 264
17.4 Information Menu...................................................................................................... 267
17.5 Power Supply for PLC Outputs ................................................................................. 268
17.5.1 Introduction ...................................................................................................... 268
17.5.2 Supply voltage for PLC outputs on the MC ..................................................... 269
17.5.3 Supply voltage for PLC outputs on the PL 4xx B ............................................. 272
17.5.4 Supply voltage for PLC outputs on the PL 510 ................................................ 274
17.6 Power Supply for the Display Units........................................................................... 276
18 Encoder Interface ............................................................................................................. 277
18.1 Position Encoders...................................................................................................... 277
18.1.1 Introduction ...................................................................................................... 277
18.1.2 Possible causes of errors ................................................................................. 279
18.1.3 Troubleshooting ............................................................................................... 280
18.1.4 Possibilities with the integrated diagnosis or DriveDiag .................................. 282
18.1.5 Possibilities with the integrated oscilloscope .................................................. 283
18.1.6 Corrective action .............................................................................................. 286
18.1.7 Determining the field angle on linear motors, torque motors and
synchronous spindles ................................................................................................ 287
18.1.8 Resetting the machine datum ......................................................................... 288
18.1.9 Restoring the spindle orientation ..................................................................... 292
18.2 Speed Encoders ........................................................................................................ 293
18.2.1 Introduction ..................................................................................................... 293
18.2.2 Possible causes of errors ................................................................................. 295
18.2.3 Trouble shooting on the CC 422 ...................................................................... 296
18.2.4 Trouble shooting on the CC 424 (B) ................................................................. 298
18.2.5 Possibilities with the integrated diagnosis or DriveDiag .................................. 300
18.2.6 Possibilities with the integrated oscilloscope .................................................. 301
18.2.7 Corrective action .............................................................................................. 304
18.2.8 Readjusting the trip dog for reference end position ........................................ 305
18.2.9 Resetting the machine datum ......................................................................... 306
18.2.10 Restoring the spindle orientation ................................................................... 306
18.3 Error Codes for Encoders with EnDat Interface ........................................................ 307
18.4 Further Examination of Position and Speed Encoders .............................................. 308

HEIDENHAIN Service Manual iTNC 530
18.5 Position Measurement via Motor Encoder (Indirect Position Measurement) ........... 311
18.6 Switching over the Position Display for Servicing ..................................................... 315
19 Reference Run .................................................................................................................. 317
19.1 Definition................................................................................................................... 317
19.2 Traversing the Reference Marks............................................................................... 318
19.3 Possible Causes of Errors ......................................................................................... 318
19.4 Troubleshooting......................................................................................................... 319
19.5 Corrective Action....................................................................................................... 320
19.6 Deselecting the Reference Run for Axes.................................................................. 320
19.7 Retraction after an Error with Control Reset ............................................................. 321
20 Interface to the Drives..................................................................................................... 323
20.1 Digital PWM Interface............................................................................................... 323
20.1.1 Introduction ..................................................................................................... 323
20.1.2 Tables for power supply modules, power stages and motors ........................ 326
20.1.3 Possible causes of error .................................................................................. 332
20.1.4 Sequence for finding errors in the control loop ............................................... 332
20.1.5 Troubleshooting: Interchanging PWM outputs on the CC 422 ........................ 333
20.1.6 Troubleshooting: Interchanging PWM outputs on the CC 424 (B) .................. 336
20.1.7 Troubleshooting: Interchanging power modules or output stages of
the same type ............................................................................................................. 339
20.1.8 Troubleshooting: Interchanging the HEIDENHAIN interface boards
for the SIMODRIVE 611 system ............................................................................... 342
20.1.9 Corrective action .............................................................................................. 343
20.2 Analog Speed Command Interface ........................................................................... 344
20.2.1 Introduction ..................................................................................................... 344
20.2.2 Possible causes of error .................................................................................. 344
20.2.3 Sequence for finding errors in the control loop ............................................... 345
20.2.4 Checking the analog speed command interface ............................................. 346
20.2.5 Adjusting the electrical offset (drift adjustment) ............................................. 349
20.2.6 Speed adjustment at the servo amplifier (tachometer adjustment) ................ 352
20.2.7 Corrective action .............................................................................................. 354
21 Visual Display Unit .......................................................................................................... 355
21.1 Introduction ............................................................................................................... 355
21.2 Possible Causes of Errors ......................................................................................... 355
21.3 Troubleshooting......................................................................................................... 356
21.4 Corrective Action....................................................................................................... 358
22 Keyboard Unit .................................................................................................................. 359
22.1 Introduction ............................................................................................................... 359
22.2 Front View of the Keyboard Units ............................................................................ 360
22.3 Possible Causes of Error ........................................................................................... 362
22.4 Checking the Keys..................................................................................................... 363
22.5 Checking the Potentiometers.................................................................................... 367
22.6 Checking the Touchpads ........................................................................................... 370
22.7 Corrective Action....................................................................................................... 371
22.8 Key Matrix of the Keyboard Units ............................................................................. 372
22.9 Key Matrix of the Keyboard Units ............................................................................. 388
23 Machine Operating Panel................................................................................................ 389
23.1 Introduction ............................................................................................................... 389
23.2 Possible Causes of Errors ......................................................................................... 390
23.3 Checking the Power Supply ...................................................................................... 391
23.4 Checking the Keys..................................................................................................... 392
23.5 Checking the Outputs ............................................................................................... 397
23.6 Corrective Action....................................................................................................... 398

July2010 HEIDENHAIN Service Manual iTNC 530
24 Handwheel........................................................................................................................ 399
24.1 Introduction ............................................................................................................... 399
24.2 Possible Causes of Errors.......................................................................................... 400
24.3 Error Location on Portable Handwheel with HR 420 Display .................................... 401
24.4 Error Diagnosis at HR 410 Portable Handwheel........................................................ 406
24.5 Deselecting and Disconnecting the Portable Handwheel ......................................... 409
24.6 Error Diagnosis at Panel-Mounted Handwheels........................................................ 410
24.7 Corrective Action....................................................................................................... 412
25 Touch Probe ..................................................................................................................... 413
25.1 Introduction ............................................................................................................... 413
25.2 Possible Causes of Errors.......................................................................................... 417
25.3 Error Diagnosis on TS Touch Probes......................................................................... 418
25.4 Error Diagnosis on TT Touch Probes ......................................................................... 422
25.5 Error Diagnosis on Laser Touch Probe ...................................................................... 425
25.6 Deselecting and Disconnecting the Touch Probe...................................................... 426
25.7 Corrective Action....................................................................................................... 427
26 Important Features of HEIDENHAIN Components ....................................................... 429
26.1 HEIDENHAIN Components in a Machine Tool .......................................................... 429
26.2 Hardware Identification ............................................................................................. 430
26.3 Display of Important System Information.................................................................. 443
27 Connector Designation and Layout ............................................................................... 447
27.1 Important Note .......................................................................................................... 447
27.2 MC and CC ................................................................................................................ 447
27.2.1 Designation and position of connectors .......................................................... 447
27.2.2 Pin Layouts on the MC and CC ........................................................................ 457
27.3 Power Supply Units................................................................................................... 487
27.3.1 UV 105 power supply unit ............................................................................... 488
27.3.2 UV 105 B power supply unit ............................................................................ 490
27.3.3 UV 106 (B) power supply unit .......................................................................... 492
27.4 Monitors .................................................................................................................... 493
27.4.1 Designation and position of connectors ......................................................... 493
27.4.2 Pin layouts ...................................................................................................... 494
27.5 Keyboard Units .......................................................................................................... 495
27.5.1 Designation and position of connectors .......................................................... 495
27.5.2 Pin layouts ....................................................................................................... 497
27.6 BTS 1x0 Monitor/Keyboard Switch............................................................................ 498
27.7 Machine Operating Panel ....................................................................................... 499
27.7.1 Designation and position of connectors .......................................................... 499
27.7.2 Pin Layouts on MB 420 ................................................................................... 499
27.7.3 Pin layouts on MB 520 ..................................................................................... 500
27.8 Handwheels............................................................................................................... 503
27.8.1 HR 4xx portable handwheel ............................................................................. 503
27.8.2 HR 130 panel-mounted handwheel ................................................................. 504
27.8.3 HRA 110 handwheel adapter ........................................................................... 505
27.9 Touch Probes............................................................................................................. 507
27.10 PLC Input/Output Units ........................................................................................ 507
27.10.1 Designation and position of connectors ........................................................ 507
27.10.2 PL 4xxB Pin Layouts ...................................................................................... 510
27.10.3 Pin layouts for PL 510 .................................................................................... 516
27.11 Encoders.................................................................................................................. 520
27.11.1 Position encoders .......................................................................................... 520
27.11.2 Speed encoders ............................................................................................. 522
27.12 Inverters and Motors.............................................................................................. 522
27.13 Interface Boards for the SIMODRIVE System 611D............................................. 522

HEIDENHAIN Service Manual iTNC 530
28 Exchange of HEIDENHAIN Components........................................................................ 523
28.1 Important Information ............................................................................................... 523
28.2 Exchange of the MC 422........................................................................................... 531
28.3 Exchange of the Drive Assembly .............................................................................. 537
28.4 Exchange of the MC 422 B, MC 422 C, MC 420 ...................................................... 542
28.5 Exchange of the HDR................................................................................................ 544
28.6 Exchange of the CC................................................................................................... 551
28.7 Exchange of the Buffer Battery................................................................................. 552
28.8 Exchange of Other HEIDENHAIN Components ........................................................ 553
28.9 Exchange of HEIDENHAIN Components in the SIMODRIVE System ...................... 554
29 Measuring, Testing and Inspection Equipment ............................................................ 561
29.1 Important Notes ........................................................................................................ 561
29.2 Test Adapter.............................................................................................................. 562
29.3 PWM 9 Encoder Diagnostic Set................................................................................ 566
29.4 PWT 10/17/18 Testing Unit ....................................................................................... 568
29.5 IK 215 Adjusting and Testing Package ...................................................................... 570
30 Machine Parameter ........................................................................................................ 571
30.1 Explanation ................................................................................................................ 571
30.2 The Machine Parameter Editor.................................................................................. 572
30.3 Meaning of the Machine Parameters........................................................................ 579
30.4 List of Machine Parameters ...................................................................................... 580
30.4.1 Encoders and machines .................................................................................. 580
30.4.2 Positioning ....................................................................................................... 586
30.4.3 Operation with Velocity Feedforward Control ................................................. 592
30.4.4 Operation with following error (servo lag) ....................................................... 593
30.4.5 Integrated speed and current control .............................................................. 594
30.4.6 Spindle ............................................................................................................. 603
30.4.7 Integrated PLC ................................................................................................. 606
30.4.8 Configuration of the Data Interface ................................................................. 609
30.4.9 3-D touch probe ............................................................................................... 611
30.4.10 Tool Measurement with TT ........................................................................... 613
30.4.11 Tapping .......................................................................................................... 616
30.4.12 Display and operation .................................................................................... 617
30.4.13 Color .............................................................................................................. 624
30.4.14 Machining and Program Run ......................................................................... 627
30.4.15 Hardware ....................................................................................................... 634
30.4.16 Second spindle .............................................................................................. 643
1 Annex: Principle of Function of the iTNC 530 Control.................................................... 645
1.1 Introduction ................................................................................................................. 645
1.2 The Control Loop......................................................................................................... 645
1.3 PWM Signals............................................................................................................... 654
2 Annex: Principle of Function of the iTNC 530 Control.................................................... 657
3 Annex: Monitoring Functions ........................................................................................... 661
3.1 Introduction ................................................................................................................. 661
3.2 During Start-Up............................................................................................................ 661
3.3 During Operation......................................................................................................... 663
3.3.1 Position or servo lag monitoring ........................................................................ 664
3.3.2 Nominal speed value monitoring ....................................................................... 666
3.3.3 Movement monitoring ....................................................................................... 667
3.3.4 Standstill monitoring .......................................................................................... 669
3.3.5 Positioning window ........................................................................................... 670
3.3.6 Monitoring of the power supply unit ................................................................. 672
3.3.7 Temperature monitoring .................................................................................... 674
3.3.8 Internal power supply and housing fan .............................................................. 675

July2010 HEIDENHAIN Service Manual iTNC 530
3.3.9 I2t monitoring ..................................................................................................... 676
3.3.10 Actual utilization of drive motors ..................................................................... 681
3.3.11 Status of HEIDENHAIN inverters ..................................................................... 682
3.3.12 Controlling the motor brakes ........................................................................... 684
3.3.13 EMERGENCY STOP monitoring during operation ........................................... 687

HEIDENHAIN Service Manual iTNC 530

July 2010 1 – 11
1 How to Use this Service Manual
1.1 Target Group
This Service Manual has been written for specialist electricians for service, maintenance and
commissioning.
Specialists who perform work on the electrical system of a machine tool and its components
must have the required technical knowledge and competence!
1.2 About this Manual
This Service Manual assists service personnel in the field in diagnosing and
correcting errors on machine tools controlled by iTNC 530.
It includes:
Error messages and types of errors that indicate technical defects
Information on possible error causes
Descriptions of error diagnosis
Application descriptions of the diagnosis tools
Information on corrective action
Data backup instructions
Theoretical explanations of functions and their correlations
The ”List of NC Error Messages” on page 4 – 29 and the ”Overview of Possible Error Patterns”
on page 5 – 55 include many references to the descriptions for error diagnosis. You will find
these descriptions in the chapters of this Service Manual sorted by topics.
The Service Manual does not provide any commissioning support!
It comprises the service possibilities with the current hardware and software at the editing date
of this manual. The service possibilities of your devices may differ from those described here.
The descriptions also provide information on any peculiarities of the hardware or software.
This manual is valid for:
iTNC 530, single-processor with NC software 340420 / 421
iTNC 530, single-processor with NC software 340422 / 423
iTNC 530, dual-processor with NC software 340480 / 481
iTNC 530, single-processor with NC software 340490 / 491
iTNC 530, dual-processor with NC software 340492 / 493
For the instructions for the field service it is assumed that ...
the machine had been working perfectly before the error occurred!
only original parts are used!
Note
Basic knowledge in Windows is required for some descriptions in this Service Manual
concerning the handling of the dual-processor control iTNC 530 and the use of a service
laptop or PC.

1 – 12 HEIDENHAIN Service Manual iTNC 530
Udpate service This Service Manual is updated at irregular intervals.
You find the current printable version on our website -->
http://www.heidenhain.de/ ... /SHB iTNC 530
If you take part in a service training, you receive also a paper version of the Service Manual.
1.3 Other Service Manuals
Service Manual for Inverter Systems and Motors
1.4 Other Documentation
For more important information please refer to the following documentation:
Machine documentation by the manufacturer
(circuit diagrams, wiring diagrams, machine operating manual, etc.)
HEIDENHAIN User's Manual for iTNC 530
HEIDENHAIN TNCguide on DVD
Mounting instructions by HEIDENHAIN
Brochures of the respective HEIDENHAIN products
PWM 9 User's Manual
PWT Operating Instructions
IK 215 Operating Instructions
1.5 Support
However, support will also be provided by the Service Department of HEIDENHAIN Traunreut
or by the HEIDENHAIN agencies.
You will find telephone numbers as well as e-mail addresses on the back cover of this Service
Manual, or on the HEIDENHAIN website (www.heidenhain.de).
1.6 Service Training
HEIDENHAIN Traunreut offers service training courses in German language. We recommend
the HEIDENHAIN Service Training Seminars for iTNC 530 for the technician who works with this
Service Manual.
Please contact HEIDENHAIN Traunreut or visit our website (www.heidenhain.de).
Note
You can find up-to-date issues of this and other HEIDENHAIN documents quickly on our
website --> www.heidenhain.de
Note
HEIDENHAIN software tools (e.g. TNCremoNT) feature detailed on-line help.
Caution
The machine manufacturer must be contacted first for error diagnosis on your machine
tool!
Note
If required, please inquire at the HEIDENHAIN subsidiary in your country whether Service
Training Seminars are offered in your language.

July 2010 1 – 13
1.7 Meaning of the Symbols Used in this Manual
1.8 Safety
DANGER
Failure to comply with this information could result in most serious or fatal injuries, and/or
in substantial material damage.
Caution
Failure to comply with this information could result in injuries and interruptions of operation,
including material damage.
Note
These boxes contain important and useful information.
DANGER
It is extremely important that you read the safety precautions in chapter 2 before you start
servicing!
See “Safety Precautions” on page 2 – 15.

1 – 14 HEIDENHAIN Service Manual iTNC 530

July 2010 2 – 15
2 Safety Precautions
2.1 Overview
Ground
Zero potential
Fundamental
knowledge
Know-how and
competence
Suitable
tools
Safety precautions
of the machine
manufacturer
Regulations for
power installations
and instructions for
safety and prevent-
ion of accidents
DANGER
Ensure that the equipment grounding conductor is continuous!
Interruptions in the equipment grounding conductor may cause damage to persons or
property.
DANGER
Ensure that the main switch of the control is switched off and that connected devices are
not under power when you engage or disengage any connectors or terminals.
Take precautions against restart!
Use an appropriate voltage test unit to ensure that the unit is not under voltage!
DANGER
In order to be able to judge the behavior of an NC controlled machine, service engineers
need to have fundamental knowledge of controls, encoders, drives, electronics and
mechanics.
Improper use can result in serious injury to persons and damage to equipment.
DANGER
Technicians who work on the electrical system of the machine must have the required
know-how and competence!
DANGER
Use suitable tools, e.g. insulated screwdrivers and pincers!
Caution
Note the safety precautions on the machine (e.g. labels, signs) and the safety precautions
in the documentation of the machine manufacturer (e.g., operating instructions).
DANGER
Observe the national regulations for power installations and the general instructions for
safety and prevention of accidents!

2 – 16 HEIDENHAIN Service Manual iTNC 530
Basic insulation
Vertical axes
Changes to
entry values
Liability
DANGER
The interfaces for the PLC inputs/outputs, machine operating panel and PL expansion cards
comply with the basic insulation in accordance with IEC 742 EN 50 178.
Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation may
be connected, otherwise damage to persons or property may be caused.
The maximum dc voltage mean value of the PLC inputs is 31 V.
DANGER
Always secure vertical axes to prevent them from falling down before you perform tests on
these axes!
DANGER
Incorrect or non-optimized input values can lead to faulty machine performance and
therefore to serious injury to persons and damage to equipment.
Machine parameters may only be changed by the machine manufacturer or after consulting
the machine manufacturer!
Uncontrolled axis and spindle movements must be expected.
Settings that have an effect on the control's feedback loops may only be altered when the
EMERGENCY STOP button of the machine is pressed.
Caution
HEIDENHAIN does not accept any responsibility for indirect or direct damage caused to
persons or property through incorrect use or operation of the machine!

July 2010 3 – 17
3 Code Numbers
3.1 Introduction
With code numbers …
certain areas of the hard disk
certain file types
certain functions
... can be called.
3.2 Overview
DANGER
Code numbers may only be passed on to and be used by trained service technicians.
Keep the code numbers confidential!
Inexpert handling may result in a loss of important data, in faulty machine performance and
thus lead to damage or injury to property or persons.
Code number Brief description Description in
this manual
0Delete the code numbers entered so far --> Code-number
softkeys, such as MP EDIT or PLC EDIT are deleted.
In this chapter
123 Edit subset of machine parameters for the machine operator See page 30 - 571
75368 Offset adjustment for analog axes See page 20 – 349
79513 Info menu (U[BATT], U[ACCU], U[VCC], TEMP, T[CPU1]), See page 17 – 267
95148 Call the active machine parameter list See page 30 – 572
531210 Reset non-volatile PLC markers and PLC words in the RAM See page 11 – 133
688379 Integrated oscilloscope See page 10 – 99
807667 Call the PLC area See page 11 – 115
857282 Reset the operating times -
LOGBOOK Call and save the internal log of the TNC See page 8 – 81
NET123 Network settings for the single-processor control See page 13 – 172
SETUP Call for loading of service packs and NC software for the single-
processor control
See page 15 – 219
SIK Display of the number of the system identification key and of the
enabled options
See page 28 – 525
VERSION Create the file TNC:\Version.a
System data is saved in this file for diagnostic purposes. The file
can be read out for diagnosis.
-
Note
The machine manufacturer can define own MP and PLC code numbers.
In this event the HEIDENHAIN code numbers do not function any longer, or only function to
a limited extent. --> Contact your machine manufacturer!

3 – 18 HEIDENHAIN Service Manual iTNC 530
3.3 Input of Code Numbers
8Select the Programming and Editing operating mode.
8If open: Close the program management by pressing the END button.
8Call the code number window.
8Enter the code number and press ENT to confirm.
When you have finished your work, reset all previously entered code numbers:
8Enter the code number 0 and press ENT to confirm.
8Press END to exit the code-number page.
Note
Pressing the MOD key while the program manager is open calls the interface settings.
Note
When certain code numbers are entered, new soft keys are displayed, MP EDIT,
PLC EDIT, OSCI.
With these soft keys you can also change to the corresponding areas without having to
enter the code number again.
Note
All key codes are reset when the control is restarted.

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Additional
notes
As long as the machine parameter list is in the editor, no further code number can be
entered. First close the MP editor if you want to enter a new code number
After you have entered the code number for the machine parameters the PLC tree can be
seen in the program manager.
Only files with the extension .MP are displayed.
After entering the PLC code number all files in the PLC tree can be seen and loaded in the
editor.
However, to edit machine parameters, the soft key MP EDIT needs to be pressed first.

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