HEIDENHAIN Inverter Systems and Motors Service Manual 2008 - PDF DOWNLOAD

HEIDENHAIN Inverter Systems and Motors Service Manual 2008 - PDF DOWNLOAD

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HEIDENHAIN Inverter Systems and Motors Service Manual 2008 - PDF DOWNLOAD

Language :English
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HEIDENHAIN Inverter Systems and Motors Service Manual 2008 - PDF DOWNLOAD

1 Safety Precautions
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 knowledge and competence!

2 How to Use this Service Manual
2.1 About this Manual

This service manual assists service personnel in the field in diagnosing and correcting errors
on HEIDENHAIN inverter systems and HEIDENHAIN motors.
HEIDENHAIN inverter systems are available as regenerative and non-regenerative
version.
HEIDENHAIN motors fall into the categories of synchronous motors for feed drives and
asynchronous motors for main spindles (see brochure HEIDENHAIN Motors of June 2006).

TABLE OF CONTENTS:

HEIDENHAIN Inverter Systems and Motors Service Manual 2008 - PDF DOWNLOAD

Inverter Systems and Motors 1
Inhalt 3
1 Safety Precautions 7
11 Target Group 7
12 Meaning of the Symbols Used in this Manual 7
13 Please Observe: 8
14 With Inverter Systems, Especially Remember: 9
15 With Motors, Especially Remember: 10
2 How to Use this Service Manual 11
21 About this Manual 11
22 Further Service Manuals 12
23 Other Documentation 12
24 Support 12
25 Service Training Seminars 12
26 Safety 12
3 Errors and Error Messages 13
31 Introduction 13
32 Overview of Possible Errors 14
33 Important Notes on the Use of HEIDENHAIN Expansion Boards in the SIMODRIVE System 17
34 Error Messages on the Monitor of the Control 23
4 Explanation of the LEDs 25
41 Compact Inverters 25
42 Power supply units 28
43 Power Modules 30
44 HEIDENHAIN Interface Cards for the SIMODRIVE System 31
441 Boards with Ribbon Cable Connection for the PWM Interface 31
442 Boards with D-sub Connection for the PWM Interface 31
5 Procedures and Tips for Error Diagnosis 33
51 Introduction 33
52 Sequence for Finding Errors in Digital Drives 33
Flowchart 34
53 Sequence for Finding Errors in the Control Loop 35
Contaminated or defective encoders 35
Flowchart 36
54 Error Localization by Process of Interchange 37
Example for the interchange of power modules 37
55 Notes and Tips 38
What is the cause of this error? 38
First steps 38
Visual inspection 38
Comparison with functioning machines or units 38
Males and females 39
Terminals 39
Shielding and grounding 39
Sources of interference 39
Contamination 40
Temperature 40
Humidity 40
Checking the safety measures for the EMV 41
6 Troubleshooting on Motors 45
61 Safety 45
62 Possible Causes of Error 45
63 Visual Inspection 46
64 Trouble Shooting on Ground Fault 47
65 Inspection for Winding Short Circuit or Interruption 50
66 Inspection of the Motor Encoder 53
67 Inspection of the Fan 61
68 Inspection of the Temperature Sensor 62
69 Inspection of the Motor Brakes 64
610 Inspection for Unbalance 66
7 Error Diagnosis on the Inverter System 67
71 Safety 67
72 Possible Causes of Error 67
73 Visual Inspection 68
74 Checking the Criteria for Water-Cooled Inverters 69
75 Error Diagnosis on the UV, UVR Power Supply Unit 71
751 Inspection for Ground Fault 71
752 Inspection for Short Circuit or Interruption 74
753 Checking the fuses 78
754 Checking the Braking Resistor Switch 79
755 Checking the LEDs 81
756 Checking the Voltages 82
76 Error Diagnosis on the UM Power Module 88
761 Inspection for Ground Fault 88
762 Inspection for Short Circuit or Interruption 91
763 Checking the LEDs 96
764 Checking the Voltages 98
765 Exchanging Power Modules or Output Stages of the Same Type100
766 Exchanging the PWM Interfaces103
77 Error Diagnosis on the UE, UR Compact Inverter104
771 Inspection for Ground Fault104
772 Inspection for Short Circuit or Interruption107
773 Checking the Fuses113
774 Checking the Internal Braking Resistor114
775 Checking the Braking Resistor Switch116
776 Checking the LEDs119
777 Checking the Voltages122
778 Exchanging Output Stages of the Same Type128
779 Exchanging the PWM Interfaces131
78 Error Diagnosis on Non-HEIDENHAIN Inverter Systems 132
781 Inspection for Ground Fault132
782 Inspection for Short Circuit or Interruption132
783 Checking the Displays on the Infeed/Regenerative Module of the Non-HEIDENHAIN Manufacturer133
784 Checking the LEDs on the HEIDENHAIN Expansion Boards133
785 Checking the Voltages134
786 Exchanging the HEIDENHAIN Expansion Boards for the SIMODRIVE 611 System135
787 Exchanging Output Stages of the Same Type136
788 Exchanging the PWM interfaces138
8 Error Diagnosis on Accessories139
81 Safety139
82 Possible Causes of Error139
83 Visual Inspection139
84 Error Diagnosis on the PW Braking Resistor140
841 Inspection for Ground Fault140
842 Checking the Resistance Value143
843 Checking the Fan144
844 Checking the Temperature Switch144
85 Error Diagnosis on the UP 1x0 Braking Resistor Module145
851 Inspection for Ground Fault145
852 Inspection for Short Circuit148
853 Checking the Resistance Value150
854 Checking the Braking Resistor Switch151
855 Checking the Temperature Switch154
86 Error Diagnosis on the SM Voltage Protection Module155
861 Inspection for Short Circuit155
862 Checking the Temperature Switch158
9 Error Diagnosis on UV Power Supply Units159
91 Safety159
92 Possible Causes of Error159
93 Error Diagnosis on UV 101 B160
94 Error Diagnosis on the UV 102 163
95 Error Diagnosis on UV 105, UV 105 B165
96 Error Diagnosis on UV 106 B171
97 Error Diagnosis on the UV 111A, UV 111B173
10 Exchanging HEIDENHAIN Components175
101 Important Notes175
102 Exchanging the Complete Inverter178
103 Exchanging the Complete Motor180
104 Exchanging the Motor Encoder of the QAN Asynchronous Motor181
105 Exchanging the Signal Socket of the Motor184
106 Exchanging the Fan of a Spindle Motor186
107 Exchanging the Fan Guard of a Spindle Motor191
108 Changing Connections to the Reserve Temperature Sensor194
109 Exchanging Inverter Accessories195
1010 Exchanging Cables and Connectors196
1011 Exchanging Power Supply Units197
10111 Exchanging the UV 101 B Power Supply Unit197
10112 Exchanging the UV 102 Power Supply Unit197
10113 Exchanging the UV 105 Power Supply Unit198
10114 Exchanging the UV 105 B Power Supply Unit199
10115 Exchanging the UV 106 B Power Supply Unit200
10116 Exchanging the UV 111 A, UV 111 B Power Supply Units201
11 Overview of Components203
111 Compact Inverters203
1111 Assembly203
1112 UE 1xx Compact Inverter204
1113 UE 2xx compact inverter204
1114 UE 2xxB Compact Inverter205
1115 UR 2xx(D) Compact Inverter205
1116 Toroidal Cores206
1117 Ribbon Cables and Covers (Only for UE 2xxB, UR 2xx)206
112 Modular Inverters207
1121 Assembly207
1122 UV 130(D) Power Supply Unit208
1123 UV(R) 1x0(D) Power Supply Unit208
1124 UM 1xx(B)(D) Power Modules209
1125 Ribbon Cables and Covers209
113 Accessories for Compact Inverters and Modular Inverters210
1131 PW 21x, PW 110(B), PW 120 Braking Resistors210
1132 UP 110, UP 120 Braking Resistor Module (Optional)211
1133 Line Filters212
1134 Three-Phase Capacitor214
1135 KDR 1x0(B) Commutating Reactor215
1136 ZKF 1x0 DC-Link Filter216
1137 SM 1xx Voltage Protection Module218
1138 Adapter Module219
1139 Axis-Release Module220
11310 Capacitor Module221
114 HEIDENHAIN interface cards for the SIMODRIVE system222
1141 Assembly222
1142 Expansion Boards222
115 Power Supply Unit223
1151 UV 101 B Power Supply Unit223
1152 UV 102 Power Supply Unit224
1153 UV 105 Power Supply Unit225
1154 UV 105 B Power Supply Unit225
1155 UV 106 B Power Supply Unit226
1156 UV 111 A, UV 111 B Power Supply Units226
116 HEIDENHAIN Motors227
12 Connector Designation and Layout229
121 Important Note229
122 Compact Inverters229
1221 Designation and Position of Connections 229
1222 Pin Layout on the Compact Inverter247
123 Power supply units255
1231 Designation and Position of Connections 255
1232 Pin Layout on the Power Supply Units267
124 Braking Resistors and Braking Resistor Module271
1241 Designation and Position of Connections 271
1242 Pin Layout of Braking Resistor or Braking Resistor Module273
125 Power Modules275
1251 Designation and Position of Connections 275
1252 Pin Layout on the Power Supply Units295
126 DC-Link Filter297
1261 Designation and Position of Connections 297
1262 Pin Layout on the DC-Link Filter298
127 Adapter Module299
1271 Designation and Position of Connections 299
1272 Pin Layout on the Adapter Module300
128 HEIDENHAIN Expansion Boards for the SIMODRIVE System302
1281 Designation and Position of Connections 302
1282 Pin Layout on the Interface Cards304
129 UV 101 B Power Supply Unit306
1291 Designation and Position of Connections 306
1292 Error Diagnosis on UV 101 B307
1210 UV 102 Power Supply Unit309
12101 Designation and Position of Connections 309
12102 Pin Layout on the UV 102310
1211 UV 105 Power Supply Unit311
12111 Designation and Position of Connections 311
12112 Pin Layout on the UV 105312
1212 UV 105 B Power Supply Unit314
12121 Designation and Position of Connections 314
12122 Error Diagnosis on UV 105 B315
1213 UV 106 B Power Supply Unit317
12131 Designation and Position of Connections 317
12132 Error Diagnosis on UV 106 B318
1214 Error Diagnosis on the UV 111A, UV 111B319
12141 Designation and Position of Connections 319
12142 Pin layout on the UV 111A, UV 111B320
13 ID Labels323
131 ID Label for Inverters323
132 Electronic ID Label for Inverters326
133 ID Label for Motors328
134 Electronic ID Label for Motor329
135 ID Label for HEIDENHAIN Interface Cards331
136 ID Label for Accessories331
14 Measuring, Testing and Inspection Equipment333
141 Important Notes333
142 Voltage Test Unit333
143 Insulation Tester334
144 Multimeter334
145 Current Probe334
146 Test Adapter335
147 Universal Measuring Adapter339
148 PWM 9 Encoder Diagnostic Set340
149 PWT 18 Test Unit342
1410 IK 215 Adjusting and Testing Package343
15 Annex: Functional Principles345
151 PWM Signals345
152 HEIDENHAIN Inverter Systems348
153 HEIDENHAIN Motors351
1531 Introduction351
1532 Asynchronous Motors352
1533 Synchronous Motors353
1534 Linear Motors354
1535 Torque Motors354

S.M 6/3/2025