235-00A4

Identify Expected Port Assignment

Refer to the machine's wiring diagram and Heidenhain documentation to determine the correct port assignment for each inverter based on the HSCI address and serial number provided in the alarm message.

Take a photo of the current wiring setup before making changes for reference in case of discrepancies.

Ensure the machine is powered off and locked out before accessing connection points to avoid electrical hazards.

Inspect Physical Connections

Locate the inverters connected to the device at the specified HSCI address. Compare the current port connections (Ist-Port) with the expected ports (Soll-Port) as per the documentation.

Label each cable and port temporarily with masking tape to avoid confusion during reconnection.

Wear insulated gloves when handling electrical connections to prevent shocks.

Reconnect to Correct Ports

If a mismatch is found, carefully disconnect the inverter cables and reconnect them to the correct ports as per the documentation. Secure all connections and double-check for accuracy.

Use a torque wrench to ensure connections are tightened to the manufacturer’s specifications.

Recheck all connections before powering on to prevent short circuits.

Access Configuration Menu

Power on the CNC control system and navigate to the hardware configuration or project settings menu using the Heidenhain interface. Refer to the service manual for specific navigation steps.

Document the current settings by taking screenshots or notes before making changes.

Ensure you have administrative access to avoid unauthorized changes.

Verify Hardware Expansion Options

Check the configured port assignments for inverters under the hardware expansion options. Compare these with the physical setup and the alarm message details (Soll-Port vs. Ist-Port).

Cross-reference with the machine’s build sheet if available to confirm original settings.

Do not alter unrelated settings to avoid introducing new errors.

Update Configuration if Necessary

If the configuration does not match the physical setup, update the port assignments in the software to reflect the correct setup. Save changes and restart the system to apply the new configuration.

Perform a backup of the current configuration before saving changes in case a rollback is needed.

Ensure no operations are running during the restart to prevent data loss.

Power Down and Lock Out Machine

Turn off the CNC machine and apply lockout/tagout procedures to ensure safety while inspecting cables connected to the inverters at the specified HSCI address.

Use a lockout kit specific to your machine to ensure compliance with safety protocols.

Failure to lock out can result in severe injury or death due to unexpected machine activation.

Inspect Cable Connections

Visually check all cables connected to the inverters for signs of wear, damage, or looseness at the ports. Gently tug on each connection to ensure they are secure.

Look for frayed wires or bent pins that might indicate a poor connection.

Do not apply excessive force to avoid further damage to connectors.

Test and Replace Cables if Needed

Use a multimeter to test cable continuity if damage is suspected. Replace any faulty cables with manufacturer-approved replacements and secure all connections before powering on.

Keep spare cables of the correct specification on hand to minimize downtime.

Ensure replacement cables match the original specifications to avoid compatibility issues.

Check Current Software/Firmware Version

Access the system information menu on the Heidenhain control to note the current software and firmware versions installed on the device.

Record the version numbers in a maintenance log for future reference.

Do not attempt updates without proper authorization or documentation.

Compare with Compatibility List

Visit the Heidenhain support website or refer to the service manual to check if the installed versions are compatible with the hardware setup, especially the inverters and port configurations.

Contact Heidenhain support if the compatibility list is unclear or unavailable.

Incorrect updates can render the system inoperable; proceed with caution.

Update Software/Firmware if Required

If an incompatibility is found, download the correct version from the Heidenhain portal and follow the update procedure as outlined in the manual. Restart the system after updating.

Perform updates during scheduled downtime to avoid production interruptions.

Backup all system data before updating to prevent loss of critical settings.

Run Diagnostic Tests

Use the built-in diagnostic functions of the Heidenhain control system to test the inverters and associated hardware at the specified HSCI address for errors or failures.

Save diagnostic logs for review by a technician if escalation is needed.

Ensure the machine is in a safe state before running diagnostics to avoid unintended movements.

Swap with Known Good Hardware

If diagnostics indicate a potential fault, temporarily replace the suspected inverter or control module with a known good unit to see if the alarm clears.

Mark the suspected faulty unit clearly to avoid reuse until repaired.

Power down and lock out the machine before swapping hardware to prevent electrical hazards.

Contact Heidenhain Support for Repair

If swapping confirms a hardware defect, contact Heidenhain support for repair or replacement options. Provide diagnostic logs and serial numbers for faster service.

Keep a record of all communications with support for warranty claims or future reference.

Do not attempt internal repairs on inverters without manufacturer authorization.