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Service Instructions TNC 151/155B/Q

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1. Kupplung 12pol kompl Kabel VB 8x0 14 kompi Sweats 6 21 wsign 13 Reset 16 15V 17 42V 22 5V 24 Ok md 20 15v i ue u sv Platine 15 43V wisel Netzteil Ce hane 19 52V 26 1VBildschirm 7 DA 3prsft eeteessenossoceve so ge i 3 ASTI se er 28 OVBildschurm i E S Birtz E H D E rM ee ei WE Netzteil Pm Duis in kompl 9 x lf p i e i i S BI d BEER cs 7 Dunt Ltd d Sob Ag 9 PER rr Ar Rare rra rara fe E y i 32 AE DXX CR E gs 32 i 4 55 DEER Spannungsw hler m Sicherung M PPP PP O A As 6 STS Entst r b L Sr 100 120 140 V T1 0A j ARA 200 220 240 V TO 80A Ia rz E EE SR ES Gd H 7a iz Bge S Ka 4 v n i Ca ae ER Platine De ae Sp PeCRORHEHEHEE TEER DE RES z a Ka mnm m eh sen I 11 LEES gt SSO se evoteobtbonte es i is ER d d E 67 secos Platine Stecker L N ER c Netz klemme kompl Alle mit gekennzeichneten Drahte m ssen vor dem Ver l ten mechanisch gesichert werden Platine Tastatur P1 P2 P3 PL S TN 3 3 8 dnt te ih Ar d CH s 8 x SoBe b m 2 3 2 BIE Midis 0 39 10 bai ES ES A EJ 20935 ARE Win Jk RM F21 BA 233 550 Code KAF ident Nummer Fur dese Ze chnung behalten wr uns al
2. OV 1 Over Reset E hn gen p US IC F ROMPE NE 2 ME Monitor F 703 U3 Power orward Converter V are Switch with Low Pass Filter oni only with TNC 151 err MM EC e Switching Regulator TL 494 O Reset t 160 180 ms Block Diagram TNC151 155 Power Supply Unit ext Feed Pot eee ce ee N Ri L mu a x toServo Filter Amplifiers Analogue Outputs Analogue Outputs CRU Adress Bus z to external PLC Boards Brd 1 Drawing No 4820 EKD 1601900 LC Reference Pulse Inhibit tL 12V Voltage Wiper Contact OO CRUIN 2 CRUIN 1 CRUOUT CRUCLK Reset EMERGENCY STOP Block Diagram TNC 151 155 Terminal Board P Q Version to Analogue Board 15V from Power Supply OV from Analogue Board from to PLC Interface Board ext Feed Pot t i LEA bl TIL ub y RIT Peo he eh ME Voltage Filter B Analogue Outputs 70 1 Fuse Resistor 23x 470 EMERGENCY STOP 70 Fuse Resistor from to Machine Interface 23 Inputs 23x510 Drawing No 4820 EKD 16018 00 Wiper Contact Regulator Analogue Outputs EMERGENCY STOP Block Diagram TNC 151 155 Terminal Board A B Version fo Analogue Board ON 15 V from Power Supply from Analogue Board SE Input Output Board to Terminal
3. f Ve tse sie DR JOHANNES HEIDENHAIN GmbH E D 8225 Traunreut Tel 08669 31 0 Kundendienst Under certain circumstances an inverse video display can again be generated by means of the exclusive or gate wiring 31 4 A discretely mounted timer circuit synchronizes the procedures of the entire CLP Graphics board On the SE board or the PLC interface board the V 24 signals of the handwheel unit are connected to the line drivers or respectively to the line receivers A serial interface module on the CLP Graphics board stands between line receivers drivers and the CLP processor to transfer data with the handwheel unit and to format data start stop pulse e g The signals of the 3D probe are buffered via the 3D probe interface on the SE board or PLC interface board 53 and is evaluated via the counter module 32 on the CLP processor graphics board Power Supply Unit 5V are generated for the TTL modules via the flow converter 70 The flyback regulator 70 1 inductively coupled with the flow converter generates 15V for the operation ampli fier The 12V supply voltage for the V 24 interface is generated with the help of the 15V by menas of a linear regulator 70 2 11V are generated via the flow converter 70 3 for the TNC 151 BE 111 BE 211 screen which in contrast to the TNC 155 BE 411 screen does not have an own power supply unit The switch regulator 70 01 and 70 31 readjust t
4. Kundendienst Section 2 2 6 Fig 3 1 Burn In Adapter TNC 151 155 P n Id No 233 513 ZY wiring Board Connector From analogue outputs qt HE Board PLC Board connector JH3 e connector From analogue outputs PLC outputs 6 qut su x SS ate III SE i 102 Ovom RIS CTS zen nm BD EU eg y Aug ov UUT E Stocker Sti 25pol as per X circuitry as per X circuitry Override pot input 4313 as per X circuitry SHG DN int as per X circuitry Handwhee ES MELENA LN i i DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Fig 4 PLC Load Adapter Id No 224 873 ZY SERVICE MANUAL TNC 151 155 Page 24 Section 2 2 6 MEPMVENMAIN ea i DR JOHANNES HEIDEN TT JO S HAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Fig 4 1 PLC Load Adapter Id No 224 873 ZY wiring de Posthion Suh VI 0 or loo Se 4 os complementary Pos 2 AZHAB complementary Pos 3 ADATAID complementar Additional circuitry for overload facility SERVICE MANUAL TNC 151 155 Page 24 1 Section 2 2 6 PLC Opus WI le PLC eh R 2400 2 AW oE0 ERN Cu ELI I E po O AR o E21 ESS o E22 ES C53 SE rp Ado Sg AER L E56 Bo oS EST um VE AE Uni polar sO i potas A Albo wem Maia D CR Ai D of 77 ER em 25w AB m E29 ED n AR CH EG1 e CE Kio o 30 EL II Le LEI Emergency OF o E ee
5. ea F IEIDEINTIZATIN DR JOHANNES HEIDENHAIN GmbH MANU EA D 8225 Traunreut Tel 08669 31 0 SE AL TNC 151 155 age Kundendienst Section 3 2 Exchanging the pluggable boards Analog Board Unscrew the 5 mounting screws and remove the housing cover Before removing the Analog Analog TTL Board pull off and Removing the boards mark the connector plugs for the measuring system inputs Press the board ejector keys outwards and pull out the indi square wave signal inputs and the electronic handwheel input vidual board from the top The connector sockets on the board are coded with coding pins UIS DU e 3 d dis EN ES te Lr Inserting the boards The connectors of the boards are coded incorrect insertion is therefore avoided Press the board firmly into the Connec tor Board using the ejector keys tilted inwards Main Processor and CLP Processor Graphics Board When exchanging these boards insert program EPROM s IC P1 and IC P2 on the CLP Processor Graphics Board and IC P3 to IC P6 on the Main Processor Board Main Processor Board During the exchange or removal of the Main Processor Board the buffered RAM will no longer be supplied with voltage which means that the machine parameters and any user programs will be lost Before inserting the new Board plug in the relevant EPROMs EPROM IC P3 to IC P6 paying particular attention to their correct location and orientation FAEIDUEIPIZALTIN DR JOHANNES HEIDENHAI
6. SERVICE MANUAL TNC 151 155 Page 33 Section 2 2 6 m Key SUPERVISION CIRCUIT TEST XX XX XX XX checks the threshold values of the circuitry which moni tors the measuring system inputs The contents of the counter status registers for the X Y Z and IV axis are displayed n Key TEST REFERENCE IMPULSE INPUT XX XX XX XX Checks the effect of a signal applied to the reference pulse inputs The contents of the counter status registers for the X Y Z IV axis and handwheel are displayed o Key iiv TEST TRANSDUCER INPUTS EXE XXXX XXXX XXXX XXXX XXXX Checks the effect of signals applied to the measuring system inputs The contents of the counter status registers for the X Y Z IV axes and handwheel are displayed Starting the sequential tests A detected fault will be displayed on the VDU the test cycle is interrupted and the BURN IN TIME is stopped With an Over Tel Tal 9 9 fault the LEDs for the following keys Sa 9 id 9 will flash A a Spindle Tal 5 eels Py etl fault the LEDs for the following keys es will flash With a Battery IE BAS both the and Re LEDs will flash In all other cases several LEDs will flash Through pressing the respective key each individual test can be restarted An error message remains memorized until overwritten by a newl detected fault An error message can be called up using the En and IG keys Pressing the key erases the fault message and restarts the sequ
7. in 79 ei M ri wn e oO E S El wo Und gt o ie D Ou DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 cb HEIDENHAIN Section 2 2 4 Kundendienst Procedure for testing the Power Supply Unit Power Supply Test Voltage selector correct No Adjust asi necessary Yes Correct fuse present and intact No Replace as necessary Yes Remove backwall Disconnect PSU connector from Connector Board Restore mains lt gt Yes Disconnect mains Disconnect transformer secondary from Power Supply Board terminals 1 2 3 amp 4 Restore mains Fuse blows Sec voltages OK Possible transformer fault x Reconnect transformer secondaries to Power Suppiy Board nominal PSU voltages ATTENTION O nie The voltages 12V board unit to DR 15V 15V can only JOHANNES HEIDENHAIN be measured under load for return Where appropriate order Probable fault on Power Supply Board exchange i unit Connect PSU connector to Connector Board Restore mains all voltages within tolerance Probable board fault Remove each board in turn until PSU volts OK Reassemble backwali Control ready for use Testing of measuring system and wiring E ie y ix LY s s AN v Swap the measuring system ff connectors around e Fault alt follows connector
8. e c e Decimal character decimal comma 1 decimal point Dialog first 2 English Memory test when switching on active 4 switched off Checksum test when switching on active 8 switched off Change from program run block sequence to program precalculated contour 16 current block run single block when processing continuous con up to 14 blocks tours according to counting mode for angular axes IV and V if they function as position displays Ie 29 999 999 9 32 0 359 999 9 Add input values for functions requested so wo co co oo joo 00100 j zl E o eo J nm dW bi Qjo Ce Overlapping with pocket milling 93 0 100 1 414 PLC Counter preset value 94 Q 65 535 for counters 15 to 109 i m CIUC NAAN hard DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Function PLC Timer duration for timer 90 15 PLC 30 position values for PLC positioning Activation of next tool number or of the following tool magazine number Setting of 16 markers to binary number Automatic lubrication to programmed X traversing distance in Y Z IV Feed rate for parameters X nos 126 to 156 X Z IV Display of current feed rate before start in MANUAL in all axes same feed rate that means smallest feed rate from parameters 4 to 7 Ramp gradient for S Analog Standstill supervision Programming station Handwheel and measuring probe KA e wo WN Fr GID KH iom iP Pa
9. Differential factor b i NK RAN KHNA P r S i C3 oH b i N eG O H N S i D r H lt Co Co oc ou PS H D KG S lt lt lt lt lt lt WN DIR to PO d h to DIR PR heje RR Aja e a w co J Ov uU i co dF lo NUT C bj xo O H oO i co ve a lt lt i Parameter 31 SERVICE MANUAL TNC 151 155 Page 73 Section 4 4 Input values 80 15 999 mm min Axis IV degrees min with axis designation A or B or C 1 20 fola 2 10 fold max traversing speed max traversing speed 16 m min 12 m min 0 Plus direction 1 Minus direction with correct programming of parameter nos 20 to 27 9 or 1 positive with positive traversing direction negative with positive traversing direction he In Ip 65 535 65 535 eee SERVICE MANUAL TNC 151 155 DR JOHANNES HEIDENHAIN GmbH P 74 N D 8225 Traunreut Tel 08669 31 0 age i Section 4 4 Kundendienst Function Parameter Input values Backlash compensation X 36 1 000 1 000 mm Y 37 Z 38 IV 39 1 000 1 000 angular axis Correction factor for X 40 1 000 41 000 mm m linear correction Y 41 Z 42 IV 43 Software limit switch ranges X m NM 30 000 000 30 000 000 mm X I Y AT i Z 49 IV 50 30 000 000 angular axis IV 51 30 000 000 Analog voltage with rapid traverse 52 44 5 9 DN Approach speed 0 1 10 m min Acceleration 54 9 001 3 0 m s Circ
10. SERVICE MANUAL TNC 151 155 Page 55 Section 4 2 External Terminal Board P Q Version Terminal Board A B Version PLC Interface Board SE input Output Board Keypad Board Main Processor Board CLP Processor Board TNC 151 Graphic Board TNC 155 Analogue Board TTL Inputs Analoque Board Sine Wave Inputs i Layout of the Block Diagrams and Boards in the TNC 151 155 Drawing No 4820 E KD 16009 00 CRU Address Bus from PLC Interface Board to 2nd Ext Ref Pulse Inhibit X Y Z IV Ref Pulse Inhibit PLC 1 0 Board to PLC Interface Board 2 CRUIN2 from 5 63 Inputs 2nd PLC 1 0 Brd t Eu CRUIN2 to c PLC Interface Board S Over load CRUIN 1 to c PLC Interface Board 5 to 2nd PLC 1 0 Brd e E1 Output P Drivers RESET CRUOUT CRUCLK from PLC Interface Board and Reset m Current EMERGENCY STOP to Sense 2nd PLC 1 0 Brd EMERGENCY EMERGENCY STOP STOP from PLC Interface Board Block Diagram TNC 151 155 Drawing No External PLC 1 0 Board 4820 E KD 16017 00 Drawing No 4820 EKD 1602000 NEEN o 45 V i 0 22 V RS 232 C 71 0 15 v OP AMP 15V MOS L Softstart 70 1 o 1S Y Hide Je Circuit Unef 1 Fly Back Regulator 0 12 V RS 232 C O 0 Y 64 Forward Converter 70 with Low Pass Filter Mains o 5 Y TTL Logic Transformer URef1 Regulator TL 494
11. circuit of the machine for checking routine see Mounting Instructions and Interface Circuit Control Machine manual Defect in Control s internal Emergency Stop supervision WRONG REFERENCE POINT Traversed over reference point lies outside of the reference point end position also see Mounting Instruc tions and Interface Circuit Control Machine Defect in Control machine interface SERVICE MANUAL TNC 151 155 Page 8 Section 2 2 2 Possible fault location Measuring system Analog Board Analog Board PLC I O Board TNC 151 155 Q PLC Interface Board TNC 151 155 Q SE Board TNC 151 155 B Terminal Board TNC 151 155 B Machine cams switches reference end position or reference pulse inhibit PLC 1 0 Board TNC 151 155 Q PLC Interface Board TNC 151 155 Q SE Board TNC 151 155 B Ter minal Board TNC 151 155 B DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 ZEB MEIDENTIAIN Kundendienst VDU Display flashing EMERGENCY STOP PLC GROSS POSITIONING ERROR A Fault cause With standard PLC program faulty reply from output AG Lock for spindle on to input E20 reply Lock for spindle on Fault message EMERGENCY STOP PLC appears only when no additional PLC marker is set for the fault message Trailing error greater than value entered in MP 174 see Mounting Instructions and Interface Circuit Control Machine manual Deviation from the intended position at
12. i Ib 9 9 1 Isi gt S JS Ib to EB ajajejsjor ib a lt ealeaiea iP Ip li i gt DO i b5 r5 I gt I gt Add 6 No output Output only when tool number changes Output of every tool number with every tool call Output of tool magazine number if MP 225 gt 1 No output of spindle rpm Coded output only when rpm changes Coded output of all rpms S Analog voltage output gear switching signal only when gear ratio changes S Analog voltage output output of all gear switching signals with every tool call S Analog voltage output without gear switching signal 1 00991 0 999 1 um 1 25 ym internal potentiometer for override and manual feed external potentiometer for override and manual feed internal potentiometer for override external potentiometer for manual feed 65 535 s Ib off 1 off 1 on on i 9 999 V 65 535 no axis inhibited X Y Z n IV input values when inhibiting several axes 65 535 s NTC ITA DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Function Feed rate override and spindle Feed rate override if rapid traverse key is pressed in operating mode Program Run Feed rate override in 2 stages or variable Feed rate override if Rapid Traverse Key and external directional keys are pressed Spindle override in 2 stages or variable Reference signal evaluation for in
13. standstill greater than the value entered in MP 169 see Mounting Instructions and Interface Circuit Control Machine manual Exceeding the range for the continuous po sition supervision determined by MP 57 see Mounting Instructions and Interface Circuit Control Machine manual Relationship between output voltage and traversed distance outside of the defined tolerance Defect in the pulse counting section Con trol circuitry after the transducer signal supervision SERVICE MANUAL TNC 151 155 Page 9 Section 2 2 2 Possible fault location Terminal board TNC 151 155 B In the Case of Gross Positioning Errors A B C D the fault could lie with any element in the closed loop servo system ie Control hardware CLP Processor Graphics Brd Control hardware Analog Brd servo amplifier offset voltages e gain too low motor tacho measuring systen external forces acting on drives inappropriate MP values programmed Aid 1 Program MP 54 acceleration as small as possible 2 Adjust rapid traverse as small a trailing error as possible 3 Gradually increase MP 54 If this does not help fault in the Control hardware closed loop or in the machine B PIICEIDEIWNPAITN DR JOHANNES HEIDENHAIN GmbH SUIZA 0 5225 Traunreut Tel 08669 31 0 Kundendienst VDU Display flashing GROSS POSITIONING ERROR B GROSS POSITIONING ERROR C GROSS POSITIONING ERROR D GROSS POSITI
14. the ME unit will first rewind the cassette tape before transmitting the data blockwise to the Control Any user programs already loaded programmed into the Control will be unaffected by loading the Burn In test program 5 The Burn In test program occupies both tracks of the cas sette tape Consequently when all the data from the first track has been transferred the following dialogue will be displayed EXCHANGE CASSETTE ME START EXTERNAL DATA INPUT To complete the data transfer turn over the cassette and press the START button on the ME unit The VDU will again display the dialogue MSN lICIDEINTIZAAIN DR JOHANNES HEIDENHAIN GmbH MANUAL TNC 151 155 lt D 8225 Traunreut Tel 08669 31 0 SERVICE f Page 25 1 Section 2 2 6 Kundendienst POWER INTERRUPTED Loading of Burn In EXTERNAL DATA INPUT test program 6 After completion of a sucessful data transfer the ME unit will rewind the cassette and the VDU will display the socket of Control question EXTERNAL UNIT CONNECTED to both units Any other display implies either a transmission error or S an incorrect faulty test program cassette on ME Wait for display POWER INTERRUPTED following MEMORY TEST Press fro on Control as often as necessary to obtain display CODE NUMBER s ses 8 2 0 1 8 8 and then Ga Ei el Program loads whilst Control displays POWER INTERRUPTED d EXTERNAL DATA INPUT Turn over cassette when Con
15. Board CRU Address Bus Reference Pulse Y Inhibit CRUIN 2 CRUIN 1 CRUOUT zeg Reset EMERGENCY STOP Drawing No 4820 E KD 16016 00 MOS TTL Conversion HIA dp oq T 51 50 CRU Address Bus from Main Processor Brd Buffer Ref Pulse Inhibit to Analogue Board to from CLP Board to Gate Arrays of CLP Board 54 Optocoupler galv Separation CRUIN 2 F mf Ts CRUIN 1 la uswahl L T JS to from Main Processor Brd c Ou CRU Data Bus i O Reset m PLC Qut Clear EMERGENCY Gecke Block Diagram TNC 151 155 Analogue PLC Interface Board Board from Main CRU Address Bus Reset Buffer 51 Ref Pulse Inhibit to Analogue Board 24 Relay Serial Parallel 2 Outputs and Conversion EMERGENCY and e STOP 24 Rel to from eiays rol 3 y EMERGENC Y CLP Board eo STOP e EMERGENCY STOP 50 c 24 Opto g coupled inputs 3 to Gate Arrays o and of CLP Board T Parallel Serial Conversion to from Main Processor Brd CRU Date Bus e EMERGENCY STOP from Analogue Board Block Diagram TNC 151 155 Drawing No 4820 E KD 16015 00 SE Input Output Board to SE PLC Interface to External Computer Tape Unit etc Board Wir ri bus Standard 16Line Address Bus Expanded 20 Line Address Bus e e ra Main Processor to SE PLC In
16. I O Board of the PL 100 110 B 39 2 Board Exchange 40 3 Software Exchange 45 4 Replacement Parts Loan Exchange Service Units 48 5 Configurations Liste 49 Additional Information 50 1 Block Diagram Description 50 2 Block Diagrams TNC 151 155 w 55 3 Wiring Diagrams 68 4 Machine Parameters 73 n HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 2 Section 1 1 Use of the Service Manual TNC 151 155 In order to determine the fault condition on an NC machine a fundamental knowledge of the machine and the drives is necessary as well a a knowledge of their interaction with the Control and measuring system In addition improper use of the Control such as incorrect NC programming or incorrect selection of machine parameters can lead to the occurrence of fault conditions Further information in this respect can be found in Operating Manual Mounting Instructions and Interface Circuit Control Machine PLC Description The TNC 151 155 Service Manual is used for the diagnosis localisation and remedying of faults on TNC controlled machines In section 2 Fault Diagnosis a set of flowcharts enables the user to pinpoint the source of a fault from its symptoms An integrated supervision system and a Burn In Test Program specifically developed for testing the Control can aid in the location of faults Important guidance for the exchange of
17. Main Processor Board 2 CLP Processor Graphics Board 3 Analogue Board Analoque Board TTL 4 with SE Board 5 it corresponds to a B F Type without SE Board with PLC Interface 5 however with PLC I O Board s it corresponds to a Q W Type or respectively QR WR Type Power Supply Board 6 Terminal Board 7 The functional processes of the control are divided between two microprocessor systems each comprising Microprocessor TMS 9995 Program Memory EPROMs Write Read Memory RAMs SERVICE MANUAL TNC 151 155 Page 50 Section 4 4 1 Input Output facilities e g keypad screen measuring system inputs analog outputs LEDs V 24 interfaces etc The functions of the control are divided between the two microprocessor systems as follows 1 Main Processor System Keypad LEDs User Program Interpreter Provision of programming environment Generation of PLC program addresses Transfer of input and output states via the SE board or PLC interface and PLC I O board Control of the V 24 interface 2 CLP Graphics System Ascertainment of instantaneous positions Interpolation Calculations VDU Control Demand Speed Values to DAC Interface with handwheel unit Serial data transfer via CRU bus Main Processor Unit Primarily on the main processor board which is common to TNC 151 and TNC 155 The operating system NC software is contained in EPROMs
18. S a a jo gi 5 S AS uie I i 3 PADS FAN Xj LJ 19 00 DUY auijojg 5 S 3 3 2 N Dd 3 SCH SCH CES Eu Ek vj E il Mys CES della ls FCR S 2820 LLEEEBLME REELLE a FAR E D x D Fa AAA o o o ei Jl o ssseserl ly 2 5t9 88 285522 228 109588 3 a Sle S 3 5 5 gx 23 222 ss88 8 35 sg od 23 t gt s Aii Sho l4 E a Y a 5 E o to o ing amp go jo bei 6 gs TA as a 1 qu gt oo N m 3 D a Wa PRESOS E e m frrbir LECT o a ai a a a Handrad NOT AUS Klemme 9549e 9e0 HEH Ki e e 2 S Y t I 235011 S 2 E LO dad i G EPA pt Kl E EL ER coo cade e S E El AR ES gt O AS a m rs 3 Sose Mie eS OG G oa M LEGI MAE FEUILLE Beresoceooc amp gt yee aH x EM 213 3 S EE i T H i l TON w EPEE uh 399 AP JEWEL EE d rafik l se es R7 5 5877 iin bn ee e e e opnzstte ev e liim i IIIA sese We J8 EE eee e URAC AAA E E E e 5 Foz d eg NI z 4 Platine Stecker Platine Tastatur Si PS PI P2 P3 4 He 5H s mln Sp 8 44 065 49004u SUV QuA b fcu 3 AA sd gt gt gt gt EUR OX 4 tao 2 eo E KR 6 65929tvyMNT T 6 Lw45055g P6 P7 D Kupplung 12pol kompl f rt sw sl 21 23 c i 227413 Reset SV ov ME s es FS i Med 2 SEED ge S 4 20 15v Platine Netzteil Sexe S Piriiiip Li 232 4 5 7 RON amp x S g Netzteil
19. SERVICE MANUAL TNC 151 155 Page 45 Section 3 3 The dialog language of the TNC 151 155 is determined by IC P3 located on Main Processor Board and is discernible from the different Id Nos of the programmed EPROMs Following dialog languages are available at this time German D English GB French F Italian I Spanish E Swedish S Finnish SF Dutch NL The Id No of the other programmed EPROMs are the same for a given IC position in all languages prerequisite same software issue Exception IC P6 PLC software The standard PLC program EPROM position IC P6 can be replaced with a custom PLC program for the TNC 151 155 Q IC P2 The export NC Software differs from the standard NC Software in EPROM position IC P2 The dot matrix for all VDU displayed characters is contained in IC P1 character generator DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 ea n EILDEINZATN Kundendienst TNC 151 155 T O a gt Ge zi EA Le EU omm NE 3 E s pi Rd Se Lm Ses DES IE TI tee S Ens eens prre E OCT UD Main Processor Board 232 264 01 SERVICE MANUAL TNC 151 155 Page 46 Section 3 3 TNC 151 CLP Processor Board 233 556 01 TNC155 CLP Graphics Board 233 554 01 MoIiVENnAIN DR JOHANNES HEIDENHAIN GmbH NEA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 47 Kundendienst Section 3 3 Soft
20. VDU from the Control Disconnect the Handwheel Unit from the Control if present Disconnect any external data devices Disconnect connector strips J1 J6 using a screwdriver to prise the connectors apart Do not unscrew individual wires ee YO Y O Y OQ AO Q OO S EN WC A o aca EE EE E EE EE EE E ERC prise apart with a screwdriver Remove the faulty Control removing the fixing screws if not already removed in 1 Install the new Control check the voltage selector posi tion Check the fuse rating see type plate Reconnect all cables previously removed Obtain from the type plate the Control s Id No NC and PLC Software Nos and write them in the machine handbook Refit the connector box cover plate Turn on the mains voltage Reprogram the machine parameters TNC is now ready to use Mains connection SERVICE MANUAL TNC 151 155 Page 37 Section 3 1 3 1 1 Connector to machine interface Handwheel HR 150 Touch probe system V 24 RS 232 C interface for data input output ar VDE Operational ground connection B eb HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 1 2 Procedure for exchanging the TNC 151 155 Q W Control 1 2 3 10 11 12 13 14 15 16 17 18 Gain access to the rear of the Control Remove the mains supply Remove the connector box cover plate from the rea
21. o kompl Tr 1 EENEG P 32 Kg RSENS o SD lm i 32 65 7 i 8 a i PCR Spannungsw hler m Sicherung jii 100 120 140 V 71 04 i ak hac 200 220 240 V 70 804 2 sa 5 3 nk ep 4 NET PEPPER i Mcd H Platine PHRSHK ESE RACER EEE KE Gr SE w deeg Entsto 1 2 L4 zl e 4 228 22 gelgn P E 4 67 e O Een L N Netzklemme kompl sormessa e F Alle mit gekennzeichneten Orahte mussen vor dem Ver loten mechanisch gesichert werden P10 Si P8 EBEN ES ENT C hj Bla IS E ES E E sana Grannies e e eS e DS eel yaa His 217 aiunt 8 6 e ES SEI al Ki GS AE cl Tal fev ali a Vedrahtungsplan Code Gal F D renon aoma IE o F21 BA 233552 Fur gese Ze nung behalten wr uns ate Rechte vor COGN ENE E k Tete Nummer DR JOHANNES HEIDENHAIN v Fassung Fanner name Opin wat ase e EN 110 PC Ein Ausgangsplatine 11 12 Re eRe ERE ee x ee latine s ar sesta grata es A reen rr c0 cnm syna T SER TIR Aer dos Da E D zone Saree e Tata LSA Age Ps La M ce un A G Xy ap Sono Ra Soa P a i Ses D Agen c SASE 4 Tse ese D mo sionis Tex ms Oy asom anis Segen s RON Cre MS OMA i NY ER EW rxoun El e nn E L
22. output If a fault is detected a O on an input the input conditions are displayed on the VDU eg INPUT OUTPUT TEST 1 PC BOARD INPUT OUTPUT FAILURE INPUT 01234567890123456789 0 01111111111111111111 20 11111111111001111111 40 111111111111 m1111111 60 1111 AN AX EX EY i Input 31 is used to monitor a 20 ms monostable pulse ge nerated on the Emergency Off output If the duration of this pulses falls outside its tolerance limits a fault condition will be displayed eg MONOFLOP TIME TOO SHORT 20MS This pulse can be generated manually by individual presses of the key or repetitively by pressing the key twice in quick succession This repetitive mode will be indica ted by a 1 at input position 31 on the VDU oe ACIVENNAIN DR JOHANNES HEIDENHAIN GmbH SEN D 8225 Traunreut Tel 08669 31 0 id MANUAL TNC 151 155 age Kundendienst Section 2 2 6 eg INPUT 01234567890123456789 To aid in locating an I O fault each output can be 0 10000000000000000000 driven individually By pressing the Key gt 20 00000000000010000000 after a short delay the VDU will display the input 40 00000000000000000000 conditions when only output 0 is being driven high 60 0001 AX EX EY iser eg INPUT 01234567890123456789 0 10000000000000000000 Subsequent pressing of the key 20 00000000000010000000 40 00000000000000000000 60 0001 allows successive outputs in ascending order to be driven AX EX EY rers 3 hi
23. overcurrent no emergency stop results in the standard PLC program The input E63 is used to indicate an overloaded output to the main processor 20 PL 100B 31 unipolar programmable outputs emergency stops protected against overload PL 110B 26 unipolar programmable outputs 5 bipolar outputs protected against overload On the PLC I O board a 12V voltage is generated by an external 24V supply PLC I O board On the PLC interface board this 12V voltage is transformed in a 5V voltage for its TTL modules SS n EID EINFIEZATIN MN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 155 Page 52 Section 4 1 CLP Processor System Primarily on the CLP processor board which is common to the TNC 155 CLP Graphics board Operating system is contained in EPROM IC P2 30 1 The main task is the calculation of the instantaneously intended values of the analog output voltages dependent on the instantaneous actual positions the programmed intended position the distance of the intended position influence on deceleration ramp the programmed feed rate the fast traverse rates determined per machine parameter the settings of the override and feed potentiometer The calculating speed requires a wait free RAM 30 2 The measuring system signals are processed on the analog board These signals are amplified at first 40 1 and then subdivided 40 by delaying pha
24. tool Load and run Burn In Test Burn In Test OK Burn In error message on VDU Board exchange with the aid of e message in conjunction with TNC block diagram and pertaining description experience Defective board send to Heidenhain for repair Send Control and VDU to Heidenhain for repair Where appropriate ask for loan or exchange unit Control and VDU ready for use again PFIEILDEIWPILAATINM aged Cp JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kendendienst Burn In Test Programs for TNC 151 B F on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialog Id No TNC 151 B 235 565 99 vss ees OF D 230 615 02 TNC 151 F 235 565 98 TNC 151 B 235 565 99 eee coe Ol GB 230 616 02 TNC 151 F 235 565 98 Burn In Test Programs for TNC 155 B F on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialog Id No TNC 155 B 235 567 99 sew ses OL D 230 609 02 TNC 155 F 235 567 98 TNC 155 B 235 567 99 eee ee OL GB 230 610 02 TNC 155 F 235 567 98 SERVICE MANUAL TNC 151 155 Page 20 Section 2 2 6 Burn In Test Programs for TNC 151 Q W on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialog Id No TNC 151 Q 235 566 99 ve 5 OL D 230 617 02 TNC 151 W 235 566 98 TNC 1519 235 566 99 Ses jew
25. unit that is re turned for repair This exchange unit is equipped with the latest hardware and software issue and is externally in excellent condition The only charges to the customer in this case are for the repair of his own unit Transaction Requested loan or exchange units are shipped on the date of request or the following day provided that the unit is available from our stock A customer s faulty unit should be returned to DR JOHANNES HEIDENHAIN within 14 days of receiving the exchange unit Service units Service units are new units which are used for service purposes and can be obtained from DR JOHANNES HEIDENHAIN at non repeatable discount prices ZEE E iE eS es Eh DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 5 Configuration List 212 300 BE 111 Visual Display Unit 230 802 Power Supply Board new 233 556 CLP Processor Board 282 394 037 204 737 825 273 264 601 387 532 168 370 206 091 212 216 225 213 217 224 233 232 227 212 217 228 202 213 215 TNC 151 B F TNC 155 B F 235 656 99 89 235 567 99 98 232 228 Analog Board sine 227 278 SE Board 228 164 Terminal Board 222 674 TNC 151 BR FR TNC 155 BR FR 235 916 99 98 235 918 99 98 SERVICE MANUAL TNC 151 155 Page 49 Section 3 5 TNC 155 BE 211 Visual Display Unit 226 917 BE 411 Visual Display Unit 212 462 4 key Graphics Keypad Assembly 2
26. with M06 programmed stop 1 no programmed stop Output of M89 normal output at the beginning of the block 2 modal cycle call at the end of the block Axis standstill if only one spindle rpm is output Axis standstill with a TOOL CALL 4 no axis standstill Axis standstill with output of an M function Axis standstill 8 5 no axis standstill Exceptions The axis stands still with M functions Add input values for functions requested resulting in a programmed stop as M00 M02 or with a STOP or a CYCL CALL block Touch probe system probing speed 80 3000 mm min Touch probe system measuring distance 216 90 19999 999 mm Switch over from HEIDENHAIN Dialog Programming 217 0 HEIDENHAIN Dialog to DIN ISO Programming 1 DIN ISO Blockwise Transfer 218 0 65 535 ASCII code for data input Blockwise Transfer 219 65 535 ASCII code for data output Blockwise Transfer ASCII code for the beginning and the end of the command block Blockwise Transfer ASCII code 221 to repeat transfer correction or block Data format and transfer stop for data inter face V 24 Operating mode data interface V 24 0 0 12 079 0 12 079 255 0 Standard data interface 1 Blockwise Transfer FRLIVENIIATN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 S Kundendienst Function Blockwise Transfer ASCII code data transfer finished Central tool memory Graphic printout Num
27. 1 1 41 41 IMMO wO Q0 V b wNHP 2 1V Mains transf 2 1V sec voltage no connection x not used with TNC 151 155 Fuses Fl and F2 not used with TNC 151 A not used with TNC 155 ZEN FIEIDENHAIN DR JOHANNES HEIDENHAIN GmbH Su D 8225 Traunreut Tel 08669 31 0 Kundendienst Test Data New Power Supply Board 230 802 for TNC 155 only The diagram opposite and the table below show the locations of the test points solder terminals on the new Power Supply Board 230 802 and the respective nominal and actual test voltages under load Previous TNC 155 Controls may be fitted with Power Supply Board 227 601 as used in the TNC 145 150 151 Plug and solder terminal signal designation Plug pin Cable colour Solder terminal Voltage Signal Test values V under load test points Nominal 7 12 0 1 black 23 24 OV TTL 2 brown 1 12 Processor supply 0 5 at 100 ohms 3 red 21 22 45V TTL 5 2 0 1 at 1 5 ohms 4 grey 15V Switching reg 15 0 1 5 at 150 ohms 5 n C 6 green 15V Analogue Board 7 8 9 green white n c 21V Mains transf Sec voltage Y Mains transf sec voltage ON 1 2 1V Mains transf 2 140 sec voltage no connection 10 11 12 not used with TNC 151 Test points on the Power Supply Board 230 SERVICE MANUAL TNC 151 155 Page 15 1 Section 2 2 4 Power Supply C nnector Assembly
28. 1 3 Procedure for exchanging the PLC I O Board of the PL 100 B 110 1 Remove the fixing screws of the heatsink cover plate 2 Remove the heatsink cover plate 3 Disconnect the TNC 151 155 connecting cable 4 Disconnect connector strips J1 J9 using a screw driver to prise the connectors apart Do not unscrew individual wires 5 Remove the voltage supply 24V and OV 6 Remove the fixing screws of the PL 100 B 110 B unit 7 Install the new unit following the above procedure in reverse order i or Axis Du a i S Ca o E hd ba sul MI EQ Reterance El Reference E Output for currant supervision for bipolar outputs EN FIEILDEIMPTZATN i DR JOHANNES HEIDENHAIN GmbH pum D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 2 Board Exchange Board Arrangement The TNC 151 155 consists of three main sections 1 The frontplate Keypad Board assembly 2 The housing Connector Board assembly with five plug in boards namely Main Processor Board CLP Processor Graphics Board Analog Board either SE Board TNC 151 155 B F or PLC Interface Board TNC 151 155 Q W 3 The backplate Power Supply Unit and Terminal Board assembly SERVICE MANUAL TNC 151 155 Page 40 Section 3 2 Board arrangement TNC 151 155 B F TNC 151 155 Q W PLC 1 0 Board TNC 151 155 Q 224 389 223 691 Connector Board 233 273 Terminal Board 228 164 228 166 Power Supply Board 230 802 PLC Interface Board 7 T
29. 100 10 000 VIEIL EIWMFIAIUN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 CE Kundendienst Function Counting direction of spindle axis Position value of reference mark for spindle axis Cycle to mill pockets with any contour Cycle Reaming milling direction to rough out contour Cycle Reaming sequence for reaming and roughing out Combining corrected or uncorrected contours Reference mark distance for distance coded linear transducers X Y Z IV Position window for spindle axis Hysteresis for electronic handwheel Spindle rpm for spindle orientation Setting of 16 markers to binary number Setting of 16 markers to binary number Touch probe rapid traverse to scan Cycle time for automatic offset adjustment Parameter 239 e e a ib je 241 247 250 251 SERVICE MANUAL TNC 151 155 Page Section 4 4 Input values I positive traversing direction negative traversing direction 360 Ib Roughing out contour pockets counterclockwise with islands clockwise 1 Roughing out the contour with pockets clockwise with islands counterclockwise Mill channnel round the island then ream the pocket 2 5 Ream pocket first then mill channel around the contour Combining corrected contours 4 Combining uncorrected contours Add input values for functions requested 0 65 535 0 no distance coded reference mark Input value for distance coded referenc
30. 20 1 IC P3 Dialog Language 20 3 IC P4 IC P5 23 1 IC P6 PLC Software qa E EE ILL IMA IM DR JOHANNES HEIDENHAIN GmbH EA D 8225 Traunreut Tel 08669 31 0 Kundendienst The RAMs 20 2 on the main processor board con be accessed either by the main processor 20 or by the CLP processor The intended coordinates programmed feed display texts etc can therefore be transferred These RAMs also serve as register file memory for the main processor 20 User programs machine parameters and under certain circum stances the PLC program are programmed in RAMs 20 4 The 16 bit address bus is extended to 20 bit by a memory mapper 1 The keyboard controller 22 has the task of driving the LEDs and scanning the keypads 22 1 on the front plate The main processor is connected with V 24 interface via a serial CRU bus This interface is used to exchange data by means of a magnetic tape unit ME or respectively an external processor The PLC program contained in IC P9 23 1 is processed by the l bit PLC processor 23 mounted discretely on the main processor board The input and output states are stored in a 8k x 8 PLC RAM 23 2 1 O Functions a TNC 151 155 B Versions 24 galvanically separated inputs EO to E23 50 and 24 floating relay contact outputs AO to A22 emergency stop 51 on the SE Board The inputs and outputs are protected on the terminal board B F ve
31. 33 544 CLP Graphics Board Housing Front Panel Housing Assembly ISO Format Keypad 20 key Keypad Assembly 10 key Keypad Assembly Keypad Board Connector Board Main Processor Baord Power Supply Board old Mains Filter Board Battery Holder Assembly Potentiometer Assembly Mains Voltage Selector with Integrated Fuse Holder 3 pols Mains Clamp Mains Transformer BV 15714 TNC 151 QR WR TNC 155 OR WR 235 915 99 98 235 917 99 98 TNC 151 Q W TNC 155 Q W 235 566 99 98 235 568 99 98 234 509 Analog Board TTL 232 228 Analog Board sine 226 761 PLC Interface Board 228 166 Terminal Board 223 836 PL 100 B PLC 1 0 Board 223 216 PL 110 B PLC I O Board Y ELEVEN iN NE DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 4 Additional Information 4 1 Block Diagram Description The TNC 151 155 block diagram shows in simplified form the internal functional units of the control their relationship to the various boards and their interconnections The graphic layout of the diagrams and the way it is folded permit the representation of any of the TNC 151 155 B BR Q QR models simplified representation of functional processes Numbers enclosed between dashes inform about the board and its functional unit e g 50 1 Lo Subdivision of functional unit Functional Unit Board Simplified Description of the TNC 151 155 Block Diagram Keypad Board 1
32. 51 is comprised of the following individual tests a Key C TEST INT POT BATTERY TRIGGER The internal potentiometers on the front panel are in order when set to 100 2 b Key EPROM TEST CPU XXXX XXXX The contents of the EPROMS addressed by the main processor are tested through their CRC check sums The sums of the individual address ranges are displayed in one data word The MS byte contains the generated check sum the LS byte contains the expected check sum The address range dis played in a fail condition is the first that deviates from the expected check sum c Key 1 RAM TEST NOT MAPPED Addressed is the range from EOO0H to FFF9H which is battery backed up during power interruption d Key 2 RAM TEST MAPPED Addressed is the range from FFFFFH and upwards depending on RAMS equipped During this test no power interruption should occur e Key 3 TEST PC RAM Range E000H to FFFFH through CRU addressing f Key 4 TEST STATIC RAM CLP PROCESSOR BOARD Range D800H to DFFFH SERVICE MANUAL TNC 151 155 Page 30 Section 2 2 6 The sequential test for the TNC 155 is comprised of the following individual tests a Key TEST INT POT BATTERY TRIGGER The internal potentiometers on the front panel are in order when set to 100 2 b Key EPROM TEST CPU XXXX XXXX the contents of the EPROMS addressed by the main proces sor are tested through their CRC check sums The sums of t
33. ANUAL TNC 151 155 Page 29 DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 ES DIEREINPOAAIIW Section 2 2 6 Kundendienst Fig 9 Complete initialization of the Burn In test program Program run by Program run irterrupted by Progran run interrupted by Program run interrupted by n Em Si Re initialization of Loading the Burn In existing Burn In test test program program see fig 8 mee fig 7 Program interrupts DISABLED o VDU d splays EXTERNAL UNIT CONNECTED Respond with i9 Control checks program data gt For further explanation see the corresponding section of the written explanation on pagas 29 and 30 VOU displays RERE AD IN PROGRAM XXXX CHECK SUM ERROR Keyboard teat already carried out Error messace stored yes VOU displays VDU displays error nexsace 4 BI SOFTWARE NUMBER xxx XXX xx JUMP OVER KEYBOARD TEST Program interrupts 0 ENABLED Program interrupts ENABLED Jump to sequential tests see page 32 VDU displays O 1 OR 2 PC BOARD Program interrupts ENABLED 6 Calibration of front panel potentiometers TE ETE En i LS E N A N NA DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Sequential duration test Check that all test adapters are correctly connected inclu ding the connection to the V 24 interface socket The sequential test for the TNC 1
34. E o T Netzteil kompl 32 i 4 65 Spannungsw hler m Sicherung 100 120 140 V T1 0A i 200 220 260 V 70 804 P Platine i i Entst r o 1 228 gelgn Hr PE ms Alle mit e gekennzeichneten Drahte mussen vor dem Ver loten mechanisch gesichert werden F21 BA 233 597 i1 12 Led xd ex mon Sume TOS AN misme We ope pe 2 jure env e 9099 1 a Son o SAR Ku ar e i 2 e ss 3 e noe ton yt C ei uem ad E M M e Za gt fra euy Y 1 dm Deron n ex Mies TS Te e s B ig n m e Y bo lis g g rsene p E Ce Seen Y PTT c e e a al lyst tus SIS ju yen ae SAO 201750 ume ei mue wv N 1d gs amp e poo Al sie Gi S a zn ens n Qum e o Na H E q 6 ds a s 3 inne De ns OI 2 pem UT e 3 H Jajaurouuajodg eee we ya e S Tavse ra m ugoe pde MAS LA e e o i l No _ Tas ed an 9 o Corm Var Emo cree Ne a e Dol uo AAA dwog gt s gt oj gt us Deza f d CIE LL s Le ary DEAD D S al E lesen 6 SESE nes die ee Be a PS JejuogusSjog a x i as es Ties Derino zve Se v e el ine KR a METEO f 2 i e 1 1 6 9 e S 9 mi y PS s v ai Ki Ki E e 5 2 3 a ei H a E s ES doy o E A d 53 LT 918440819 10H s 2 m em I x3 5 y A y ij E d Lee 9 y SI i gs SER SU Scr SP x M
35. EHEIDENHAIN j DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Service Instructions TNC 1251 7155 B Q Subject to change without notice DR JOHANNES HEIDENHAIN GmbH is constantly working on further developments of its TNC Controls It is therefore possible that details of your Control may differ slightly from those described herein If that is the case please order a suitably revised issue of the Service Manual Copying Duplication This manual is provided subject to the condition that no part of it shall be reproduced in any form or by any means without our prior consent in writing Issue 04 88 EN HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH a D 8225 Traunreut Tel 08669 31 0 i MANUAL TNC 151 155 age Kundendienst Contents 1 Use of the Service Manual Page 2 5 Fault Diagnosis 3 ol Procedure for fault finding i 3 2 Flow diagrams for fault location 4 2 1 Fault diagnosis for the complete installation 4 2 2 Use of the integrated supervision system 5 2 3 Testing of the VDU and associated circuitry 14 2 4 Testing of the Power Supply Unit 15 2 5 Testing of the measuring systems and wiring 17 2 6 Burn In Test 18 Exchange Information G G PP uU uU wu uu ww t YN MYDD NIN 1 Exchanging Control units H 37 1 1 Procedure for exchanging the TNC 151 155 B F Control 37 1 2 Procedure for exchanging the TNC 151 155 Q W Control 38 1 3 Procedure for exchanging the PLC
36. F Start PLC Positioning Y axis We d i WW or incremental positioning Z x S M a G Start PLC Positioning Z axis s T K A or incremental positioning IV M H Start PLC Positioning IV axis or incremental positioning IV n la 7 mt I Directional Key X LA UD n n HI J Directional Key X D H Er 2 x K Directional Key Y n oo L Directional Key Y FIEIDEIMVPIATIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 155 D 8225 Traunreut Tel 08669 31 0 Page 11 1 Section 2 2 2 Kundendienst VDU Display flashing Fault cause Possible fault location ERROR IN PLC PROGRAM Error with non erasable marker see also PLC Description M M Directional Key Z PLC Program Main Processor Board n T W d kW N Directional Key Z 0 Directional Key IV or supplementary axis to be changed to another axis M 2590 and M 2591 E P Directional Key IV We T or Start PLC Positioning S axis d ix Q Non defined macro called up via PLC marker MENE DR JOHANNES HEIDENHAIN GmbH DERNIER BANURBCINE SiO D 8225 Traunreut Tel 08669 31 0 Page 12 Section 2 2 2 ca EEE ERS CIARN Kundendienst VDU Display flashing Fault cause Possible fault location PROCESSOR CHECK ERROR 0 Incorrect CRC checksum of machine related data Main Processor Board excluding machine parameters Baud rate limitation preset etc sj 1 Incorrect CRC checksum machine parameters Ma
37. N GmbH D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 43 Kundendienst Section 3 2 Exchanging the Keypad Board Remove the 6 cross head fixing screws from the frontplate Tilt the frontplate outwards Remove connectors J13 feedrate override potentiometer and Ji4 spindle override potentiometer from the Connector Board Remove the ribbon cable connector P10 from the Keypad Board Remove the 7 cross head fixing screws which secure the Key pad Board to the frontplate Pull off the Keypad connectors Pl to P8 respectively P9 for the TNC 155 from the Keypad Board Remove the Keypad Board 4 d e P9 ds not used with TNC 151 wer When rebuilding the assembly ensure that the keypad connec tors are firmly engaged in their respective sockets and that the LEDs project through the corresponding bored holes in the keypad housing i A ME EiL DIN mAN DR JOHANNES HEIDENHAIN GmbH A D 8225 Traunreut Tel 08669 31 0 E MANUAL TNC 151 155 Page Kundendienst Section 3 2 Exchanging the Power Supply Unit Exchanging the Connector Board Remove the 4 cross head mounting screws from the rear of the Remove the 2 cross head fixing screws of the V 24 connector Control 2 screws are found in the connector box on the rear of the Control Remove the back wall with the Power Supply Unit and Terminal Push the V 24 socket through its recess in the Control Board housing Disconnect th
38. NC 151 155 Q 226 761 SE Board TNC 151 155 DC 227 278 Analog Board 232 228 234 509 CLP Processor Board TNC 151 233 556 CLP Graphics Board TNC 15 233 554 Main Processor Board 235 647 Keypad Board 224 825 cB MEIVENMNMAIN eed DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 155 Page 41 Section 3 2 Caution Please observe MOS protection measures when exchang ing boards Exchange boards with the same assembly no only The assembly no is impressed on every board to the left of the serial no Assembly No Work area requirements The TNC 151 155 contains sub assemblies with MOS elements Although MOS ICs are equipped with an input protection diode network to eliminate the build up of static charges care must be taken when handling these elements The following requirements in the work area must be met Prior to working with MOS components or with assemblies con taining MOS elements all table coverings instruments tools and work personnel must be properly grounded A portable MOS HANDLING SET for field service is necessary when exchanging the operating software and or servicing the Control 2 amp conductive work surface a wristband that provides an electrical connection O between person and conductive work surface a cable that equalizes potential differences 3 between conductive work suface and ground
39. NICS DEFECTIVE 0 3 A K example of fault with measuring system X MEASURING SYSTEM DEFECTIVE example of fault on machine tool GROSS POSITIONING ERROR SERVICE MANUAL TNC 151 155 Page 5 Section 2 2 2 The system distinguishes between what are considered to be harmless errors and serious faults in that faults are shown as flashing displays Examples of faults are measuring system faults drive faults and faults in the TNC s internal elec tronics The occurrence of a fault leads to the machine being switched off via the emergency stop contactor The fault must then be rectified before the TNC is switched on again Flashing fault messages TNC 151 155 AXIS X Y Z 4 MEAS SYSTEM DEFECTIVE EMERGENCY STOP DEFECTIVE WRONG REFERENCE POINT EMERGENCY STOP PLC GROSS POSITIONING ERROR A B C D TNC OPERATING TEMP EXCEEDED ERROR IN PLC PROGRAM A Q TNC ELECTRONICS DEFECTIVE 0 3 A K CHECK SUM ERROR XX00 XXFF The significance of these fault messages is explained on pages 8 to 13 key on the TNC after which normal operation may resume gf key on the 1 error message can be cleared by pressing the ist of error messages is given on page 7 A E HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH Ee D 8225 Traunreut Tel 08669 31 0 Kundendienst Use of the integrated supervision system Not flashing Flashing Error Message Harmless error Serious fault no Emergency Stop 3 Emergency Stop eg
40. ONING ERROR E TNC OPERATING TEMP EXCEEDED The analog output voltage calculated by the see above SERVICE MANUAL TNC 151 155 Page 10 Section 2 2 2 Fault cause Possible fault location control implied by trailing error is greater than 10 V The analog output voltage required to obtain see above a desired speed deviates more from the calcu lated voltage than the voltage programmed in MP 234 The actual position at standstill deviates see above more from the intended position than the distance programmed in MP 169 Automatic offset adjustment MP 252 Offset voltage is greater than 100mV Ambient temperature inside the TNC has Ambient temperature of Control exceeded 65 C Fault in the temperature supervision Analog Board ea P EILD EIwWMPZZAUUN SERVICE MANUAL TNC 151 155 DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Page i 11 Section 2 2 2 Kundendienst VDU Display flashing Fault cause Possible fault location ERROR IN PLC PROGRAM Fault with non erasable marker see also PLC Description moe d A Start Key PLC Program Main Processor Board or incremental positioning X jt T n B Rapid Traverse Key LLI n at or incremental positioning X FE C Direction Latch Key mt Ui n T or incremental positioning Y n n D Feed Release LI n LII n or incremental positioning Y E e d We E Start PLC Positioning X axis v or incremental positioning Z oe oe i
41. PLC Load Adapter LC Load Adapter RBk a TNC 151 Q W b TNC 155 Q W NHEILUEINPAAIINW DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 155 Page 22 Section 2 2 6 SUIZA D 8225 Traunreut Tel 08669 31 0 Kundendienst Fig 2 Burn In Adapter TNC 151 155 A n Id No 233 514 ZY cub EEE il EN rA N DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 22 1 Kundendienst Section 2 2 6 Fig 2 1 Burn In Adapter TNC 151 155 A n Id No 233 514 ZY wiring Board 7 m conne r An pE Prom analogue outputs 48 9 ISO m 45012 M61 IA Jet ATS CTS DER DIR 43 i 12 i f f P a seth n 2518 Su 2606 60 JOA mm 2500 Bin RI 1517 25 pia plug Ek P T 415 4418 756 7815 A 151 Bil L1 I iti switching signe stand by 9 pin plug circuitry IUB JHS JI HI FH AT 42082 2213 AN HM INT INE as per Xx circuitry ZUG ANG JT 72 2 22H An 228 ur 20 22099 JNO Am as per X circuitry Relays within TNC 150 A Burn In as per X Adapter circuitry Bandwheel i A as per x EN FIEIDEIVBHATN DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 vicc da MANUAL TNC 21 159 Section 2 2 6 Kundendienst Fig 3 Burn In Adapter TNC 151 155 P n Id No 233 513 ZY ZEN HECIDENRHAIN DR JOHANNES HEIDENHAIN GmbH hd D 8225 Traunreut Tel 08669 31 0 s SE TNC 151 155 age 23
42. PUT OUTPUT FAILURE INPUT 01234567890123456789 0 01111111111111111111 20 11111111111001111111 40 111111111111 11111 111 60 1111 AX EX EY Ear Input 31 is used to monitor a 20 ms monostable pulse genera ted on the Emergency Off output If the duration of this pulses falls outside its tolerance limits a fault condi tion will be displayed eg MONOFLOP TIME TOO SHORT 20MS This pulse can be generated manually by individual presses of the key or repetitively by pressing the key twice in quick succession This repetitive mode will be indicated by a 1 at input position 31 on the VDU To aid in locating an I O fault each output can be driven individually By pressing the key after a short delay the VDU will display the input condi tions when only output 0 is being driven high g h i 3 SERVICE MANUAL TNC 151 155 Page 31 Section 2 2 6 Key TEST DYNAMIC RAM CLP GRAPHICS BOARD Key 6 TEST VIDEO RAM CLP GRAPHICS BOARD Key 7 PC INSTRUCT DECODER ACCU FF TEST The circuitry used for decoding and carrying out the PLC instructions is tested Key INPUT OUTPUT TEST 1 PC BOARD only with Q versions The PLC I O Board outputs are resistively loaded and con nected to the inputs by means of the PLC Burn In Adapter Each output is connected to 2 inputs By writing 1 s to the outputs and checking the corresponding inputs the Control is able to deduce whether a fault is on an input or an
43. Send VDU and CLP i Processor Board to HEIDENHAIN for repair Order exchange unit if required TNC ready for use Testing of the VDU BE 111 211 and associated circuitry EN HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 14 1 Kundendienst Section 2 2 3 Visual Display Unit BE 411 in conjunction with TNC 155 The Display Units BE 411 is supplied by 11 Vds from the units own integrated power supply A defect in this power supply may cause an apparent CRT display fault E If the fault is not due to the detective power supply it is likely to be due to the CLP Graphics Board which contains the control circuitry for the Display Unit This can be verified by exchanging the board for one which is known to function correctly T Exchange If the fault still persists then must be due either to bad mo connections within the TNC eg on the Connector Board or to faults on both the VDU and the CLP Graphics Board See the diagram opposite for a logical procedure for locating the fault in the system Send VDU to Heidenhain Send CLP Graphics for repair Board to Where appropriate ask for a loan or exchange unit Heidenhain for repair Where appropriate ask for a loan or exchange unit Control and VDU ready to use aga n Testing of the VDU BE 111 211 and associated circuitry 3 Mea GE EIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunre
44. Standard circuitry with unipolar bipolar switch over ED VUEILZLCIWMFIABPSG DR JOHANNES HEIDENHAIN GmbH EAE D 8225 Traunreut Tel 08669 31 0 Kundendienst Loading the Burn In test program Burn In test program not already loaded 1 Connect the Magnetic Tape Cassette Unit ME 101 102 to the V 24 socket on the rear of the Control N D Prepare the ME unit to down load the test program to the Control by inserting the appropriate program cassette see list page 20 and pressing the following buttons M e Y o o Es E Ex o EI Fig 6 Initialization of ME unit 3 Control must now be prepared After applying power to the Control it automatically car ries out a memory test During this time the dialogue MEMORY TEST will be displayed on the VDU Upon completion of this test the dialogue will be replaced by POWER INTERRUPTED SERVICE MANUAL TNC 151 155 Page 25 Section 2 2 6 The necessary code number for reading in the Burn In test program is entered by pressing the Fosen lm e as often as mecessary to obtain the garten CODE NUMBER and then le 2 o 1 s s Errors in entering these numbers can be correcte amp by pressing cel 4 The data transfer is then intiated by pressing During the loading of the Burn In test program from the ME unit the following dialogue will be displayed POWER INTERRUPTED EXTERNAL DATA INPUT If necessary
45. TOO LARGE CYCLE INCOMPLETE SELECTED BLOCK NOT ADDRESSED PROGRAM START UNDEFINED POSITIONING ERROR EMERGENCY STOP ARITHMETICAL ERROR OPERATION PARAMETERS ERASED 3D INTERPOLATION NOT PERMITTED SERVICE MANUAL TNC 151 155 Page 7 Section 2 2 2 FURTHER PROGRAM ENTRY IMPOSSIBLE PROGRAM NUMBER UNAVAILABLE PROGRAM NUMBER ALLOCATED LABEL NUMBER ALLOCATED TOOL NUMBER ALLOCATED RELAY EXT DC VOLTAGE MISSING POWER INTERRUPTED PGM XXXXXXXX UNAVAILABLE TWO TOOL DEF XXX WITH PGM CALL CIRCLE CENTRE UNDEFINED XXXX ADDRESS LETTER ALREADY ASSIGNED BLOCK TOO LONG G CODE GROUP ALREADY ALLOCATED ILLEGAL G CODE BLOCK NUMBER ALREADY ALLOCATED BLOCK FORMAT INCORRECT N CODE MISSING BLK FORM DEFINITION INCORRECT PGM SECTION CANNOT BE SHOWN TOO MANY USER PARAMETERS PROTECTED PGM ILLEGAL NC BLOCK CHAMFER NOT ALLOWED FAULT IN PLC PROGRAM ZEB INCIDENTA 2h DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Fault descriptions TNC 151 155 VDU Display flashing Fault cause TRANSDUCER X DEFECT A Fault code A signal amplitude fault TRANSDUCER Y DEFECT A B signal frequency fault TRANSDUCER Z DEFECT A Measuring system not connected TRANSDUCER S DEFECT A Cable damaged TRANSDUCER X DEFECT B Glass scale dirty or damaged TRANSDUCER Y DEFECT B Scanning head damaged TRANSDUCER Z DEFECT B Measuring system supervision damaged TRANSDUCER S DEFECT B EMERGENCY STOP DEFECTIVE Fault in the emergency stop
46. Ul GB 230 618 02 TNC 151 W 235 566 98 Burn In Test Programs for TNC 155 Q W on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialog Id No TNC 155 Q 233 568 99 Lera OL D 230 611 02 TNC 155 W 233 568 98 TNC 155 Q 233 568 99 sim wee OL GB 230 612 02 TNC 155 W 233 568 98 D 8225 Traunreut Tel 086 69 31 0 Kundendienst IMPORTANT The following section BURN IN TEST pages 21 35 contains thb procedure for testing older TNC 151 155 versions and is therefore to be used as a guide only for the newer TNC 151 155 controls described in this manual An updated section pertaining to the newer TNC 151 155 is in print The description contained herein is outdated and should be destroyed upon receiving the updated version 5 MECEL IWAN DR JOHANNES HEIDENHAIN GmbH UA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 21 i 2 2 6 Kundendienst Section Fig 1 Interconnections of Burn In Adapters and TNC 151 155 B F BE 211111 Burn In Adapter TNC 151 155 A Burn In Adapter TNC 151 155 A a TNC 151 B F b TNC 155 B F NV E a Eni kS INN H REN DR JOHANNES HEIDENHAIN GmbH MANU E D 8225 Traunreut Tel 08669 31 0 SE 1 ARSEN 534 SS age Kundendienst Section 2 2 6 Fig 1 Interconnections of Burn In Adapters and TNC 151 155 Q W BE 211 111 TNC 151 Q W Burn In Adapter Burn In Adapter TNC 151 155 P TNC 151 155 P
47. User or programming eg X MEASURING SYSTEM error DEFECTIVE Error message Switch off Control cleared with key and remedy fault Control ready to use again Use of the integrated supervision system SERVICE MANUAL TNC 151 155 Page 6 Section 2 2 2 Error message EXCHANGE BUFFER BATTERY Particular mention should also be made about the implications of the instruction to exchange the buffer battery If the dialog display indicates EXCHANGE BUFFER BATTERY new batteries must be inserted within one week The buffer battery compartment is located behind the screw cover in the lower left hand corner of the operating panel When exchanging the batteries special care should be taken that the polarity is correct POS pole of battery outwards The battery needs to have IEC designation LR 6 and must be of the leak proof type We especially recommend the use of VARTA Alkaline batteries type 4006 With discharged or missing buffer batteries the memory for the machine para meters and for the user program will be supported only as long as the mains remains switched on Continued operation is still possible but the memory contents will become erased in the event of a mains failure Please note that the TNC has to be switched on when exchanging the buffer batteries If a mains failure occurs during a battery change or when the battery is discharged or missing the re entry of the machine para meters and the user program will be n
48. a si Yes Z Fault lies with measuring system E Z N S ow E N i No E 2 3 LN Repair wiring D DO Et me Fault cleared Scale contaminated No Fault cleared Scale damaged Yes Return scale to REIDENHAIN for repair Yes fault cleared Detective scanning head Replace scannina head Fault Yes cleared No Return complete measuring system to HEIDENHAIN for repair 2 Replace measuring system Fault lies with TNC Measuring system amp wiring OK Continue with flow diagram of section 2 2 1 D 8225 Traunreut Tel 08669 31 0 E z 29 mE ul 2 2 Lis Es Pm 2 2 5 Testing of the measuring systems and wiring tundendienst ZEB mi Ci CINTA SA DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 2 2 6 Burn In Test In some cases inspite of there being definite fault condi tions on the control error messages may not be displayed on the VDU However the Control s electronics can be tested with the help of the Burn In test program This test program is a means of dynamically testing the Control s hardware and can be used not only for duration testing but also for fault diagnosis The test program is stored on a digital cassette and can be loaded into the Control via magnetic tape units ME 101 B 102 B or ME 101 C 102 C Program versions 212 902 05 212 902 09 The test program
49. age 27 Section 2 2 6 The lines of dots represent the individual keys in each of the four keying fields The keys must now be pressed once each in a defined sequence in order that the Control can check that each key is making contact and delivering the correct code to the keyboard interface The keying sequence is as follows top right set of 20 keys top left set of 10 keys middle left set of 20 keys bottom left set of 4 keys only with TNC 155 bottom right set of 10 keys In each case the sequence is from left to right beginning with the top row For each correct key push the respective dot on the VDU will be replaced with a If an incorrect code is received the keyboard test will start again from the beginning 1f the keyboard test has previously been carried out eg before a power failure the option of carrying out the test is not displayed In this case assuming no error message has been stored from a previous run the program jumps into the sequential tests see page 30 If the keyboard test has previously been carried out and an error message has been stored from an earlier run this error message will be displayed and the program will wait for an interrupt see point 7 In the case of a Control designed for use with an external PLC I O Board TNC 151 155 Q W the following text will appear on the VDU following a successful keyboard test O 1 OR 2 PC BOARD 2 This refers to the number of e
50. agu i Ll e o gas o y qe 1 sve Quee oe pne Haag ida 169 T e Sara e zeg Case e uina S Ha Y eon a ove SEE 1109 Ap Te gt ree Deren zve O a 1104 30D LM AO xD an VE e E ae ny H Wa Sg SE 9 He le ue ere oe wr rs rara RL wm e Qvo D age fon ave eav ave Ad Flz7 fer nye asw ye la As va 3 e eso e D atse Ins soe ava D Boa ax i ig aan o D Bruser aY S 506 bts RAE KRESS EH UMS ki m dwog cR K 48jeuiouajog E T dh ub m teers LU JOJDWONUIJOS a x e D a 4 e a H ydwoy ee LT 214211 Dg Ua oH gt rau gt e N ej E al s je o s5 L ses BX fa Ka I QX x v Sale 5 alze o O uso BU X ag E w e S 5 E gt v x y E eng 3 Q E N S a E 3 amp g m Ka E Platine PC Interface ERA S lis l r4 i d a ES DB vel BE E E bui D S DEI TF H Bi e SN Lo L habon SUND N i gt AAA LIE AS Sl gt 2 KEE 96 P Hyer ees Soc Es gt SCHERER gfs aX 553352 238 53388 P oke SIS 5 gt do So Box 27 E g 2 Bis o Seg 9 gt S IER z5 c 2 ZS NO x e e u Le D N N e B i sS oH Weg AS S E az s bd o i x 5 gs T gesh RPR Ga O SL Salk ole c d i ow won m won E W UR m t Nee Q S m Qarang Srssage on amp oh on y e S x 1 9 t6 x o D w a 2 EBENEN EORR IJozu
51. ation as per figure 9 if you wish to erase the Burn In test program and return to the normal operating system To restart the Burn In test programm press e Fig 8 Re initialization of a previously loaded Burn In test program ES HEIDENHAIN MA DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Continuation of the Burn In test initialization The remainder of the initialization procedure must be described in conjunction with the flow diagram of figure 9 page 29 1 Beginning with the display EXTERNAL UNIT CONNECTED 27 which refers to the use of an external test computer the operator must respond by pressing 2 A check is now automatically carried out to ensure that the test program data has not been corrupted in any way If an error is detected the display REREAD IN PROGRAM XXXX CHECK SUM ERROR will appear on the VDU and the test program must be reloaded from the ME unit 3 If the keyboard test has not already been carried out eg prior to a mains interruption the option of carrying out this test will now be displayed BI SOFTWARE NUMBER XXXXXX XX JUMP OVER KEYBOARD TEST The keyboard test can be skipped by pressing the key Any other key will cause the test to be carried out in which case the following display will appear on the VDU s Li Ei E only with TNC 1551 s e e o e o o E D tj SERVICE MANUAL TNC 151 155 P
52. ber of control signs to set the printer inter face 1 control sign Graphic printout 2 control signs to set the printer interface Graphic printout number of control signs ig front of every printer line 1 control sign Graphic printout 2 control signs in front of every printer line Movement supervision Touch probe Safety clearance over measuring point for automatic measuring Graphic Representation of graphic in three planes Rotating the coordinate system of machining plane Activation and function of spindle axis Kv factor for spindle axis Parameter 224 221 229 230 231 235 to bo bo w tC t d Co bo 236 231 238 SERVICE MANUAL TNC 151 155 Page Section 4 4 Input values e us 12 079 no central tool memory 99 central tool memory with number of tool stores 65 535 65 535 65 535 65 535 10 V 999 999 mm a ee 19 Ib German standard 1 American standard no rotation 2 rotation by 96 Add input values for function requested Spindle axis not active 1 Spindle axis serves to orientate the main spindle without position display 2 as input value 1 with position display however is displayed instead of axis IV 3 Spindle axis is not controlled the position display however is active axis designation A is displayed instead of axis IV 4 as input value 3 axis designation B however 5 as input value 3 axis designation C however 0
53. cannot be loaded into the Control if the flashing error message TNC ELECTRONICS DEFECTIVE is present on the VDU In this case the faulty board must be determined by exchanging each board in turn until the fault is eliminated However before exchanging any board it is advisable to check the output voltage from the Power Supply Unit see section 2 2 4 To run the Burn In test program it is necessary to have a set of Burn In Test Adapters Figs 2 to 4 1 show pictorial and schematic representations of each individual adapter SERVICE MANUAL TNC 151 155 Page 18 Section 2 2 6 Depending on the type of Control TNC with either a standard SE interface or with an external PLC I O Board the appro priate adapters must be connected as shown in fig 1 It is important to have the correct test program for the type of Control and for the Control s current NC Software issue The test programs are listed on page 20 The type of Control can be determined from the identification number of the unit the issue of the NC Software can be determined form the NC Software issue number Both these numbers are found on the type plate on the rear of the Control SERVICE MANUAL TNC 151 155 Page 19 D 8225 Traunreut Tel 08669 31 0 FIEIDEINHAIN DR JOHANNES HEIDENHAIN GmbH Section 2 2 6 Kundendienst Application of the Burn In Test Application of Burn In Test Dismantle the Control and VDU from the machine
54. cessor Board Emergency Stop Block Diagram TNC 151 155 Drawing No 4820 E KD 16014 00 Analogue Board TTL Inputs to Terminal Board CRU Address Bus from CLP Processor Board Shaper IRI Position Ref Inhibit from SE PLC Inter f Brd from Main Proc Brd CRU Address Bus E g 422 E Mono Mono Sample a flop flap ICH E u ls E o Z 4 K Measuring Systems from Main Proc Brd CRU Data Bus Handwheel 90 CRU Data Bus from CLP Processor Board Emergency SS Block Diagram TNC 151 155 Analogue Board Drawing No 4820 EKD 16013 00 D EE Cies LINIEN DR JOHANNES HEIDENHAIN GmbH RS D 8225 Traunreut Tel 08669 31 0 Kundendienst 4 3 Wiring diagrams Wiring diagram Wiring diagram Wiring diagram Wiring diagram TNC 151 B TNC 151 Q TNC 155 B TNC 155 Q Drawing No Drawing No Drawing No Drawing No 232 239 00 232 240 00 239 292 00 232 293 00 SERVICE MANUAL TNC 151 155 Page 68 Section 4 3 WELTI ATIA a LE DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 4 4 Machine parameters Function Rapid traverse Manual feed Speed when approaching the reference marks Signal evaluation Traversing direction when approaching the reference marks Counting direction Polarity of nominal value voltage Integral factor
55. e Rechte vor Tede Nummer Mofistob DR JOHANNES HEIDENHAIN rena then Dam cre toute On pesi He AAA SAO E E x ez Zeichnungs Nummer asa IP YT 206 468 00 PC EinlAusgansplatine 72 110 EEN Iupzuapjepuids of xgene expoo ione sec dme Ar ee H I sene Less D Steg mus Ce D Lime eus m icy E Hog i eos E d rene iro Mr SEN H rne Ty Xe mei e Deis gt bl bcc eee N l n Sne EA esa Seas mm e e E D nyme RS Wf 8 Sean He stan om De enn ae D S e nme NND Tae osama make p e e 1 ox D 2 rave Cole d ONUS 13A o Y so E v 0 E cmo Lens me 4 ke QNI a 9 2 9 Sol ee 8 Y GIE i Ze 912 G 5 E 2 p a gt a gt af e s S e Y s D x e e e e a e kd Za ej D X we o E 5 3 7 ze 5 3 6 e 9 E i lt I O N x i 2 MR AE 8 gt 8 E a EI g 3i v y ed c Pap MI 8 3 zc 59 a 1 MEE Be 128 A H a i o En T e i i t zu iL jiejbojouy oul S S 3 i m y N a a EE ajs i 5 E y AH d gt dl HU AH Sisi a dy s 8 dd os M uj M H ER 3 a ES a ei a o jut o gt gt epg SIDE es go tee etd oot LES gt Se S S BISS E E EE ax 5553552358 5533388 5 Tare Sic o x amp Oo oe E HI a x E E 99 Hi p rFESENES c GQ ra 5 basi 2 3539 HW Ex Sang SA we E all x m ka S 29 2 2a 8 S a Qo B se
56. e marks Ref distance 1 000 grating pitch Q0 65 535 Incrementals 9 65 535 Incrementals 99 999 999 U min 65 535 Marker 2208 to 2223 9 65 535 Marker 2224 to 2239 80 15 999 mm min 1 65 535 in units of 20 ms 0 no automatic adjustment 20 mm 20 pm e g D m Ci CN NAAL DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SERVISE ANUA DTN gone eee Section 4 4 Kundendienst Function Parameter Input values Allocation of the axes to the X 253 0 X1 1 5 Measuring system input X1 measuring system inputs Y 254 x2 2 Measuring system input X2 Z 255 0x3 3 Measuring system input X3 IV 256 0514 4 Measuring system input X4 V 251 0 X5 5 Measuring system input X5 Input Standard allocation Spindle rpm if marker 2501 is set 99 999 999 U min Direction of rotation always positive Language conversion for user cycles 0 50 Difference between dialog numbers of the second English and the first dialog without function 50 if only DLG CALL blocks Difference between Q parameter numbers for DLG DEF block and DLG CALL block N BO be AND Nr S amp S 10 OV pect 3D Taster ZE Aa s Derecho 2 E 3 Batteriewarnung E Innenschirm 7 Sw 1 GND 13 frei 2 Ve frei 3 Hor Synch 15 frei 4 16 P Vert Synch 7 2 Hell Dunket 67 frei 18 7 79 d Video ER lov Digital 20
57. e mx o E eos s BD C SEE Entst r o i o intent 8 f g H 2 reg AD ee sm m Me B zl e EA Ss e S 4 H SES e E gs f Rs E D Wf becases r H H e d 228 222 TEE gelgn Se ez H P a E s a Platine Stecker 2 i O E 9 L N D Netzktemme kompi Alie mit gekennzeichneten Drahte mussen vor dem Ver toten mechanisch gesichert Zeien a dd lr oli werden Platine Tastatur PI P2 P3 Ei Er SR GRAPHICS ETT Wm Code ChF ideni Nummer Fur diese Ze nung Demoen wir uns aie Rechte vor y Mofistab Ident Nummar Zexhnungs Nunvner zi 170 AD 206 468 04
58. e parameters have to be re entered into memory F IEIDEINFTZATIN LZ d DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 4 Replacement Parts Loan Exchange Service Units Replacement Parts TNC 151 155 In general replacement parts are available for all sub assem blies discernible from the wiring diagrams see section 4 2 However it is strongly recommended that all repairs and main tenance work are entrusted to an official HEIDENHAIN agency No responsibility can be accepted by DR JOHANNES BEIDENHAIN GmbH for repairs undertaken by anyone else The list on page 49 shows the Id Nos and names of all parts available for the TNC 151 155 These parts can be ordered from the department Kundendienst Customer Service at HEIDENBAIN Traunreut It is of utmost importance when ordering to give i the Id No 3i the name in German and iii the quantity of each part required Telexed order should be sent to the Kundendienst Telex 17 866 982 SERVICE MANUAL TNC 151 155 Page 48 Section 3 4 Loan xchange Service Units In order to keeep machine down time as short as possible HEIDENHAIN offers a loan and exchange service Loan units Loan units are available free of charge for the duration of a repair carried out at HEIDENHAIN Traunreut or by an official HEIDENHAIN agent The only charges to the customer are the shipping charges Exchange units An exchange unit can be requested for a
59. e ribbon cable connector Pl from the Connector Unsolder the connectors to the VDU socket from the Connec Board see diagram tor Board solder terminals 1 4 5 6 7 8 10 Note the colour Remove the voltage supply plug P2 from the Connector Board of the wire connected to each terminal see diagram Pull the Connector Board from the front of the Control hous ing RS 232 C M ey H3 14 ee VSEELZE IMERZARIM DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 3 Software Exchange General The TNC 151 155 operating software is stored in 6 EPROMs consisting of IC P1 IC P2 CLP Processor Graphic Board IC P3 IC P6 Main Processor Board Every operating software is specified with an 8 digit Software No example TNC 151 TNC 155 234 000 01 complete software Id No 234 020 01 234 000 primary software Id No 234 020 01 update software index Each of the 6 programmed EPROMs IC P1 IC P6 is specified with an 8 digit Id No example TNC 151 TNC 155 234 000 4A complete Id No of the Prog EPROM 234 020 4A 234 000 primary Id No of the Prog EPROM 234 020 4 position on the board A update index The operating software includes o NC software IC P2 IC P5 o PLC software IC P6 TNC 151 155 B Control with o NC software and o PLC standard software TNC 151 155 Q Control with o NC software and o PLC standard software or PLC custom software
60. ecessary Gs HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Error messages TNC 151 155 The meanings of many of these error messages are explained in Operating Manual Mounting Instructions and Interface Circuit Control Machine PLC Description KEY NON FUNCTIONAL PROGRAM MEMORY EXCEEDED SEARCH ADDRESS MISSING TOOL DEF NOT PERMITTED PROGRAM NUMBER ON TAPE ALLOCATED JUMP TO LABEL NOT PERMITTED ENTRY VALUE INCORRECT CC BLOCK MISSING CIRCLE END POS INCORRECT TOOL DEF MISSING TOOL CALL MISSING LABEL NUMBER NOT ALLOCATED EXCESSIVE SUPROGRAMMING ANGLE REFERENCE MISSING PLANE WRONGLY DEFINED TOOL RADIUS TOO LARGE ROUNDING RADIUS TOO LARGE PATH OFFSET WRONGLY STARTED PATH OFFSET WRONGLY ENDED ROUNDING OFF UNDFINED ROUNDING OFF NOT PERMITTED AXIS DOUBLE PROGRAMMED WRONG RPM NO EDITING OF RUNNING PGM RADIUS COMP UNDEFINED LIMIT SWITCH X LIMIT SWITCH X LIMIT SWITCH Y4 LIMIT SWITCH Y LIMIT SWITCH AXIS Z LIMIT SWITCH AXIS Z LIMIT SWITCH AXIS 4 LIMIT SWITCH AXIS 4 EXCHANGE BUFFER BATTERY TRANSFERRED DATA INCORRECT ME CASSETTE MISSING ME CASSETTE LOCKED ME WRONG MODE SELECTED ME WRONG PROGRAM DATA ME CASSETTE EMPTY ME PROGRAM INCOMPLETE ME TAPE END WRONG PROGRAM DATA MACHINE PARAMETER INCOMPLETE EXT IN OUTPUT NOT READY MIRROR IMAGE ON TOOL AXIS WRONG AXIS PROGRAMMED WRONG SIGN PROGRAMMED SPINDEL ROTATES MISSING SLOT WIDTH
61. eg testing using 100 line rotary encoder 20 fol TNC interpolation pulse count no of lines x interpolation 100 x 20 2000 From this example the display has to be diviseable by 2000 Display 32000 2000 16 in order Display 32250 2000 16 125 defective n TUI LIN TEEN MEE DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 36 Kundendienst Section 3 3 Exchange Information Note All inputs outputs from the TNC 151 155 Control can only be connected to circuits which have voltages conforming to VDE S 73 8 Do not disconnect or connect plugs under power NC machines also need protection and installation safety as required for manually operated machines e g Emergency Stop Their function should be checked during commissioning of the machine and of a new Control Before exchanging a Control the machine parameters should be noted or stored on magnetic tapel qub MEIVENPIAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 086 69 31 0 Kundendienst e 3 3 1 2 3 10 11 12 13 14 15 16 17 1 1 1 Procedure for exchanging the TNC 151 155 B F Control Exchanging Control Units Gain access to the rear of the Control Remove the mains supply Remove the connector box cover plate from the rear of the Control Mark the measuring system plugs X Y 2 4 Axes S if present 3D Touch Probe and remove them Disconnect the
62. ential tests o p q Key iv SUPERVISION CIRCUIT TEST XX XX XX XX checks the threshold values of the circuitry which moni tors the measuring system inputs The contents of the counter status registers for the X Y Z and IV axis are displayed Key a TEST REFERENCE IMPULSE INPUT XX XX XX XX Checks the effect of a signal applied to the reference pulse inputs The contents of the counter status registers for the X Y Z and IV axis are displayed Key Wl TEST TRANSDUCER INPUTS EXE XXXX XXXX XXXX XXXX XXXX Checks the effect of signals applied to the measuring system inputs The contents of the counter status registers for the X Y Z IV axes and handwheel are displayed muB FREILEIuWNFITAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Individual test runs Each of the individual sequential tests can also be made to run cyclically To do this the test program must be interrup ted with the key The VDU will then display 3 2 CYCLIC STOP AT FAULT H Pressing key 1 causes the test still to be selected to run cyclicall regardless of whether a fault is detected Pressing key 2 causes the test to run cyclically until such time as a fault is detected When one mode or the other has been selected the VDU will display SELECT TEST The desired test must then be selected with the appropriate key Another possible interrupt to the B
63. entire Controls individual boards or software is given in section 3 Exchange Information Section 4 Additional Information contains a block dia gram of the Control a wiring diagram for each version of the Control and a list of machine parameters with permis sible entry values ZEN HEIDENAIIN DR JOHANNES HEIDENHAIN GmbH MEA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 3 Kundendienst Section 2 2 1 2 Fault Diagnosis 2 1 Procedure for fault finding To locate and rectify a fault that has arisen in a TNC in stallation it is of foremost importance to analyse the be haviour of the system as a whole that is the TNC Control the machine tool and the measuring system 2 2 1 shows in flow diagram form the procedure for exam ining the complete installation In addition the HEIDENHAIN TNC 151 155 Contouring Control includes an extensive integrated supervision system for the avoidance of entry operator faults and for the recognition and diagnosis of technical defects in the installation see section 2 2 2 The Burn In Test Program can be used as further support in fault localizing and in the dynamic testing of the Control s hardware see section 2 2 6 HEIDEINTPAILN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 155 Page 4 Section 2 2 2 2 1 2 2 Flow diagrams for fault location 2 2 1 Fault diagnosis for the comp
64. eupijapuids 9pi49AQ E 2 _Patman aomone J10 D opem Handrad NOT SE Klemme ss E gt ass 5853 8888 Geh use YY cy qr us i 12 1 12 SC ES y 18 LS Kupplung 12 pol kompi rt sw g coe ery 23 e men Po md i SP 13 Reser sv w peer Ree a za i i j pe hey ue RR E ay q i 4 22 e5v n EL sw ov nar Lg ou f 20 15v E Platine iH P TH Netzteil ox ER E enone oe TH adf 336 32222228 EE A a Qul H Ja go EE Mild i i Besa nicest ony jose GEEEEETES sarena ifippEsgEg CH s E y EEE RES 2001 G B E Sd F E CHEN E ek DEDE E 2 5 amp 7 oan E Netzteil P kompl D w E MEO n S x EM D i A Ze xd d PEL A Hn we EBB E S y 2 ce FS dana canos ou Sopas x de 6 c ae M Srt BF J4 J5 32 Over sis aeea dl ae SEE Tax eo en uui amp E bd E E B ns cms 5 E 32 zz 4 65 7 EH a GE Spannungsw hler m Sicherung Y Gab E Hara 7 100 120 140 V 71 04 ee aE ER syeonnesan Bets se 200 220 260 V TO 80A rafik WW ZS y gt ze Cee 34 4294429949 442 9v757 r7 7 20 ie IMs i i ES n a x iix E D e ES e ILI T m dies ob yk Gz 5 bs imm oum T 8 EXT MEE mai PED rry Soe PRY amp BES OC CRE RRB HHT RE Cee ewer Ae SS Pus evas sass ee i 4 ber zs 48 Ek 2 Platine Reet oe Ee oO vo GRe eT AAA BENE HDI R SEEKS D Le HE im
65. gh or in descending order with the key Subsequent pressing of the key um All outputs can be cleared with the key allows successive outputs in ascending order to be driven high or in descending order with the key i Key EXT POT ANALOG OUTPUT TEST CONNECTION ANALOG OVER EXT All outputs can be cleared with the key RELAY ON INPUT EXT POT Five external relays within the TNC 151 155 A P Burn In x Key 9 Adapter driven from outputs A16 A20 are used to connect EXT POT ANALOG OUTPUT TEST the analogue outputs X Y Z IV S in turn to the ext CONNECTION ANALOG OVER EXT pot input see Burn In Adapters TNC 151 155 A P The test RELAY ON INPUT EXT POT is made at three different voltages 200mV 5V 9 5V Five external relays within the TNC 151 155 A P Burn In Adapter driven from outputs A16 A20 are used to con 3 Key nect the analogue outputs X Y Z IV S in turn to the TEST V24 INTERFACE ext pot input see Burn In Adapters TNC 151 155 A P The test is made at three different voltages 200mV 5V k Key 9 9 5V TEST 3D SCANNER INTERFACE 1 Key X Key X TEST V24 INTERFACE PEST SERIAL HANDWHEEL INPUT Checks the interface to the HE 310 Handwheel Unit m Key v TEST 3D SCANNER INTERFACE n Key TEST SERIAL HANDWHEEL INPUT Checks the interface to the HE 310 Handwheel Unit VE Ss ARIY em DR JOHANNES HEIDENHAIN GmbH es D 8225 Traunreut Tel 08669 31 0 Kundendienst
66. he output voltage load controlled The soft start 71 limits the relatively high switch on current SERVICE MANUAL TNC 151 155 Page 54 Section 4 1 On the power supply board there is moreover a voltage supervision 62 triggering a reset signal if the power supply is interrupted or if the supply voltage drops below a predetermined minimum level 187V if set for 220V opera tion for a short time If U2 5V exceeds if there is a failure the overvoltage recognition 63 is immediately effective and causes the overvoltage protection thyristor 63 1 to connect through Thus Ul is short circuited coming directly from the power supply transformer 64 via the rectifier 65 A greater damage at the subsequent electronics is thus inhibited by means of this protective measure MESS E U in E ES En iM E EAE EN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 4 2 Block Diagrams TNC 151 155 Block Diagram Drawing Number Page Arrangement 4820 EKD 1600900 56 PLC I O Board 4820 EKD 1601700 57 Power Supply 4820 EKD 1602000 58 Terminal Board P Q Version 4820 EKD 1601900 59 Terminal Board A B Version 4820 EKD 1601800 60 PLC Interface Board 4820 EKD 1601600 61 SE I O Baord 4820 EKD 1601500 62 Main Processor Board 4820 EKD 1601000 63 CLP Processor Board 4820 EKD 1601100 64 CLP Graphic Board 4820 EKD 1601200 65 Analog Board TTL Input 4820 EKD 1601400 66 Analog Board 4820 EKD 1601300 67
67. he individual address ranges are displayed in one data word The MS byte contains the generated check sum the LS byte contains the expected check sum The address range displayed in a fail condition is the first that deviates from the expected check sum c Key 1l RAM TEST NOT MAPPED Addressed is the range from EOOOH to FFF9H which is battery backed up during power interruption d Key 2 RAM TEST MAPPED Addressed is tha range from FFFFFH and upwards depen ding on RAMS equipped During this test no power interruption should occur e Key 3 TEST PC RAM Range EOOOH to FFFFH through CRU addressing f Key 4 TEST STATIC RAM CLP GRAPHICS BOARD Range AOOOH to BFFFH D800H to DFFFH ES HEIDENHAIN Reape DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst g Key 5 PC INSTRUCT DECODER ACCU FF TEST The circuitry used for decoding and carrying out the PLC instructions is tested h Key INPUT OUTPUT TEST 1 PC BOARD only with Q versions The PLC I O Board outputs are resistively loaded and connec ted to the inputs by means of the PLC Burn In Adapter Each output is connected to 2 inputs By writing 1 s to the out puts and checking the corresponding inputs the Control is able to deduce whether a fault is on an input or an output If a fault is detected a O on an input the input condi tions are displayed on the VDU eg INPUT OUTPUT TEST 1 PC BOARD IN
68. hibited axes Display and transducer supervision Display and transducer supervision for inhibited axes Transducer supervision Input X1 X2 X3 X4 X5 The switching off of the transducer supervision is valid for inhibited and for released axes PLC program from RAM or from EPROM SERVICE MANUAL TNC 151 155 Page Section 4 4 Parameter Input values 74 0 inactive 1 active 2 stages 2 variable inactive 4 active 2 stages 8 variable Add input values for functions requested inactive 1 active 76 05 switched off 1 active 258 active 42 active 8 active 16 active 32 active switched off switched off switched off switched off switched off Add input values for functions requested 71 0 5 RAM 1 5 EPROM EM mI L ENNAN ATN DR JOHANNES HEIDENHAIN GmbH ua MANUAL TNC 151 155 D 8225 Traunreut Tel 08669 31 0 Page Section 4 4 Kundendienst Function Parameter Input values RPM range gear ratios 0 99 999 999 RPM S Analog output 0 1 2 3 4 5 6 7 S Analog voltage with S Override at 100 0 9 999 V S Analog voltage with S Override at max output voltage Limitation of S Override 0 150 Maximum Minimum Axis designation for axis IV Ib Ib Ip A 1 lt B 2 C angular axis U 4 V 5 W linear axis 179 999 angles in degrees Ib gt I Constant contouring speed on external corners Multiple function parameter ll ja
69. in Processor Board N S 2 Incorrect CRC checksum user memory Main Processor Board 3 Integrated Test Program execution incomplete Main Processor Board A A Software error Main Processor Main Processor Board s i B Software error CLP Processor CLP Processor Graphics Board C MID interrupt CLP Processor Main Processor CLP Processor Graphics Board x i D CLP Processor instruction stack overflow CLP Processor Board j E False instruction Main Processor Main Processor CLP Processor Graphics Board CLP Processor i F False instruction display mode Main Processor Main Processor CLP Processor Graphics Board CLP Processor S 2 G CLP Processor RAM CLP Processor Graphics Board i d H Overflow interrupt Main Processor Board n I MID interrupt Main Processor Main Processor Board S i J Equipped with incorrect language version Main Processor Board K RAM E000 FFFF Main Processor Main Processor Board N We L Enable a function via machine parameters which is False machine parameter not integrated in the software CRC Cyclic Redundancy Check MID Macro Instruction Detection VB HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH MANU h D 8225 Traunreut Tel 08669 31 0 E RUIN SII age Kundendienst Section 2 2 2 VDU Display flashing Fault cause Possible fault location CHECK SUM ERROR xXx00 CRC CHECK SUM error with EPROM Main Processor Board XX correct CHECK SUM value 00 c
70. l sine analog board If instead of linear position transducers incremental enco ders are used to ascertain actual values a reference pulse appears once per revolution Since only one reference pulse is to be evaluated all other reference pulses of the axes X Y Z IV are inhibited on the analog board 40 The signal lines are connected with the analog board via the PLC I O board and the PLC interface board The level conversion MOS TTL as well as the galvanic decoupling is carried out on the PLC interface boards via 51 and 50 TR DOEILIEIWIIZAIIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst The data of the CLP processor is transferred to the analog outputs via the serial CRU bus The digital output values calculated for all axes are multiplexed on the CRU OUT line and are converted in a 12 bit parallel format on the analog board These successive digital values are then converted in analog values voltages by means of a DAW 42 1 digi tal analog converter These voltages are compared with the adjusted values of the override and feed potentiometers 42 and the results are transmitted to the CLP processor via CRUIN The output voltages can thus be adapted to the values adjusted by the override or respectively the feed potentiometer The X Y Z IV and S analog values generated shortly one after the other at the output of the DAW are allocated to the single axes by means of five sa
71. lete installation Control Measuring System Machine tool Fault in TNC installation Error ind cation on VDU Use integrated supervision system section 2 2 2 VDU amp LEDs dark VDU dark VDU amp LEDs functio PSU fault section 2 2 4 Check measuring system and wiring section 2 2 5 fault cleared Load amp run Burn In Test section 2 2 6 fault cleared Send TNC to HEIDENHAIN for repair Order exchange unit as appropriate Control ready for use VDU fault section 2 2 3 PDIEIDEINIAINV DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 2 2 2 Use of the integrated supervision system The TNC 151 155 incorporates an extensive integrated super vision system for the avoidance of operator errors and the detection and diagnosis of technical faults in the TNC installation ie the installation comprising the TNC the machine tool and the measuring system The supervision system is made up of a mixture of hardware and software within the TNC and operates continuously whilst the TNC is switched on If a fault is detected or if an operator error occurs a message will be displayed indi cating in abbreviated form the nature of the problem example of operator error a KEY NON FUNCTIONAL b ENTRY VALUE INCORRECT example of fault with TNC internal electronics a TNC OPERATING TEMP EXCEEDED b EXCHANGE BUFFER BATTERY c TNC ELECTRO
72. lsewhere with the associated circuitry in which case repairs may be possible without returning the unit Visual Display Units BE 110 and BE 211 in conjunction with TNC 151 The Display Units BE 111 and BE 211 are supplied by an 11V dc supply from the Power Supply Board This is a possible source of the fault in which case the test and repair pro cedure continues according to section 2 2 4 Testing of the mains supply and the Power Supply Unit If the fault is not due to a detective power supply it is likely to be due to the CLP Processor Board which contains the control circuitry for the Display Unit This can be verified by exchanging the board for one is known to function correctly If the fault still persists then must be due either to bad connections within the TNC eg on the Connector Board or to faults on both the VDU and the CLP Processor Board See the diagram opposite for a logical procedure for locating the fault in the system SERVICE MANUAL TNC 151 155 Page 14 Section 2 2 3 Testing of the VDU amp associated circuitry Exchange the VDU Test 11V supply pins 23 24 of VDU socket on rear of TNC w r t pins 21 22 No voltage Test amp repair PSU correct section 2 2 4 Test connections from CLP Processor Brd to VDU socket then replace orig CLP Processor Board cleared No Exchange VDU AND CLP Processor Board Send entire PNC amp VDU to BRIDENHAIN for repair i
73. mples and hold circuits 42 2 The five individual analog voltages are amplified and buffered subsequently 42 3 and are led to the terminal board On the analog board the buffer battery 3 46V and the internal temperature 65 of the control are also super vised 41 The supervision signals are led to the CLP processor via the CRUIN line Two watch dog monoflops 41 1 are on the analog board These must be triggered separately once every 5ms by the CLP processor 20 and once every 20ms by the main pro cessor 30 If the monoflops are not driven within 5ms or 20ms error state an emergency stop signal is triggered The drive of the screen is another important task of the TNC 151 CLP processor It only has to write the texts to be displayed into the CRT RAM 31 1 A special CRT con troller TMS 9937 31 generates the necessary addresses for the CRT RAM and the character generator IC P1 31 2 so that the data are transferred to the shift register 31 3 in the right sequence Thus signal can be inverted by means of an exclusive or gate 31 4 to generate an inverse video display The video signal the bright dark signal the horizontal vertical sync signals and an 11V supply are used to operate the screen SERVICE MANUAL TNC 151 155 Page 53 Section 4 1 The function of the TNC 155 CLP graphic processor is simi lar The screen can either be operated in the text or in the graphic mode The control of the routine proce
74. ode for faulty EPROMs to CHECK SUM ERROR XXOF CRC CHECK SUM error wi EPROM 3 Main Processor Board y 5 XX10 EPROM 4 Main Processor Board to CHECK SUM ERROR XX1F CRC CHECK SUM error EPROM 4 Main Processor Board XX2B Ke 5 EPROM 5 Main Processor Board to CHECK SUM ERROR XX2F CRC CHECK SUM error with EPROM 5 Main Processor Board T XxX40 pe le e P with EPROM 2 CLP Processor Graphics Board T le XX41 CRC CHECK SUM error in RAM area on the CLP Processor Graphics Board CLP Processor Graphics Board in which a part of the operating program is stored XX42 CRC CHECK SUM error with EPROM 2 CLP Processor Graphics Brd export vers XX43 CRC CHECK SUM error in the RAM area on the CLP Processor Graphics Brd export vers CLP Processor Graphics Board where part of the operating program is stored XXFF CRC CHECK SUM error with PLC RAM Main Processor Board s XX30 PLC Program from addr 0 1000H virtual addr Main Processor Board 30000 30FFFH in PLC EPROM PLC RAM XX31 PLC Program from addr 1000 FFECH virtual Main Processor Board addr 31000 3FFECH in PLC EPROM PLC RAM EN HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 2 2 3 Testing of the VDU and associated circuitry The first objective is to determine wether the fault is actually with the Display Unit in which case it must be returned to DR JOHANNES HEIDENHAIN for repair or whether it lies e
75. r of the Control Mark the measuring system plugs X Y 2 4 Axes S if present 3D Touch Probe and remove them Disconnect the VDU from the Control Disconnect the Handwheel Unit from the Control if present Disconnect any external data devices Disconnect connector strips J1 33 using a screwdriver to prise the connectors apart Do not unscrew individual wires Remove the connecting cable P2 to the PL 100 B 110 B from the Control DS 9 O 9 O ODO GG O 0 0 ATA E E EE E EE EE E E E E prise apart with a screwdriver i Remove the faulty Control removing the fixing screws if not already removed in 1 Install the new Control check the voltage selector posi tion Check the fuse rating see type plate Reconnect all cables previously removed Obtain from the type plate the Control s Id No NC and PLC Software Nos and write them in the machine handbook Refit the connector box cover plate Turn on the mains voltage Reprogram the machine parameters TNC is now ready to use SERVICE MANUAL TNC 151 155 Page 38 Section 3 1 2 Connections for analogue signals Touch probe system i V 24 1RS 232 C interii e tor data input output Connection P2 for PLC power board Operational ground Switch with fuse holder connection B MMC MITA IM ee DR JOHANNES HEIDENHAIN GmbH ur D 8225 Traunreut Tel 08669 31 0 do MANUAL TNC 151 155 age Kundendienst Section 3 1 3 3
76. rameter 110 to 125 126 to 157 158 165 ed ed pea fi i Ja pa ajajaja ju wi i jw bo e juo e 167 168 170 171 SERVICE MANUAL TNC 151 155 Page Section 4 4 Input values 0 65 535 in units of 20 ms 30 000 000 30 000 090 mm Il output of next tool number Co t9 ki Ip TOOL DEF if MP 225 1 65 535 Marker 2192 2207 65 535 in 65 535 um units oje 80 15 999 mm min Ib 0 off 1 on 1 999 V ms 001 30 mm Control amp Programming station PLC active Ib HR 150 250 TS 511 HE 310 TS 511 HR 150 250 TS 111 HE 310 TS 111 No Output only with change of tool number Output of next tool number with every tool call Output of next tool number programmable with Programming station PLC inactive TIL IDE IMA IA DR JOHANNES HEIDENHAIN GmbH SUIZA 0 8225 Traunreut Tel 08669 31 0 Kundendienst Function Polarity of S Analog voltage Cancellation of status display with M 2 M39 and program end Trailing error supervision in trailing operation emergency stop erasable Multiplication factor for Kv factor Kv factor for H t lt 1 4 E jm H e je je rr m e a a fp co joo co e o oo oo oo 3 2 3 10 co s Go o ja o jo fon y Characteristic kink Minimun for feed rate override with tapping Maximum for feed rate override with tapping Minimum voltage for S Analog output Wai
77. rsion by special protective resistances 5 1k 70 and 47 70 1 Protective resistances should never be replaced with normal resistances They are led via LC filter 71 as protection against the oscillation of analog outputs SERVICE MANUAL TNC 151 155 Page 51 Section 4 1 TNC 151 155 Q Versions The inputs and outputs are loaded on an external PLC I O boards e g PL 100B or respectively PL 100B which is driven by the main processor 20 via the PLC interface board The data is serially transferred via the CRU bus All lines of this bus as well as the required addresses are galvanically separated by the optocoupler 50 and are converted from the TTL level 5V to the MOS level 12V by means of a level converter 51 Thus a higher noise immunity is obtained Under the control of CRU addresses 63 programmable inputs EO to E62 E2 located on the PLC I O board are multi plexed on CRUIN 1 line If 2 PLC I O boards are connected the inputs from the 2nd board are multiplexed on CRUIN 2 On the PLC interface board either CRUIN 1 or CRUIN 2 are selected 54 and are led to the main processor via CRUIN The serial CRUOUT signal is converted in 31 outputs via a serial parallel converter El 1 The outputs each having its own current supervision El are transferred via line drivers to the machine interface An overloaded output only switches off during the period of the overload If the current supervision detects
78. se shifted and combining them differently The subdivided 0 degree 90 degrees and RI signals are then led to the gate arrays 32 of the CLP processor board The gate arrays are especially developed LSI circuits consisting of different gates and counters in which the direction of the movement and the number of pulses are calculated This information can then be scanned by CLP processor 30 to ascertain the actual values of the axes The symmetry the on to off ratio and the amplitude of the system signals are constantly controlled by a supervision circuit 40 The signals from the handwheel if present are shaped via the functional block 43 and are also processed by the CLP processor If the distance between the control and measuring system is more than 20m an EXE has to be interposed The measuring signals are thus already amplified subdivided evaluated supervised and converted in TTL signals An R version of the control is used accordingly e g TNC 151 BR equipped with a combined EXE connection for X Y and Z axis and an analog board TTL The input amplifiers and the wiring for the signal subdivision are replaced with line receivers 40 on this analog board whose outputs are directly con nected to the gate arrays 32 on the CLP processor board The supervision signal of the EXE is also buffered 40 and transferred to the CLP processor board The signals of the handwheel are likewise processed 43 as on the norma
79. sses required for the test an the graphic representation are taken over by the graphic controller uPD 7220 31 This controller has to receive the corresponding commands and pertaining parameters of the CLP processor via the data bus To permit a fast generation of a given representation all necessary commands and parameters are calculated in advance and are stored in the 64K x 8 dynamic graphic momory Priority decisions between reading or respective ly writing and refreshing of the memory are carried out by the DRAM controller 31 5 The graphic controller which is dependent on the commands received by the CLP processor sets up the required bit pattern in the 32k x 16 video memory The constant issue of these data and the synchroni sation signal to the screen is also controlled by the graphic controller In the graphic mode the 16 bit pixel words are read out by the CLP processor and are converted in a serial format by means of a graphic shift register 31 7 The signal can be inverted by means of an exclusive or gate 31 4 to generate under certain circumstances an inverse video display In the text mode the video memory contains the 6 bit ASCII values and the pertaining mode data The ASCII values and some of the mode bytes form the addresses for the character generator IC P1 31 2 The bit pattern for the momentarily addressed sequence of the intended sign is converted in a serial format by means of a video shift register 31 3
80. st Key 2 Analog output voltage The performance of the analog output circuitry can be checked by connecting a DVM to each of the analog outputs eg X axis Jl pinl w s t pin 2 and selecting this test Using the keys x vj z ly voltage increments of 2 44mV 24 4mV 244mV and 2 44V respec tively can be summed at at each of the analog outputs X Y Z IV S eg if thel X key is pushed 5 times the Y key 3 times and key once the output voltage should read 44mV 3 x 24 4mV 1 x 2 44V 2 525V The polarity of the output can be reversed using the key E The output can be cleared using the key o The hold time of the sample and hold amplifier can by selected to either 5ms or 500ms using the key Key 5 10V analog output The analog outputs should generate their maximum output of 10V The polarity can be reversed as in test 2 Key Battery voltage check A 1 will be displayed on the VDU if the battery voltage is adequate otherwise a O is displayed SERVICE MANUAL TNC 151 155 Page 35 Section 2 2 6 Key Transducer pulse count comparison The counting function of each axis can be checked by connecting a rotary encoder to the respective transducer input Key d Start count after reference mark is detected Key Stop count after reference mark is detected If no encoder is connected VVVVVVVVVV is displayed in the respective axis excluding handwheel
81. ter face Board to from CLP Proc Brd Keypad Board Block Diagram TNC 151 155 Drawing No 4820 EKD 16010 00 Main Processor Board Standard 16 Line Address Bus to om Touch Probe on SE PLC Interf Brd Buffer to Main N E E 2 eo from Analogue X Y 2 Signals after Processing to SE PLC Interf Brd Reset BE 111 BE 211 X CRU Data Bus toMainN y Analog mE Standard Data Bus Bed eo Block Diagram TNC 151 Drawing No CLP Processor Board 4820 E KD 16011 00 to Main N y Proc Brd lt 3 D to SE PLC Interf Brd Reset to Main 2 Proc Brd E eo Drawing No 4820 EKD 16012 00 Standard 16 Line Address Bus 31 2 Standard Data Bus Block Diagram TNC 155 CLP Graphic 31 3 CRU Address Bus CRU Data Bus to Analogue Board Buffer ig from Touch Probe on SE PLC Interf Brd 32 A ro Gate N Bord Arrays X XYZ E ay Signals after Processing Processed HR Signal from Analogue Brd to Analog Brd Buffer CRU Address Bus from CLP Processor Board 0 f Mai jm TE fe ore Shaper R1 Position CRU Address Ref Pulse Inhibit from SE PLC Interf Brd External EXE 8 easuring Systems from Main ge Proc Brd to CLP Board Pulse 43 Handwheel CRU Data Shaper y 90 inputs Bus CRU Data Bus from CLP Pro
82. ting time for cutout of remaining nominal va lue voltage with error display Positioning Tool change position M 92 X Axis Y Axis Z Axis IV Axis Programming of rpm S permitted voltage value of MP 184 may be less Display of current spindle rpm before spindle Start in Manual mode Position window for axis IV PLC Timer duration for timer 16 31 Support of PLC macro commands error Parameter 172 173 174 185 186 199 191 192 193 to 208 209 to 212 SERVICE MANUAL TNC 151 155 Page 79 Section 4 4 Input values Ip M03 positive voltage M04 negative voltage M03 negative voltage M04 positive voltage M03 and M04 positive voltage M03 and M 4 negative voltage Status display is not erased Status display is erased Da i gt H gt Il e Co ne S 100 mm 1 000 0 9 001 0 10 000 100 100 000 150 150 9 999 V 65 535 s D 30 000 000 30 000 000 mm 0 S permitted 1 S not permitted 0 off 1 on 0 001 0 5 mm or 65 535 in units of 20ms 0 65 535 ke A ee il DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 Pave 86 VANDRING 2517158 Section 4 4 Kundendienst Function Parameter Input values Scaling cycle effective for 213 0 3 axes spacial 2 or 3 axes i 1 2 axes machining plane Output of M and T functions 214 0 Programmed stop
83. trei Ar d Z Joy amp iasctirm 112 frer 2331 12 frei x d TIV Bildschirm BE Flanschdose BU 24pol kompl J8 P ME Fianschdose BU 47 14pol kompi 1 e GND 8 a frei Ae fre 9 z tre As frei 10 frei 4 2 frei 112 DIR SeRTS 12 7x0 De HL wsisw 6 DSR 13 CTS Q loe La Petre 144 xD m ls A e 909 EN 90 for ee JI Rte gr Rie innenschirm OV el 2 1 d JL Leon J2 y DO 7 Z LI Lee J3 t i 1 vw TT I ee Ja 3 i 00 35 gr 99 Le v pestes u lus ws MA Ss 90 s ch Handrad sx P3 m rt 79 ov ge Ly gel 2 7 D 2 12 HA Platine Analogteil J2 H 12 1 12 7 12 J3 Je 45 Platine Klemmleiste PI Kabel VB flach 64 x AWG 28 kompl I 1 C BA 03 Platine i SE LL kai D e CG d E 9h wir Weg Gei BE N lt ofi B FETRET UA Tye FEE 81 CINE EEN 2 ER lt Sis ist STAT eel arg A van d LRL LI A 5 ER Ke DER ANALOGAUSG Bn R RE E i ef VET EST os aufi d 4 MENS Platine quif Ed LS n Regelkr Rechner OTEA gel S REN eee Lottie El El gl Al A Ss E m a ee o al El Er Plati HEU PE Houtrechy Houptrecho t qutrecnner BIER PEE HI 30140851 EFRADRLCOARIRO PR 65 6 66 9 9 Jn JB J4 eet 59952 e ee 0 rmm Qe D A A I l H L x z 533 sie pA rA M ER Pu Piu ES SE 5 A SS EX E 2 9 8 LLL 7
84. trol displays EXCHANGE CASSETTE ME START EXTERNAL DATA INPUT Press Fur on ME i Remainder of program is read into the Control Fig 7 Loading and Initialization of Burn In Test Program ae MELITAS DR JOHANNES HEIDENHAIN GmbH SSA 0 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 155 Page 26 Kundendienst Section 2 2 6 Re initialization of a previously loaded Burn In test program The following dialogue will then be displayed The possibility exists that the Burn In test program has been EXTERNAL UNIT CONNECTED loaded and then the power removed In this situation the buffer batteries will maintain the program in memory until the mains Any other display implies an error in the stored test program is restored and the program must be reloaded from the cassette It is also possible that the system has been warm booted during the execution of the Burn In test by pressing CL PGM Burn In test program i x present in Control Under both of these circumstances the following procedure is to be followed in order to restart the Burn In test program The Control will automatically carry out a memory check This P A Restore power after El test takes approx 17 sec during which time the dialogue Warm boot with MEMORY TEST wili be displayed on the VDU VDU displays Upon completion of this test the dialogue will be replaced MEMORY TEST by IMPORTANT Only press the key Es Y Continu
85. tts E E Pre Boa d GER EE S g p Wa YO i Wo 35 o a SE 2 DU nsus 2iirirrsi M 3222282 on OO ND ui nun on n CAIDAS ed A wei d o E 49 DWONUIJOS 81484408 JONOH D en um Handrad NOT AUS Klemme js Se RUCK wi oA AW Ung PEE c S i Serene ad CELESTE fist x gt gt gt EZ 31915 RER Bd ef E E e REF o d ec Ue Y siria e i z Lk parc o wg Co Deal 39 Ua2 X il il etnettet 090 MAER H o illl H ze SEI gt as Ss i QQ See e 7n TT ME EES i Z1 Tr o Po So B sig 2 CEE 3 60 LLLI aS RSC ESE de i SEN Ss AED ba 0 8994934909 9099 900674 44099 9999346 AES bk a z a D e t ru ee x e Dii ies Kees EM af a TG WG 124 domo ii E Hi EN pggttv ee 8 LE MUN KT EE Li RE EMA We e 2 2 g HE 5 SS e o D P oim i e a NUR on CT Stecker Pla SCH Tastatur e Gl ES CIC SOS 718 AMIN Ej CO C ER ki El ES DIE EGER RE K Kupplung 12pol kompl ODE y i 2 UM PUE o TS 2 ufe i M 4 JEN EM 1 REH LL iaa EE 21 23 13 Reset Sy ov 76 15v 17 42V 22 45V A OV 20 15V 1 4 3V Platine wsibr 15 4 3v es Netzteil 19 52V 26 11V Bildschirm 28 OV Bildschirm sw 1 2 3 5 I
86. ular acceleration 55 0 00 3 0 m s Position supervision erasable 56 0 001 30 000 mm in precontrolled mode emergency stop Position window X Y Z 58 9 001 9 5 mm Axis sequence for reference points approach 05x Y Z IV 1252 X Y IV 12x Y IV Z 13 7 X IV Y 22X Z Y IV 14 2 2 Y X IV 3 2 Z IV Y 15 2 Y IV X 42x IV Y Z 16 Z IV X Y 5 X IV Z Y 17 2 IV Y X 6 Y X Z IV 18 IV X Y Z 7 5 Y X IV Z 19 IV X Z Y 8 y Z X IV 20 IV Y X Z 95Y Z IV X 21 2 IV Y Z X 10 5 Y IV X Z 22 3 IV Z X Y 11 5s Y IV Z X 23 IV Z Y Z Speed pre control 60 03o0n 1 3 off i mi C iL EC N NAAN DR JOHANNES HEIDENHAIN GmbH ESAE D 8225 Traunreut Tel 08669 31 0 Kundendienst Function Output of tool numbers or tool store numbers Output of spindie speed codes or as S analog voltage rpm code limit Oscillation behaviour when accelerating Display step External feed rate potentiometer Dwell time rotation change of spindle in tapping cycle Memory function for directional keys Special procedure for reference mark approach Nominal value voltage for spindle drive when changing gear Program end character Selection for control of inhibited axes Pre cutout time for tapping cycle only active with BCD output of spindle rpm Parameter an E e tb JIA v e w ec J o J 3 SERVICE MANUAL TNC 151 155 Page 75 Section 4 4 Input values M db D Ib Ib Ib db uN SDR Ra
87. urn In test program is by means of the key With this key the entire set of ASCII characters can be dis played on the VDU With TNC 155 only A graphics display consisting of a square grid with a circle in the centre can be displayed by pressing the key marked a Similarly the NC and PLC software numbers can be displayed by pressing the key SERVICE MANUAL TNC 151 155 Page 34 Section 2 2 6 Calibration check of the Analogue Board TRIMMING ROUTINES Interrupting the Burn In test program with the key gains access to the calibration tests Exit from these tests is only possible with the key Within the calibration mode the following tests can be selec ted Key 1 Reference amplifier performance TRANSMISSION BEHAVIOUR REF AMP Key 2 Analogue output voltage ANALOG VOLTAGE OUTPUT Key 3 32 step monotonic DAC MONOTONIY DAC 32 STEPS Key 4 DAC performance TRANSMISSION BEHAVIOUR DAC Key 5 10V analogue output DAC ANALOG OUTPUT 10v Key Linearity of analogue output DAC ANALOG OUTPUT LINEARITY Key Battery voltage check TEST BATTERY VOLTAGE Key Transducer pulse count comparison PULSE COUNT OUTPUT text in brackets appears on VDU these test are not suitable for customer use see following explanations TILING EAN es DR JOHANNES HEIDENHAIN H WE S Gmb D 8225 Traunreut Tel 08669 31 0 Kundendien
88. ut Tel 08669 31 0 Ar MANUAL TNC 151 155 age Kundendienst Section 2 2 4 2 2 4 Testing of the Power Supply Unit The procedure for testing the Power Supply Unit is shown in Test points on the Power Supply Board 227 601 the flow diagram on page 16 As part of that procedure it es may be necessary to test the voltages at various points on The Power Supply Board under load Test Data Old Power Supply Board 227 601 for TNC 151 155 The diagram below and the table opposite show the locations of the test points solder terminals on the old Power Supply Board 227 601 and the respective nominal and actual test voltages under load Plug and solder terminal signal designation Plug pin Cable colour Solder terminal Voltage Signal test points Nominal Power Supply Connector Assembly Test values V under load black OV TTL 1 MU brown 12 Processor supply 12 0 0 5 t 0 15A red 5V TTL 5 16 t 0 08 i 3 5A grey 15V Switching reg 0 6 14 15 blue OV Display Unit 7 green 15V Analogue Board 15 0 at 0 3A 18 yellow 45V Switching reg 45 2 at 0 06A 19 white 11V Display Unit green white Reset 21 yellow white 22V Display 21 6 0 8 at 0 01A 22 brown white 4 2V Heater 4 2 0 2 at 0 17A 22 24 wg 25 26 27 w 28 brown white 21V dies transf sec voltage 21V Mains transf Tee voltage 13151
89. ware Exchange After the software exchange has been concluded the Id Nos of the NC and PLC software have to be changed The description Caution When exchanging the software observe the MOS plate for the software numbers is found on the rear of the protection procedures control under the type plate o The cover of the Control can be removed after unscrewing the 5 cross head mounting screws top side o To exchange the program the following boards Main Processor Board CLP Processor Graphics Board have to be removed from the assembled Control AN Control id No Thereto lift the board ejector keys and press NC Software No outwards pull out board from above and lay onto MOS PLC Software No protection mat ICTY Nd NA A A Push screwdriver blade carefully between EPROM and socket remove EPROM with extraction tool and place onto MOS protection mat 2 ZIN o Insert EPROM into appropriate socket using insertion tool important When exchanging EPROMs observe the position number second to last digit of the programmed EPROM Id No The EPROM package index must point in the same direction as the ICs on the board Visually check if the EPROMs are contacting their The RAM memory of the Memory Board is unbuffered during respective sockets after an exchange the EPROM software exchange The machine parameters and any stored user program are therefore erased For continued operation the machin
90. xternal PLC I O Boards con nected to the Control during the test and must be answered with the appropriate numeric key to D 2 AEIVENNAIN S l DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 6 The final step of the full initialization procedure is the calibration of the two potentiometers on the front panel of the Control These must be adjusted to give the display OVERRIDE POT ADJUST 100 SP ROT SPEED ADJUST i00 If necessary the caps of tbe knobs must be removed the Securing screws slackened and the knobs realigned and tightened in the 100 position At the beginning of the initialization procedure inter ruptions of the program are inhibited After completion of the initialization interrupts are enabled to permit jumps at any time to various points in the test procedure Once the interrupts have been enabled the test program can be interrupted by pressing one of a number of keys The keys CL TOOL CYCL LE 0 PGM CALL CALL CALL for example cause restarts at various points during the initialization routine as shown in figs 8 and 9 System re boot Ed EXTERNAL UNIT CONNECTED 2 tat JUMP OVER KEYBOARD TEST cul 0 1 OR 2 PC BOARD OVERRIDE POT ADJUST 100 SP ROT SPEED ADJUST 100 SERVICE MANUAL TNC 151 155 Page 28 Section 2 2 6 Other interrupts are also possible these are described in the following section SERVICE M

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