HEIDENHAIN TNC151B Operating instructions

HEIDENHAIN
DR.JOHANNES HEIDENHAIN GmbH
D-6225 Traunreut ‘Tel. [phone]-O
Kundendienst
Service Instructions
TNC x51/155 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

Tm
HtlUtNHAlN
u DF JOHANNES HElDENHAlN GmbH
- D 8225 Traunreut ‘Tel. [phone]-O
SERVICE MANUAL TNC 151/155
Page 1
Kundendienst
contents
1.
2. use of the service Manual Fault Diagnosis Page 2
" 3
2.1 Procedure for fault-finding " 3
2.2 Flow diagrams for fault location 1‘ 4
2.2.1 Fault diagnosis for the complete installation " 4
2.2.2 Use of the integrated supervision system " 5
2.2.3 Testing of the VDU and associated circuitry 1' 14
2.2.4 Testing of the Power Supply Unit " 15
2.2.5 Testing of the measuring systems and wiring " 17
2.2.6 Burn-In Test " 18
3. Exchange Information
3.1 Exchanging Control units
3.1.1 Procedure for exchanging the TNC 151/155 B/F Control
3.1.2 Procedure for exchanging the TNC 151/155 Q/W Control
3.1.3 Procedure for exchanging the PIG I/O Board of the PL lOO/llO B
3.2 Board Exchange
3.3 Software Exchange
3.4 Replacement Parts, Loan/Exchange/Service Units
3.5 Confiqurations Liste
36
37
37
38
39
40
45
48
49
4. Additional Information " 50
4.1 Block Diagram Description " 50
4.2 Block Diagrams TNC 151/155 " 55
4.3 Wiring Diagrams " 68
4.4 Machine Parameters " 73

1
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F!!!
DR. JOHANNES HEIDENHAJN GmbH
- D-8225Traunreut .Tel.[phone]-O
Kundendienst
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
he found in:
-Operating Manual
.Mcmnting Instructions and Interface Circuit Control-Machine
.PLC-Description
SERVICE MANUAL TNC 151/155
Page 2
Section 1
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 scmrce 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 entire Controls,
individual hoards, 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.

Kundendienst
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 HEIDENWGN 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).
SERVICE MANUAL TNC 151/155
Page 3
Section 2/2.1

HCIUCNHAIN
DR. JOHANNES HElMNHAlN GmbH
D-8225 Traunteut .Tel. [phone]-O
Kundendienst
SERVICE MANUAL TNC 151/155
Page 4
Section 2.2/2.2-l
2.2 Flow diagrams for fault location
2.2.1 Fault diagnosis for the complete installation
(Control/Measuring System/Machine-tool)

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DR. JOHANNES HEIDENHAN GmbH
D-6225 Traunreut .Tel. [phone]-O
SERVICE MANUAL TNC 151/155
paae 5
Kundendienst
Section 2.2.2
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 end 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 ELECTRONICS DEFECTIVE O...3/A...K
example of fault with measuring system:
X-MEASURING SYSTEM DEFECTIVE
example of fault on machine-tool:
GROSS POSITIONING ERROR A
The system distinguishes between what are considered to be
harmless errors and serious faults, in that faults are shown
es 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 l'NC 151/l%
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 O...3/A...K
CHECK SUN ERROR XXOO...XXFF
The significance of these fault messages is explained on
pages 8 to 13.
error message can be cleared by pressing the
after which normal operation may resume.
is given on page 7.

SERVICE MANUAL TNC 151/155
Pawa 6
Kundendienst
Se&ion 2.2.2
Error message "BXCBAUGB BUFFER BATTBRY"
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-pale 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 necessary.
Use of the integrated supervision system

HEIDENHAIN
DR.JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut'Tel.[phone]
Kundendienst
Error messages Twc 151/155
The meanings of many of these error messages are explained in:
- Operating Manual
- Mounting Instructions and Interface Circuit Control-Machine
- PI&Description
KEY NON-FUNCTIONAL
PROGRAM MEMORY EXCEEDED
SEARCH ADDRESS MISSING
TOOL DEF ‘$ NOT PERMITTED
PROGRAM NUMBER ON TAPE ALLOCATED
JUMP TO LABEL 0 NOT PERMITTED
ENTRY VALUE INCORRECT
CC-BLCCK MISSING
CIRCLE END POS. INCORRECT
TOOL DEF MISSING
TOOL CALL MISSING
LABEL NUMBER NC'I' ALLOCATED
EXCESSIVE SUPROGRANMING
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 Y+
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 LOClcED
NE: 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 TCO 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
TN0 TOOL DEF XXX WITH PGM CALL
CIRCLE CENTP.E UNDEFINED XXXX
ADDRESS LETTER ALREADY ASSIGNED
BLCCKTOO LONG
G-CODE GROUP ALREADY ALICCATED
ILLEGAL G-CODE
BLCCK 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

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DR.JOHANNES HEIDENHAJN GmbH
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SERVICE MANUAL TNC 151/155
Pase 8
Kundendienst Se&ion 2.2.2
Fault descriptions TNC 151/155
VDU Display (flashing)
TRANSDUCER X DEFECT A
TRANSDUCER Y DEFECT A
TRANSDUCER Z DEFECT A
TRANSDUCER S DEFECT A
TRANSDUCER X DEFECT B
TRANSDUCER Y DEFECT B
TRANSDUCER Z DEFECT B
TRANSDUCER S DEFECT B
EMERGENCY STOP DEFECTIVE
WRONG REFERENCE POINT
Fault cause
Fault code: A = signal amplitude fault
B = signal frequency fault
.Measuring system not connected
.Cable damaged
.Glass scale dirty or damaged
.Scanning head damaged
.Measuring system supervision damaged
.Fault in the emergency stop
circuit of the machine (for checking
routine see Mounting Instructions and
Interface Circuit Control-Machine
manual
.Defect in Control's internal Emergency
Stop supervision
.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
Possible fault location
Measuring system
Analog Board
Analog Board
PI& I/O Board (TNC 151/155 Q)
PIC 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")
PIG I/O Board (TMC 151/155 Q)
PIG Interface Board (TNC 151/155 Q)
SE Board (TN'2 151/155 B)
Ter minal Board (TNC 151/155 B)

ml
~EIDENHAIN
DR.JOHANNES HEIDENHAIN GmbH
D 8225 Traunreut .Tel.(O8669)31-0
SERVICE MANUAL TNC 151/155
Paqe 9
Kundendienst Se&ion 2.2.2
VDU Display (flashing)
EMERGENCY-STOP$I;tii
GROSSPOSITIONING ERRORA
Fault cause
With standard PLC program, faulty reply
from output A6 ("Lock for spindle on") to
input E20 ("reply: Lock for spindle on")
Fault message EMERGENCY-STOPPLC
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
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
Possible fault location
Terminal hoard (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 Bra.),
Control hardware (Analog Brd.),
servo amplifier (offset voltages),
n II (gain too low),
motor,
tacho,
measuring system,
external forces acting on drives,
inappropriate MP values prograuaned.
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

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DR.JOHANNES HEIDENWN GmbH
D-8225Traunreut'Tel.(O8669) 31-O
SERVICE MANUALTNC 151/155
Page 10
Section 2.2.2
Kundendienst
VDU Display (flashing)
GROSSPOSITIONING ERRORB
GROSSPOSITIONING ERROR C
GROSSPOSITIONING ERRORD
GROSSPOSITIONING ERRORE
TNC OPERATING TEMP. EXCEEDED
Fault cause
.The analog output voltage calculated by the
control (implied by trailing error) is greater
than + 10 V
.The analog output voltage required to obtain
a desired speed deviates more from the calcu-
lated voltage than the voltage programmed in
MP 234
.The actual position at standstill deviates
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
exceeded +65'Y
.Fault in the temperature supervision
Possible fault location
see above
see above
see above
Ambient temperature of Control
Analog Board

SERVICE MANUALTNC 151/155
Page 11
Section 2.2.2
Kundendienst
VDU Display (flashing)
ERROR IN PLC PROGRAM. . . .
A
B
C
D
E
F
G
H
I
J
K
L
Fault cause
Fault with non-erasable marker
(see also PLC-Description)
Start Key
or incremental positioning Xt
Rapid Traverse Key
or incremental positioning X-
Direction Latch Key
or incremental positioning Yt
Feed Release
or incremental positioning Y-
Start PLC Positioning X-axis
or incremental positioning Zt
Start PLC Positioning Y-axis
or incremental positioning Z-
Start PLC Positioning Z-axis
or incremental positioning IV+
Start PLC Positioning IV-axis
or incremental positioning IV-
Directional Key X+
Directional Key X-
Directional Key Y+
Directional Key Y-
Possible fault location
PLC Program, Main Processor Board

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DR.JOHANNES HEIDENHAIN GmbH
D-8225Traunreut.Tel.[phone]-O SERVICE MANUALTNC 151/155
Page 11.1
Section 2.2.2
VDU Display (flashing) Fault cause
Error with non-erasable marker
(see also PLC-Description)
Directional Key Zt
Directional Key Z-
Directional Key IV+
or supplementary axis to be changed to
another axis M 2590 and M 2591
Directional Key IV-
or Start PLC Positioning S-axis
Non-defined macro called up via PLC marker
Possible fault location
PLC Program, Main Processor Board

1
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mlli
DR. JOHANNES HElDENHAlN GmbH
D-8225 Traunreut ‘Tel. [phone]-O
Kundendienst
SERVICE MANUALTNC 151/155
Page 12
Section 2.2.2
VDD Display (flashing)
PROCESSOR CHECK ERROR 0 I
1
2
3
A
B
C
D
E
F
G
H
I
J
K
L
Fault cause
Incorrect CRC checksum* of machine-related data
excluding machine parameters. (Baud rate, limitation,
preset etc)
Incorrect CRC checksum* (machine parameters)
Incorrect CRC checksum* (user memory)
Integrated Test Program execution incomplete
Software error Main Processor
Software error CLP Processor
MID interrupt** CLP Processor
CLP Processor instruction stack overflow
False instruction: Main Processor
CLP Processor
False instruction (display mode): Main Processor
CLP Processor
CLP Processor RAM
Overflow interrupt
MID interrupt Main Processor
Equipped with incorrect language version
RAM EOOO. ..FFFF Main Processor
Enable a function via machine parameters which is
not integrated in the software
Possible fault location
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
CLP Processor/Graphics Board
Main ProcessorjCLP Processor/Graphics Board
CLP Processor Board
Main Processor/CLP Processor/Graphics Board
Main Processor/CLP Processor/Graphics Board
CLP Processor/Graphics Board
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
False machine parameter
* CRC = Cyclic Redundancy Check
** MID = Macro Instruction Detection

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D-8225 Traunreut .Tel. [phone]-O
SERVICE MANUAL TNC 151/155
Page 13
Kundendienst
Section 2.2.2
VDU Display (flashing)
CHECK-SUM ERROR
to
CHECK-SUM ERROR
II II
to
CHECK-SUM ERROR
II "
to
CHECK-SUM ERROR
11 II
I II
xx00
XXOF
xx10
XXlF
XXZB
XX2F
xx40
xx41
XX42
xx43
XXFF
xx30
xx31
t
Fault cause
CRC CHECK-SUM error with EPROM 3
XX = correct CHECK-SUM value
00 = code for faulty EPROMs
CRC CHECK-SUM error with EPROM 3
II n n II with EPROM 4
CRC CHECK-SUM error with EPROM 4
II II II II with EPROM 5
CRC CHECK-SUM error with EPROM 5
n II I II with EPROM 2
CRC CHECK-SUM error in RAM area on the
CLP Processor/Graphics Board in which a
part of the operating program is stored
CRC CHECK-SUM error with EPROM 2
CRC CHECK-SUM error in the RAM area on the
CLP Processor/Graphics Board where part of
the operating program is stored
CRC CHECK-SUM error with PLC RAM
PLC Program from addr. O-IOOOH (virtual adds.
30000-3OFFFH) in PLC-EPROM/PLC-RAM
PIG Program from addr. lOOO-FFECH (virtual
addr. 31000-3FFECH) in PLC-EPROM/PLC-RAM
Possible fault location
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
CLP Processor/Graphics Board
CLP Processor/Graphics Board
CLP Processor/Graphics Brd. (export vers.)
CLP Processor/Graphics Brd. (export vers.)
Main Processor Board
Main Processor Board
Main Processor Board

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DR JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut .Tel [phone]-O
SERVICE MANUAL TNC 151/155
Page 14
Kundendienst
Section 2.2.3
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 elsewhere, 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.
: ’
Testing of the WU BE 111/211 and associated circuitry

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DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut .Tel.(O8669)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.
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.
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-Graphics Board.
See the diagram opposite for a logical procedure for
locating the fault in the system.
Testing of the VDU BE 111/211 and associated circuitry

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DR. JOHANNES HElDENHAlN GmbH
D-8225 Traunreut ‘Tel. [phone]-O
SERVICE MANUAL TNC 151/155
Page 15
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
the flow diagram on page 16. As part of that procedure, it
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 ..I 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
Test points on the Power Supply Board 227 601 . . I
'Power supply. ~1
Connector Assembly!
._
-ii,
-19
- 20
- 21
1,‘:
-24
-25
*not used with TNC lSl/lSS~
A not used with TNC 155 I Fuses Fl and F2 not used with TNC 151

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D-8225 Traunreut .Tel. [phone]-O
SERVICE MANUAL TNC 151/155
Page 15.1
Kundendienst
Section 2.2.4
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 'INC 155 Controls may be fitted
with Power Supply Board 227 601 . . (as used in the TNC 145/150/151). Test points on the Power Supply Board 230 802 . .
Plug and solder terminal signal designation
* not used with TNC 151
Pbww SupplY,~
C5nnector Assembly
I’ I I
56 7 6
13

r
* return defective
board/unit to DR
JOHANNES HEIDENHAIN
for return. where
appropriate, order
;y”“ge ,+,