HEIDENHAIN TNC 150 User manual

DR. JOHANNES HEIDENHAIN
D-5225 Traunreut
Telefon [phone].O. Telex 56831
Kundendienst
Service Manual TNC 150
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 f&m 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 repro+ced in any'form or by any xpeans~without
our prior consent in writing.
Ir*uer Ol/rii‘

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
T&fan (08669) 31-O. Telex 56931
SERVICE MANUALTNC 150
Page 1
contents
1. Use of the Service Manual TM! 150 Page 2
2. Fault Diagnosis " 3
2.1 Procedure for fault-finding " 3
2.2 Flow diagrams for fault location " 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 drive circuitry " 13
2.2.4 Testing of the mains supply and the Power Supply Unit " 14
2.2.5 Testing of the Control/machine interface " 16
2.2.6 Testing of the measuring system II 17
2.2.7 BURN-IN Test/Test Program TNC 150 " 18
3. Exchange Information " 32
3.1 Exchanging Control units 1' 33
3.1.1 Procedure for exchanging the TNC 150 A/B/B/F Control " 33
3.1.2 Procedure for exchanging the TNC 150 P/Q/V/W Control " 34
3.1.3 Procedure for exchanging the PLC I/O Board of the PL 100 B/110 B u 35
3.2 Board Exchange I 36
3.3 Software Exchange 1' 41
3.4 Replacement Parts, Loan/Exchange/Service Units " 45
4. Additional Information n 46
4.1 Block Diagram Description " 46
4.2 Block Diagram TNC 150 " 50
4.3 Wiring Diagrams " 63
4.4 Machine Parameters " 68

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
Telefon [phone],Telex 56831
SERVICE MANUAL TNC 150
Page 2
Section 1
l.Ose of the Service Ham&al TIY: 150
In order t&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
t&e Control and measuring system. In addition, improper use
of the Control, such as incorrect NC programing or incorrect
selection of machine parameters can lead to the occurrence
of fault conditions. Further information in this respect can
be found in:
.TNC 150 OPERATING MANUAL
.TNC 150 MOUNTING INSTRUCTIONS AND INTERFACE CIRCUIT CONTROL-
MACHINE
.TNC ~150 PLC-DESCRIPTION
The TNC 150 Service Manual is uSed for the diagngsis, loca-
lisation and remedying of faults on TNC controlled machines.
In chapter 2, Fault Diagnosis, a set of flowcharts enables
the user to pinpoint the source of a fault from its symp-
tams .
An inbuilt supervision system and a BURN-IN Test Program
specifically developed for testing thebContro1 can aid in
the location of faults.
Important guidance for the exchange of 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 permissible
entry values.

DR. JOHANNES HEIDENHAIN
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Telefon [phone]-O. Telex 56831
Kundendienst
2. Fault Diagnosis
2.1 Procedure for fault-finding
For fault diagnosis of the Control/machine it is of prime
importance to analyse the behaviour off the installation as
a whole.
SERVICE MANUAL TNC 150
Page 3
Section 2/2.1
When fault finding, the solutions should be determined using
the flowcharts provided in this document. Starting from the
initial apparent fault, the symptoms of the fault should be
analyzed in order to pinpoint the cause oft failure (see
section 2.2).
In addition, the HEIDENRAIN TNC 150 Contouring Control in-
cludes an extensive integrated supervision system for the
avoidance of entry/operator faults and for the recognition
and diagnosis of technical defects on the machine/Control
system (see section 2.2).
The BURN-IN Test Program and the Test Program TNC 150 can
be used as further support in fault localizing and in the
dynamic testing of the Control's hardware (see section 2.2.71.;

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
Telefon [phone].O.Telex 56831
Kundendienst
SERVICE MANUAL TNC 150
Page 4
Section 2.2/2.2.1
2.2 Flow diagrams for fault location
2.2.1 Fault diagnosis for the complete installation (Control/neasuring-Syst~/~chine)

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
Telefon [phone]-O. Telex 56831
Kundendienat
SERVICE MANUAL TNC 150
Page 5
Section 2.2.2
~2.2.2 use of the integrated supcrpision system
.~?.he integrated supervision system of the TNC 150 comprises
TNC hardware and software. It operates continuously whilst the
Control is switched on, and recognizes a major proportion of
faults as well as irregularities in the Control and the in-
stallation.
The following are supervised:
.Programning and operator errors
Example error messages:
KEY NON-FUNCTIONAL
CIRCLE END POS. INCORRECT
ENTRY VALUE INCORRECT
.Control's internal electronics
Example errcar messages:
TNC OPERATING TEMP. EXCEEDED
EXCHANGE BUFFER BATTERY
TNC-ELECTRONICS DEFECTIVE
.Measuring system and certain machine functions
Example error messages:
X-MEASURING SYSTEM DEFECTIVE
GROSS POSITIONING ERROR
RELAY EXT. DC VOLTAGE MISSING
The Control distinguishes between harmless errors and serious
faults, in that faults are shown as flashing displays
(eg. measuring system faults, drive faults and faults in:the
Control's electronics). The occurrent* of faults leads to the
machine being switched off via the emergency stop contactor.
*

DR.JOHANNES HEIDENHAIN
D-5225 Traunreut
Telefon [phone]-O. Telex 56831
SERVICE MANUAL TNC 150
Page 6
Section 2.2.2
Kundendienst
Error messages TNC 150
Error messages are not follow d by an emergency stop
and can be cleared with the El key. Their meanings are
explained in "Operating Manual TNC 150 B/TNC 150 Q",
and "Mounting Instructions and Interface Circuit
Control-Machine TNC 150 B/TNC 150 Q” .
KEY NON-FUNCTIONAL
PROGRAM MEMORY EXCEEDED
SEARCH ADDRESS MISSING
TOOL DEF 0 NOT PERMITTED
PROGRAM NUMBER ON TAPE ALLOCATED
JUMP TO LABEL 0 NOT PERMITTED
ENTRY VALUE INCORRECT
CC-BLOCK MISSING
CIRCLE END POS. INCORRECT
TOOL DEF MISSING
TOOL CALL MISSING
LABEL NUMBER NOT ALLOCATED
EXCESSIVE SUBPROGRAMMING
ANGLE REFERENCE MISSING
PLANE WRONGLY DEFINED
TOOL RADIUS TOO LARGE
ROUNDING RADIUS TOG LARGE
PATH OFFSET WRONGLY STARTED
PATH OFFSET WRONGLY ENDED
ROUNDING-OFF UNDEFINED
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 LOCKED
ME: WRONG MODE SELECTED
ME: WRONG PROGRAM DATA
ME: CASSETTE EMPTY
ME: PROGRAM INCOMPLETE
ME: TAPEEND
WRONG PROGRAM DATA
MACHINE PAPAMETER INCOMPLETE
EXT. IN-/OUTPUT NOT READY
MIRROR IMAGE ON TOOL AXIS
WRONG AXIS PROGBD
WRONG SIGN PROGRAMMED
SPINDLE ROTATES MISSING
SLOT WIDTH TOO LARGE
CYCLE INCOMPLETE
SELECTED BLOCK NOT ADDRESSED
PROGRAM START UNDEFINED
POSITIONING ERROR
EMERGENCY STOP
ARITHMETICAL ERROR
OPERATION PARAMETERS ERASED
3D-INTERPOLATION NOT PERMITTED
FURTHER PROGRAM ENTRY IMPOSSIBLE
PROGRAM NUMBER UNAVAILABLE
PROGRAM NUMBER ALLOCATED
LABEL NUMBER ALLOCATED
TOOL NUMBER ALLOCATED
CONTROL VOLTAGE FOR RELAYS MISSING
POWER INTERRUPTED

DR. JOHANNES HEIDENHAIN
D-8225Traunreut
Telefon [phone].O.Telex 56831
Kundendienst
Error message "EXCHANGE BUFFER BATTERY"
If the dialogue display indicates "EXCHANGE BUFFER BATTERY";
new batteries must be inserted (discharged batteries support
the program contents for at least 1 week). The buffer battery
compartment is located beneath the screw cover in the lower
left-hand corner of the operating panel (see section C).
When exchanging the batteries, special cars should be taken
when inserting, that the polarity is correct (POS-pole of
battery outwards). The batteries to be used have IEC desig-
nation "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 parameters and for the user-
program will be supported 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 power failure. Please note that the TNC has to be
switched on when exchanging the buffer batteries. If a mains
power failure occurs during a battery change (discharged or
missing batteries), new entry of the machine parameters and
user program is necessary.
SERVICE MANUAL TNC 150
Page 7
Section 2.2.2
-Flashing fault messages
Important functions of the TNC 150 Control are
supervised through self diagnostics (electronic sections
such as wP, EPROM, RAN, positioning system, transducer
system etc.)
If a fault is detected, a flashing plain language fault
message will appear in the dialogue display and is
followed by the opening of the emergency-stop contact.
This condition can be reset by switching-off the Control,
eliminating the fault and then switching the Control on
again.
.Flashing fault messages TNC 150
AXIS X/Y/Z/4 MEAS. SYSTEM DEFECTIVE
EMERGENCY STOP DEFECTIVE
WRONG REFERENCE POINT
SWITCH POWER OFF, THEN ON AGAIN
EMERGENCY STOP PLC
GROSS POSITIONING ERROR A/B
TNC OPERATING TEMP. EXCEEDED
ERROR IN PLC PROGRAM A...Q
TNC ELECTRONICS DEFECTIVE O...3/A...K
CHECK SUM ERROR XXOO...XXFF

DR. JOHANNES HEIDENHAIN
D-8225 haunreut
Telefon [phone]-O. Telex 56831
SERVICE MANUAL TNC 150
Page 8
Kundendienst
Section 2.2.2
Fault descriptions TNC 150
VDU Display (flashing)
X-MEASURING SYSTEM DEFECTIVE
Y-MEASURING SYSTEM DEFECTIVE
Z-MEASURING SYSTEM DEFECTIVE
AXIS 4 MEAS. SYSTEM DEFECTIVE
RELAY EXT. DC VOLTAGE MISSING
EMERGENCY STOP DEFECTIVE
WRONG REFERENCE POINT
SWITCH POWER OFF, THEN
ON AGAIN
Fault cause
.Measuring system not connected
.C&le damaged
.Glass scale dirty or damaged
.Scanning head damaged
.Measuring system supervision damaged
.Machine voltage (+24V) missing
(for checking routine, see Mounting
Instructions and Interface Circuit
Control-Machine manual TNC 150 B/
TNC 150 Q page 19 and 20)
.Supervision circuit defective
.Fault in the emergency stop
circuit of the machine (for checking
routine see Mounting Instructions and
Interface Circuit Control-Machine
manual TNC 150 B/TNC 150 Q page 19/20)
Defect in Control's internal Emergency
Stop supervision
.Traversed-over reference point lies
outside the reference point end-pos-
ition (also see Mounting Instructions
and Interface Circuit Control
Machine TNC 150 B/TNC 150 Q, pg.20.21.22
.Defect in Control/machine interface
Changing of machine parameters 12,13,
14,15,60,72,90,170 during operation
Possible fault location
Measuring system
Analogue Board
PLC I/O Board (TNC 150 P/Q)
PLC Interface Board (TNC 150 P/Q)
SE Board (TNC 150 A/B)
Terminal Board (TNC 150 A/B)
Analogue Board
PIC I/O Board ONC 150 P/Q)
PLC Interface Boaid (TNC 150 P/Q)
SE Board (TNC 150 A/B)
Teminal Board U-NC 150 A/B)
kchine (cams/switches
"reference end position" or "&&fere&
pulse inhibit")
PLC I/O Board (TNC 150 P/Q)
PLC Interface Board (TNC 150 P/Q)
SE Board VTNC 150 A/B)
Terminal Board YlYNC 150 A/B)

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
T&ion (08669) 31-O. Telex 56831
SERVICE MANUALTNC 150
Page 9
Kundendienst
Section 2.2.2
VDU Display (flashing)
EMERGENCY-STOPPC
GROSSPOSITIONING ERRORA
GROSSPOSITIONING ERRORB
TNC-OPERATING TEMP. EXCEEDED
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 with positioning greater
than value entered in MP 174.
(see Mounting Instructions and Interface
Circuit Control-Machine manual TNC 150 B/
TNC 150 Q page 45)
.Deviation from the intended position at
standstill greater than the value entered
in MP 169
(see Mounting Instructions and Interface
Circuit Control-Machine manual TNC 150 P/
TNC 150 Q, page 40)
.Exceeding the range for the continuous po-
sition supervision determined by MP 57.
(see Mounting Instructions and Interface
Circuit Control-Machine manual TNC 150 B/
TNC 150 Q, page 43)
.Relationship between output voltage and
traversed distance outside of the defined
tolerance.
.Defect in the pulse counting section (Con-
trol circuitry) after the transduce+ signal
supervision
The Control-calculated analogue output vol-
tage (implied by trailing error) is greater
than 10 V
.Ambient temperature inside
the TNC has exceeded +65OC
.Fault in the temperature supervision
Possible fault location
Terminal Board (TNC 150 A/B)
.Machine
.Machine parameter programming
Aid:
1. Program MP 54 (acceleration) as
small as possible.
2. Adjust rapid travers (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
Ambient temperature of Control
Analogue Board

P!!
DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
- Telefon [phone]-O. Telex 56831
Kundendienst
SERVICE MANUAL TNC 150
Page 10
Section 2.2.2
VDU Display (flashing)
TNC-ELECTRONICS DEFECTIVE 0
1
2
3
A
B
C
D
E
F
G
H
I
J
K
t
Fault cause
False CRC CHECK-SUM* of machine-referred data with-
out machine parameters. (Baud rate, limitation,
preset etc)
False CRC CHECK-SUM* (machine parameters)
False CRC CHECK-SUM (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 Processo+
CLP Processor RAM (only with TNC 150 B/Q)
Overflow interrupt
MID interrupt Main Processor (only with TNC 150
B/Q)
Equipped with incorrect language version (only
with TNC 150 B/Q)
RAM&M0 . ..FFFF Main Processor (only with 'I'NC 150
B/Q)
Possible fault *ocation
Main Processor/Memory Board
Memory/Main Processor Board
Memory/Main Processor Board
Main Processor/Memory Board
Main Processor Board
CLP Processor Board
CLP Processor/Main Processor Board
CLP Processor Board
CLP Processor/Main Processor Board
CLP Processor/Main Processor Board
CLP Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board
* CRC = Cyclic Redundancy Check
** MID = Macro Instruction Detection

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
T&fan (08669) 31-O. Telex 56831
SERVICE MANUAL TNC 150
Page 11
Kundendienst
Section 2.2.2
VDU Display (flashing)
CHECK-SUM ERROR xx00
xx02
xx04
XXOA
XXOB
xxoc
xx10
XX16
XX18
xx20
xx21
XXFF
Fault cause
CRC CHECK-SUM error with EPROM 4
XX = correct CHECK-SUM value
00 = code for faulty EPROMs
CRC CHECK-SUM error with EPROM 5
I, 11 II II with EPROM 6,7,8
1, 11 II 11 with EPROM 3
1, II ,1 II with EPROM 9
II II 11 II with EPROM
A
I, II II II
with EPROM B,C,D
(EPROM B,C,D,E with TNC 150 A/P)
CRC CHECK-SUM error with EPROM E
(not with TNC 150 A/P)
CRC CHECK-SUM error with EPROM F
(not with TNC 150 A/P)
CRC CHECK-SUM error with EPROM 2
CRC CHECK-SUM error in RAM area on the
CLP Processor Board in which a part of
the operating program is stored
CRC CHECK-SUM error with PLC-P.AM
PLC Marker 2815 is set
Possible fault location
Main Processor Board
Main Processor Board
Main Processor Board
Main Processor Board (PLC program)
Main Processor Board (PLC dialogue)
Main Processor Board
Menu~ry Board
Memory Board
Memory Board
CLP Processor Board
CLP Processor Board
Main Processor Board

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
Teiefon (08669) 31-O.Telen 56831
SERVICE MANUAL TNC 150
Page 12
Kundendienst
Section 2.2.2
CRT display (flashing)
ERROR IN PLC PROGRAM . . . .
A
B
C
D
E
F
G
H
I
J
K
L
M
N
0
P
Q
Fault origin
Fault with safety-related marker (see PLC-
Description manual TNC 150 B/TNC 150 Q pages
36 . ..40)
start Key
Error with safety-related marker
Rapid traverse key
Direction latch key
Feed release
Start PLC positioning X-axis
Start PLC positioning Y-axis
Start PLC positioning Z-axis
Start PIG positioning IV-axis
Direction key X+
Direction key X-
Direction key Y+
Direction key Y-
Direction key Z+
Direction key Z-
Direction key IV+
Direction key IV-
Undefined macro cal led-up via PLC marker
Possible fault location
PIG Program, Main Processor Board

Q
2

DR. JOHANNES HEIDENHAIN
D-8225 Traunreut
Telefon KJ86691 31-O. Telex 56831
Kundendienst
Power Supply Test Data
The voltages are to be measured under load
(witlfboard or load unit connected)
SERVICE MANUALTNC 150
Page 15
Section 2.2.4

------,A
i.

I I

DR. JOHANNES HEIDENHAIN
D-8225Traunreut
Tel&n 108669) 31-O. Telex 56831
SERVICE MANUALTNC 150
Paqe 18
Kundendienst Se&ion 2.2.7
2.2.1 BURN-IN Test
In some cases, inspite of these 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 or the Test Program
TNC 150.
These Test Programs are a means of dynamically testing the
Control's hardware and can be used not only for duration
testing but also for fault diagnosis.
These Test Programs are stored on digital cassettes 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 07). The Test Programs 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 Test Programs it is necessary to have a set of
BURN-IN Test Adapters.
Depending on the type of Control, (TNC with either a
standard interface or with an additional PLC I/O Board) the
appropriate adapters must be connected.
Control Type Test-Adapters
(see figure)
TNC 150 A/B/E/F
TNC 150 P/Q/V/W
PLC with bipolar outputs
TNC 150 P/Q/V/W
PIG without bipolar outputs
5.6,7,8,9
2,3,4,7,8,10
1,3,4,7,8,10
It is necessary to have the correct Test Programs for the
Type of Control and for the Control's current software
issue. The type of Control can be determined from the
type-plate or from the identification number of the Con-
trol; the software issue is determined from the NC Soft-
ware number. The Id. No. of the Control and the NC
Software number can be found on the rear of the Control
on the type-plate.