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Service Manual TNC 151

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1. 2 eichnungs Nr 4820 EKD 16041 00 SE Ein Ausgang Platine zu SE PLC Inter face zum externen Computer Platine Magne t bandeinheit usw 6 Re K egelkr CRU Adress Bus Plati Standard 16bit Adress Bus Erweilerter 20bit Adress Bus 7 bit 30 Haupt rechner CPU IMS 9995 stelle Adressen OP Generator enl pp Puffer zu SE PLC Interface Platine s r Tastatur Platine Blockschaltbild TNC 151 155 Hauptrechner Platine anos Zeichnungs Nr 4820 EKD 16026 00 a 0 5808 ST zu Speicher Platine zu Haupt FT RU zu Piatine Standard 16 bit Adress Bus M quis Analagtail 3 Q T von 3D Taster au SEIPLL Inter face Platine zu SE PLC d Bausfeine viet EG KYLIE Zeichen Signale nach Generator Ver or beitung wertung Z hler usw hade ACA CA Verarbeitetes ahlschalter HR Signal von Analogteil Platine RU Daten Bus zu Analogt Platine zu Haupt rechner Standard Daten Bus zu Speicher Platine Platine Pu m Blockschaltbild TNC 151 Zeichnungs Nr 4 820 EKD 16029 00 Regelkreis Rechner Platine zuHaupt 5 A5 rechner AS Mal Standard 16 bit Adress Bus 2 a Taster auf SE PLE Interface 12 Platine_ Zahler Pa von b in o Analogteit Inter Hire Bausteine Platine_ Board Gate X Y 2 1
2. Kundendienst Fig 3 TNC 150 P Burn In Adapter Id No 224 875 ZY Board connector From analegue outputs fut de Board PLC Board connector From analogue outputs PLC outputs connector 4H3 Jit x ANG 1208 412 OYint JHE JUS 116 circuitry EES X circuitry Override pot input SHI circuitry san OV int as per X circuitry Handwheel Schematic of interconnections created by connecting the TNC 150 P Burn In Adapter to the Control TES MEINENMAIN DR JOHANNES HEIDENHAIN GmbH SA D 8225 Traunreut Tel 08669 31 0 od MANUAL TNC 151 age Kundendienst Section 2 2 6 Fig 4 PLC Adapter Id No 224 873 ZY External Relo bo PLC Din fig 3 An 1 0 5 ES1 oE26 EB oE23 ED NO Eb Pos O Unpowr Loading Pos 4 A complementary Pos 2 AZHAB complementoly Pos 3 AZAD complementary Emergency OFF Internal circuitry schematic Internal circuitry schematic Additional circuitry for overload Standard circuitry with unipolar facility bipolar switch over a HEIDENHAIN E DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 D 8225 Traunreut Tel 08669 31 0 Page 25 Section 2 2 6 Kundendienst Fig 5 TNC 155 Additional Burn In Adapter Id No 228 881 ZY battery warning 4 switching 9 pin 14 pin 7 pin Internal connections ZR HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH INA gt 8225 Traunreut Tel 08669 31
3. Libr d dg F H i Platine Tastatur L Pi P2 e Pt P5 ES P7 er 9 906 89800 30088 19000 08098 Ep emm DIE 0000 BASEN OE 0000 i ggg ojala gd m en 29774 13 Rese NIY D E NG 4 3V TET 2r 17 32v MP i gy r De 22 EY eno BA 28 sts Brissenem Doa o ginem i Tr Spannungsw hier m Sicherung 390 1200 TIGA 20022020v TOMA pne Piatine Speicher La 22 3 Jw A a um N 4 en L Beseging Fionsendose Beiegung Flonsendose tm e 68D 8 eter I 58D 13 a frei Za fe 9 atrer 2 14 s trai Batre 10 a frer NL 15 tra hate NM 2 OTR ka S RIS 12 TaD d luet Synch 17 Mel Dunker 2098 13 ETS Gan Petre 14 e BRD M To Luss a Jr fm 20 a me 2 a trei 27 Voy aues a Signa potentalires Ws yd 5 ang tt x fre E a 12a fe x ap tty Seas S Code CAP k t Aven taa mese ern beraten av una e Archip ver Mer MI MC d ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 Page 74 Section 4 3 Kundendienst Handrad y NOT AUS Klemme sg 3586358 Y 2 H Y E 3 m Ye ER 9 Y 1 ETT UZ B sl MEC EE i pa y i zur PC EinlAusgangsplatine P2 i p fe d i 1110 Platine Klemmleiste i pa j Kupplung 12
4. 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 a HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 Page 44 Section 3 2 Exchanging the Power Supply Unit Remove the 4 cross head mounting screws from the rear of the Control 2 screws are found in the connector box Remove the back wall with the Power Supply Unit and Terminal Board Disconnect the ribbon cable connector P1 from the Connector Board see diagram Remove the voltage supply plug P2 from the Connector Board see diagram Exchanging the Connector Board Remove the 2 cross head fixing screws of the V 24 connector on the rear of the Control Push the V 24 socket through its recess in the Control housing Unsolder the connectors to the VDU socket from the Connec tor Board solder terminals 1 4 5 6 7 8 10 Note the colour of the wire connected to each terminal Pull the Connector Board from the front of the Control hous ing solder terminals Connector Board E HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 3 Software Exchange General The TNC 151 operating software is stored in 17 EPROMs IC P3 IC P19 CLP Processor Board IC PA IC P10 M
5. Leistungs schalter Schalt regier TL 496 nn mmm mma E ar nm IV 0 45 V 0 22 V 0 15 V 03515 V 1202 Regler 920 12 v 0 0 V U o 5 V EO CES q U3 oe 11 Y Blockschaltbild TNC 151 155 Netzteil Zeichnungs Nr 4820 E KD16046 00 RS 237 C OP AMP MOS Logic OP AMP RS 232 C TTL Logic Bildschirm einheit ext Poti Vorschub TUT Schleifer zur Analogteil Platine IV Netzteil 0v zum S Anatogteit Maschinen Analog Ausgange Analog Ausg nge UTER Antrieb Platine es CRU Adress Bus Referenzimpuls Sperre CRUIN 2 CRUIN 1 CRUOUT CRUCLK Rese i NOT AUS Blockschaltbild TNC 151 155 Zu r externen PLC Platine n Pl 1 von zur PLC Interface Platine Zeichnungs Nr 4820 E KD 16044 00 Klemmleisten Platine P Version Pots Schleifer 23 Eing nge stande ext zur Analogter Vorschub e Platine psc ov ung Ed a H EEE 12 V pen rv Sp uni Ae Netzteil i Annlogteil Analog Ausgange Analog Ausgange Guter a o gd c 2c 23 Ausg nge o E Schutz wider Ki T 23 Ausg nge st nde u usgang NOT AUS g u a 23x470 2 c Y 80 1 E E uy g m Ly d 23 Eingange UA x c 3 N jc Schutz o S gt wider 23x51 kN L Blockschaltbild TNC 151
6. Signale nach Arrays Verarbeitung Signalaus wertung Raves Zahler usw ese Verarbeiteles HR Signal von Analogteil Platine CRU Daten Busje zu Analogt Platine X CRU Daten Bus zu Haupt zu Spe peicher rechner Standard Daten Bus Platine cC m Platine 5 7 a Blockschaltbild TNC 155 Regelkreis Grafik Platine Zeichnungs Nr 4820 EKD 16030 00 CRU Adress Bus von Regelkreis Platine von Hauptrech ner Piatine CRU Adress Bus 0 spindel C11 me mu Former RI Position Referenz impuls Sperre von SE PLC Interf Platine Extern EI TEN en H Y 2 1V sec Ju 2 Ng ed sl d Ignale wW g E EXE Hen kl cyto me 4 53 0 Handrad zuRegelkr Platine impuls E orn 90 Eingange CRU Daten Bus von Regelkreis Platine von Hauptrech ner Platine CRU Daten Bus NOT AUS Blockschaltbild TNC 151 155 Zeichnungs Nr 4820 EKD 16028 00 Analogteil Platine TTL Eingange zur Klemmieisten Platine CRU Adress Bus von Regelkreis Platine Impuls goe Spindel Ta Planer Former RI Position ts S 20ms sms Hox TS flop flop zur Klemmleisten Platine von Hauptrech 0 Handrad CRU Daten 90 Eing nge Bus AUS Blockschaltbild TNC151 155 Zeichnungs Nr 4820 E KD 16027 00 Analogteil Platine Speicher Adress Bus RAM Anwender 3160 Siitze
7. 200mV 5V 9 5V Key TEST SERIAL HANDWHEEL INPUT Checks the interface to the HE 310 Handwheel Unit SERVICE MANUAL TNC 151 Page 33 Section 2 2 6 m Key SUPERVISION CIRCUIT TEST checks the tbreshold values of the circuitry which moni tors the measuring system inputs n Key Zz TEST REFERENCE IMPULSE INPUT Checks the effect of a signal applied to the reference pulse inputs o Key TEST TRANSDUCER INPUTS EXE Checks the effect of signals applied to the measuring system inputs Starting the sequential tests The test sequence can be started or restarted at any point by pressing the appropriate key eg key to begin with the V 24 interface test All 15 keys associated with the sequential tests act as interrupts to the Burn In test program Fault recognition The detection of a fault will be displayed on the VDU The test cycle will be halted and the Burn In Time stops If one or more faults arise during the execution of the Burn In test program the fault message associated with the first fault will be stored The stored message can be retrieved at any time by pressing the key PGM This causes a system re boot as explained on page 30 All fault messages can be cleared with the key This key also causes a restart of the sequential tests begin ning with the test TEST INT POT BATTERY TRIGGER Y HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst
8. eub FIEILZLEIMFILZAABIVM DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 Kundendienst Id No Name Id No Name 229 134 95 TNC 151 A E mit 1280 S tzen with 1280 blocks 227 278 Platine SE SE Board 229 134 99 TNC 151 A E mit 3160 S tzen with 3160 blocks 226 761 Platine PC Interface PLC Interface Brd 229 135 95 TNC 151 AR ER mit 1280 S tzen 228 164 Platine Klemmleiste Terminal Brd for A E units 229 135 99 TNC 151 AR ER mit 3160 S tzen 228 166 Platine Klemmleiste Terminal Brd for P V units 229 136 95 TNC 151 P V mit 1280 S tzen 224 825 Platine Tastatur Keypad Board 229 136 99 TNC 151 P V mit 3160 S tzen 227 267 Platine Stecker Connector Board 229 137 95 TNC 151 PR VR mit 1280 S tzen 213 204 Tastenfeld kompl 20 Tasten 20 key keypad assy 229 137 99 TNC 151 PR VR mit 3160 S tzen 217 737 Tastenfeld kompl 10 Tasten 10 key keypad assy 217 532 Halter Batterie kompl Battery holder assy 223 836 PL 100 B Leistungs Pl PLC I O Board 228 168 Potentiometer kompl Potentiometer assy 223 216 PL 110 B Leistungs Pl PLC I O Board 202 370 Spannungsw hler m Si halter Voltage selector fuse 213 206 Klemme Netz 3 pol kompl 3 way mains conn 212 300 BE 111 Bildschirmeinheit 9 VDU 215 091 Trafo BV 15714 Transformer 222 674 BE 211 Bildschirmeinheit 12 VDU 212 282 Geh use Frontteil TNC Fro
9. i ti n us Platine Speiche eg 1 akot Te M re Ener e e a Naabot komo pg JOO A ee E uL 410 vv gt E ma ult fe LE Du Z aa BES 193 AR i y a e JAY MIT So a TS as ol 02 EU A ARE f xod die c unum JE bed uf ATE Ht pt pio en m amo i AL nd HI to i u ver je AH D tes SE VE etc 40 Platine Tastatur rud S D st 1 ki Schw e f V 4 vius 1 LU Li a romney EE Ed LE ebe 498 925 319 4 mam Sale Kops HH ep A H jez seasno somas angele E ep i HH ji HE zeaan mugselloame Hondrad E 13 Fi BH s an0a i metal HH ause al Tu i i H OSS See pun aa Y EN 4 A Nae E n s E HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 SERVICE MANUAL TNC 151 Page 73 Section 4 3 Kundendienst ved NOI AUS Klemme Handrad Fe E 2 1 552825 2 Geh use 3 8278528 ro i g Y Y 1 Yo Y Ya Sina DY TY TTT TY 3 71 72 43 SC 8 f P2 s Platine Klemmleiste 5 3 e D A E A a Kupplung 12p0i kompt 5 N ohne Funktion ment netegen Patios FG sw ear d Gone Platine Analogteil m d D pod 000000 Hi satel nt H Hah dy cone sena TE Haiter Batterie kampi Potentiometer Guer ze kompl Potentiometer Spendetcrenzen kompl pu SEU IE Mg E teetovesesosoeseovotest MENE EEE EEE
10. installation Error indication on VDU 2 2 1 Fault diagnosis for the complete installation Control Measuring System Machine tool Yes Use integrated supervision system section 2 2 2 0 VDU amp LEDs dark 1 VDU dark 2 VDU amp LEDs functio VDU fault section 2 2 3 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 eae TETI ATALET aS DR JOHANNES HEIDENHAIN GmbH N D 32225 Traunreut Tel 08669 31 0 Kundendienst 2 2 2 Use of the integrated supervision system The TNC 151 incorporates an extensive integrated supervision 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 in
11. 0 KES Vos when iba are Ace oe tion tor control of inhibited axes z a e inhibited 15 2 X Y ALL EA IV a FT eener mettecuve 1 Override effecti Pre cut out time tor tapping cycle Override effective on pressing rapid button Reference signal evaluation for inhibited axes Displey and transducer supervision for inhibited axes PLC program from RAM or from EPROM RPM range gear ratios S analogue output 0 9 000 000 rpm mg eem ale nj o HA 0 9 999 Volts S Analogue voltage with S Override at 100 S Analogue voltage with S Override at max output voltage Limitation of S override Maximum Minimum Axis designation for axis IV Qnstant contouring speed at corners Decimal character in program output via V 24 Overlapping factor with pocket milling imat point ego ty hjord or Pr i tor counter Q 15 109 0 65 535 in units of 20 ms SERVICE MANUAL TNC 151 Page 76 Section 4 4 for timer O 15 iise L s000m for 31 coordinates 31 Ref 30 000 000 mm Activation of next too No 0 No output of next tool number i 12 Porrera Wi changa of tool numai 2 put of next tool No with too cali Setting of 16 markers to binary number ue a BE Op 1 Automatic lubrication io X 159 to 65 536 in 65 536 yum unitsl programmed traversing Y 162 distance in Zz iv Feed rate for
12. 155 Zeichnungs Nr 4820 E KD 16042 00 Klemmleisten Platine A Version Zur Klemmleisten Platine CRU Adress Bus Referenz impuls PU Sperre CRUIN 2 CRUIN 1 CRUOUT mp Reset NOT AUS Zeichnungs Nr 4820 E KD 16043 00 Cn c 2 O c oO 3 2 L H Eh L o a i CRU Adress Bus Platina Puffer Referenzimpuls Sperre zu Analogteil Platine zulvon Regelkreis atine cn c 2 c c pos a a Cn Im 2 a a o x 1 o Be a e NOT AUS Blockschaltbild TNC 151 155 von Analogteil f Platine PLC Interface Platine von Hauptrechner T zu Zohterbaustemen 64 der Regelkreis Platine CRUIN 2 e A 9 X CRU Ge CRUIN 1 JAuswahl TS L _ zulvon Hauptrechner Platine T CRU Daten Bus be N 2 f RESET PLC Out Clear zur Klemmleisten Platine von CRU Adress Bus Vare en Platine Puffer Referenzimpuls Sperre zu Analogteil Platine 7 Reset 61 Serien Parallel Umsetzer 24 Relais Ausg nge und NOT AUS und zuTvon 24 Relais Saas n Se NOT AUS 60 24 Eing nge ue Optokoppler T HE 24 Eing nge und Taster re nd tM Parallel Serien Umsetzer zu von Hauptrechner PUMA NA Blockschaltbild TNC 151 155 CRU Daten Bus NOT AUS von Analogteil Platine
13. 412V board unit to DR 15V 15V can only JOHANNES HEIDENHAIN be measured under load for return Where appropriate order i Probable fault on Power Supply Board exchange PP Y unit Connect PSU connector to Connector Board all voltages within tolerance Probable board fault Remove each board in turn until PSU volts OK Reassemble backwall Control ready fox us 2 2 5 SERVICE MANUAL TNC 151 Section Page 17 iring DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 SY HEIDENHAIN 2 2 5 Testing of the measuring systems and w Kundendienst Testing of measuring system IM I Pu RD 4 and wiring Swap the measuring system tonnectors around Check wiring No Repair wiring Fault cleared Fault cleared Scale contaminated Return scale to HEIDENHAIN for repair fault cleared Defective scanning head Replace scanning head Fault cleared No Return complete measuring system to HEIDENRAIN for repair Replace measuring system Fault lies with TNC Measuring system amp wiring OK Continue with flow diagram of section 2 2 1 E ITEIDEINFTZATIN DR JOHANNES HEIDENHAIN GmbH NEA 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 display
14. 47 ohms 80 1 Protective resistances should never be replaced with normal resistances The Analogue outputs are led via LC filter 81 as protec tion against the oscillation of analogue outputs SERVICE MANUAL TNC 151 Page 51 Section 4 1 b TNC 151 P Versions The inputs and outputs are loaded on external PLC I O board e g PL 100B or respectively PL 1008 which are driven by the main processor 30 via the PIC 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 optocouplers 60 and are converted from the TTT level 5V to the MOS level 12V by means of a level converter 61 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 64 and are led to the main processor via CRUIN The serial CRU OUT signal is converted in 31 outputs via a serial parallel converter El i 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 overcurrent no emergency stop resu
15. Burn In Test Program ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 D 8225 Traunreut Tel 08669 31 0 Page 28 Section 2 2 6 Kundendienst 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 PGM Under both of these circumstances the following procedure is to be followed in order to restart the Burn In test program Burn In test program present in Control The Control will automatically carry out a memory check This test takes approx 17 sec during which time the dialogue MEMORY TEST Restore power after a mains interruption Warm boot with will be displayed on the VDU Upon completion of this test the dialogue will be replaced by f VDU displays MEMORY TEST VDU displays PRESS NOENT KEY PRESS NOENT KEY IMPORTANT Only press the key Es if you wish to erase the Burn In test program and return to the normal operating system To restart the Burn I
16. Control can check that each key is making contact and delivering the correct code to the keyboard interface The keying sequence is as follows a top right set of 20 keys b top left set of 10 keys c middle left set of 20 keys d 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 If 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 32 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 the following text will appear on the VDU following a successful keyboard test 0 1 OR 2 PC BOARD This refers to the number of external PLC I O Boards con nected to the Control during the test and must be answered with the appropriate numeric key ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 6 The final s
17. D 230 602 01 229 136 95 TNC 151 P 229 136 99 s e 06 GB 230 603 01 229 136 95 DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 AN HEIDENHAIN e Kundendienst Fig 1 Interconnections of Burn In Adapters and TNC 151 BE 211 111 TNC 151 A TNC155 Zus tzl Burn in Ad TNC 55 Additional Burn in Acer te a TNC 151 A E SERVICE MANUAL TNC 151 Page 21 Section 2 2 6 BE 211 11 TNC 151 P TN 155 Zus tzi Burn in Adapter TNC 755 Additional Burn in Adapter PC Adapter b TNC 151 P V HEIDEN HAIN SERVICE MANUAL TNC 151 K DR JOHANNES HEIDENHAIN GmbH Se NEN 0 8225 Traunreut Tel 08669 31 0 Page Section 2 2 6 Kundendienst Fig 2 TNC 150 A Burn In Adapter Id No 224 874 ZY Board 1 A7 12 connector From analogue outputs A ISD PO 75r 15172 Mit Ki 7803 HiT Se 3612 ec J2 12 i Bi 518 BIS 1606 35 7 160 3619 56130 BIN RI 1517 4413 Jen 1415 46 o s y 1 23 12 Aa ISS J54 1513 Su ee Le 12 as per x circuitry CONT 45 12 JNA IMS JIM SHI GHZ SIN 342002 2203 FHI 2752 103 ING as per X circuitry as per x circuitry 4 Relays within JA TNC 150 A Burn In as per X Adapter circuitry Handwheel Schematic of interconnections created by connecting the TNC 150 A Burn In Adapter to the Control HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 REA D 8225 Traunreut Tel 08669 31 0 Page 23 Section 2 2 6
18. IC P11 1C P18 Memory Board FIEIDBENFAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 CA Kundendienst The RAMs 30 2 on the main processor board can be accessed either by the main processor 30 or by the CLP processor 40 The intended coordinates programmed feed display texts etc can therefore be transferred These RAMs also serve as register file memory for the main processor 30 User programs machine parameters and under certain circum stances the PLC program are programmed in RAMs 20 1 The 16 bit address bus is extended to 20 bit by a memory mapper 31 The keyboard controller 32 has the task of driving the LEDs and scanning the keypads 32 1 on the front plate The main processor is connected with V 24 interface 34 via a serial CRU bus This interface is used to exchange data by means of a magnetic tape unit ME or respecti vely an external processor The PLC program contained in IC P9 33 1 is processed by the l bit PLC processor 33 mounted discretely on the main processor board The input and output states are stored in a Ak x 1 PLC RAM 33 2 I O Functions a TNC 151 A Versions 24 galvanically separated inputs EO to E23 60 and 24 floating relay contact outputs AO to A22 emergency stop 61 on the SE Board The inputs and outputs are protected on the terminal board A version by special protective resistances 5 1k ohms 80 and
19. fault Error message cleared with ce xey Control ready to use again Use of the integrated supervision system ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Error messages TNC 151 The meanings of many of these error messages are explained in i Operating Manual TNC 155 A TNC 155 P SERVICE MANUAL TNC 151 Page 7 Section 2 2 2 ii Mounting Instructions and Interface Circuit Control Machine TNC 151 A TNC 151 P 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 i 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 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 ME ME ME ME CASSETTE MISSING CASSETTE LOCKED WRONG MODE SELECTED WRONG PROGRAM DATA CASSETTE EMPTY PROGRAM INCOMPLETE TA
20. if not already removed in 1 10 Install the new Control check the voltage selector posi tion 11 Check the fuse rating see type plate 12 Reconnect all cables previously removed 13 Obtain from the type plate the Control s Id No NC and PLC Software Nos and write them in the machine handbook 14 Refit the connector box cover plate 15 Turn on the mains voltage 16 Reprogram the machine parameters 17 TNC is now ready to use Ko HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 D 8225 Traunreut Tel 08669 31 0 Page 38 Section 3 1 2 Kundendienst 3 1 2 Procedure for exchanging the TNC 151 P V Control 1 Gain access to the rear of the Control 2 Remove the mains supply 3 Remove the connector box cover plate from the rear of the Control 4 Mark the measuring system plugs X Y 2 IV Electronic Handwheel and remove them 5 Disconnect the VDU from the Control 6 Disconnect the Handwheel Unit from the Control if present 7 Disconnect any external data devices 8 Disconnect connector strips J1 J3 using screwdriver to prise the connectors apart Do not unscrew individual wires 9 Remove the connecting cable P2 to the PL 100 B 110 B from the Control 63 8 3 M D H E a ES FR Am GA ED A A RT SITS DOOD OOOO 9 G9 SUEDE ER PEN NINE UG A Pees soe aegeg TITE TITE prise apart with a screwdriver 10 Remove the fa
21. ilil i DECH 2atrer Furre 4 ere SATS 64DSR Petro A W 8 tre 9 fre 10 tree ma SIR 12 RE 132575 DEL Pt Kupplung 12 pol kompl Kabel VB Hach hx AWG 28 kompt Kabet VB 8x04 kampi Se Platine Stecker gt mE CS 4A XA i Le J5 EMT P2 Platine A iss E EE ECK 196 x Dei Ee Platine Hauptrechner Platine Speicher im e Ma L J gt Platine Tastatur P LES a ECH ESCH 22 2t DE N r m r KL 19 52v Platine Netzteil 26 Thy Biktschirm 28 ov Bildschirm d Sc Entst r Netzteil kompl brje ot Ka or ot fa Aetzktemme kompl KHE L N Vardroahhinespian Spann ngsw hler m Sicherung 85 Ts 7 NG KA MOK P104 p 20220200 RAMA BA HEIDENHAIN Page 72 Section 4 3 N 0 5225 Traunreut Tel 08669 31 0 Kundendienst E 3 d LIT zurME th pol kempt pr Ws Platine Stecker Zafra 2 tre jte 12 tre amp fre 17 OTR Serts 12 5 EDSR 134 CFS Terre Rab tl o n i e e E Platine Anologteil TE 22 a BABALA ma Jr HE Tr us dis RR Be Ku M Spomngewine m Sheng Platine Regelkr m i bara id E S H C et AG a yor de A ye ja Platine gt Hauptrechner i BN alo Tm gt
22. parameters Nos 126 to 156 x 163 B0 15999 mm min Y 164 zZ 165 IV 166 Display of current feed rate before start in MANUAL OPERATION mode same feed rate in all axes Aamp gradam for S analogue a Standstill supervision Prugrommung slaton Handwheel Polarity S analogue voltage 172 M O3 positive voltage M 04 negative voltage t MO3 negative voltage M 04 positive voltage M 03 and M 04 positive voltage Cancellation of status display with 173 Status display not To be cancetle with M 02 and M 30 1 Status display to be cancelled Training error supervision n trailing operation Emergency stop 174 i eraseabie 179 s Mulupbuanon factor for Ky lactor Kytacior lor X 377 Y 178 Z 179 IV 180 Characteristic kink ter Minimum for feed rate override with tapping 182 Maximum for feed rate override with tapping Minimum voltage for S anatogue outp 0 7 Waiting time for cut out of remaining nominal value voltage with error display Positioning error ee MILL LIMA DR JOHANNES HEIDENHAIN GmbH EA D 83225 Traunreut Tel 08669 31 0 Kundendienst Programming of rpm S 0 permitted O permitted voltage value of MP 184 may be 0 not permitted Dipiay of current spindle rpm 0 2 nodisplay 2 before start in Geer 0 001 0 05 mm C Timer duration for timer 16 31 0 65 535 in units of 20 ms Support of PLC ma
23. 0 Kundendienst SERVICE MANUAL TNC 151 Page 26 Section 2 2 6 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 2 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 zZ e e 8 See 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 The necessary code number for reading in the Burn In test program is entered by pressing the following keys as often as necessary to obtain the display CODE NUMBER and then 6 2 0 1 5 8 Errors in entering these numbers can be corrected by pres sing The data transfer is then initiated 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 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 unaffe
24. 32x 2k x8 CRU Daten Bus Blockschaltbild TNC 151 155 Zeichnungs Nr 4820 EKD1603100 Speicher Platine Speicher Adress Bus EPROM IC P11 RAM Anwender 1280 S tze IC P18 8x 8kx 8 16 x 2k x 8 CRU Daten Bus Blockschaltbild TNC 151 Zeichnungs Nr 4820 EKD 16032 00 Speicher Platine CB HEIDEIVTTATIN DR JOHANNES HEIDENHAIN GmbH N p 8225 Traunreut Tel 08669 31 0 Kundendienst 4 3 Wiring diagrams Wiring diagram Wiring diagram Wiring diagram Wiring diagram TNC 151 A E TNC 151 AR ER TNC 151 P V TNC 151 PR VR Drawing No Drawing No Drawing No Drawing No 229 129 00 229 130 00 229 131 00 229 132 00 71 72 73 74 SERVICE MANUAL TNC 151 Page 70 Section 4 3 ET EiL Ciun AEN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 43 Dd el LY J Ye nm J5 Yal J6 SERVICE MANUAL TNC 151 Page 71 Section 4 3 Platine Klemmleiste J6 ohne Funktion nicht betegen J8 3 Guo DATA e frei ER 14 e Pe EN 75 Dei E jertse 15 Jetzen ee trei Kaf fs Zijde a ge a 25 For on FA t 2 La Bilas 12 Mei LEE Flenschdese BU g r BE 2kpot konpi 47 Flanschdose BU zurME 14 pot kompl i i o Le Le i pe x Le re at ram paa See E 1 Fj 3 ka ET 4 A E I
25. ANA E 2 H H _ VES ta 3 sales 20900 osea Honos 5 y 8E ES H Banane Basal asseo Handrod i HT 2080 tg 3 z aA 23 H agg Lag t i M Varcdrahhingenion OTI AROS 132 DA ry F b RN aa BETI ATAL eV DR JOHANNES HEIDENHAIN GmbH SUBA 0 6225 Traunreut Tel 08669 31 0 Kundendienst 4 4 Machine Parameters 80 15 999 mm min IV Degrees min with axis designation A or B or C Speed when approaching reference points 10 fold 0 2 Plus direction 1 2 Minus direction with correct programming of parameters Nos 20 10 27 approaching interence marks ya lv EEE Er EEE En chon ES Dori Counting direction x Y Zz IN Polarity c of nominal value voltage positive with positive traversing direction negative with positive traversing direction x 1 1 Eee ONA Integral factor Differential factor 0 65535 Values from table on section 6 2 2 Backlash compensation 21 000 mm 1 000 mm ZN lt x Corraction factor for tinear correction 1 000 mm m 1 000 mm m SERVICE MANUAL TNC 151 Page 75 Section 4 4 Drot 30 000 000 mm Y Y Sottware limit switch ES ranges X zt 2 49 tv4 IV Angular axis to 30 0009 Analogue voltage with rapid traverse 52 Ap
26. Errors see Mounting Instructions and Interface A B C D the fault could lie with any Circuit Control Machine manual TNC 151 A element in the closed loop servo system TNC 151 P ie Control hardware CLP Processor Brd Deviation from the intended position at T i Analogue Brd standstill greater than the value entered servo amplifier offset voltages in MP 169 e gain too low see Mounting Instructions and Interface motor Circuit Control Machine manual TNC 151 A tacho TNC 151 P measuring system Exceeding the range for the continuous po external forces acting on drives sition supervision determined by MP 57 inappropriate MP values programmed see Mounting Instructions and Interface Circuit Control Machine manual TNC 151 A TNC 151 P Relationship between output voltage and Aid traversed distance outside of the defined 1 Program MP 54 acceleration as tolerance small as possible Defect in the pulse counting section Con 2 Adjust rapid traverse as small a trol circuitry after the transducer signal trailing error as possible supervision 3 Gradually increase MP 54 If this does not help fault in the Control hardware closed loop or in the machine EN HEIDENHAIN SERVICE MANUAL TNC 151 DR JOHANNES HEIDENHAIN GmbH SUIZA D 8225 Traunreut Tel 08669 31 0 Page 10 Section 2 2 2 Kundendienst VDU Display flashing Fault cause Possible fault location GROSS POSITIONING ERROR B The Control cal
27. 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 1 CYCLIC 2 STOP AT FAULT Option i means that the test still to be selected will be run cyclically regardless of whether a fault is detected Option 2 means that the test will be 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 Burn 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 SERVICE MANUAL TNC 151 Page 34 Section 2 2 6 Calibration check of the Analogue Board TRIMMING ROUTINES Interrupting the Burn In test program with the key ce gains Access to the calibration E85ts Exit form these tests is only possible with the key S L l Within the calibration mode the following tests can be selec ted Key 1 Key 2 Analogue output voltage ANALOG VOLTAGE OUTPUT Key 3 Seale a ce OP sem Reference amplifier performance TRANSMISSION BEHAVIOUR REF AMP 32 step monotonic DAC MONOTONIY DAC 32 STEPS DAC performance TRANSMISSION BEHAVIOUR DAC 10V analogue output DAC ANALOG OUTPUT 10V Linearit
28. LP Processor Graphic Board 4 Analogue Board Analogue Board TTL 5 with SE Board 6 it corresponds to a A E Type without SE Board with PLC Interface 6 however with PLC I O Board s it corresponds to a P V Type or respectively PR VR Type Power Supply Board 7 Terminal Board 8 The functional processes of the control are divided between two microprocessor systems each comprising Microprocessor TMS 9995 Program Memory EPROMs Write Read Memory RAMs 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 Keyboard LEDs User Program Interpreter Provision of programming environment Generation of PLC program addresses Transfer of input and output states between PLC Inter face Board SE Board and PLC RAM Control of the V 24 interface 2 CLP Processor System Ascertainment of instantaneous positions Interpolation Calculations VDU Control Demand Speed Values to DAC Interface with handwheel unit 1 Serial data transfer via CRU bus Main Processor Unit Primarily on the ma n processor boar and the memory board The operating system software is held in EPROMs 30 1 IC P4 not mapped 30 3 IC P5 IC P8 A 30 3 IC P10 dialogue language Main Proc Board 20
29. NHEIDENHAIN EX DR JOHANNES HEIDENHAIN GmbH S D 8225 Traunreut Tel 08669 31 0 Kundendienst Seite Manual TNC 151 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 1f 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 01 87 EB FICIL CIVNTILALIV 3 DR JOHANNES HEIDENHAIN GmbH Eed D 8225 Traunreut Tel 08669 31 0 dig MANUAL TNC 151 Page Kundendienst Contents 1 Use of the Service Manual Page 2 2 Fault Diagnosis 3 2 1 Procedure for fault finding 3 2 2 Flow diagrams for fault location 5 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 14 2 2 4 Testing of the mains supply and the Power Supply Unit 15 2 2 5 Testing of the measuring systems and wiring H ZE 2 2 6 Burn In Test 38 3 Exchange Information 36 3 1 Exchanging Control units 3T 3 1 1 Procedure for exchanging the TNC 151 A E Control 37 3 1 2 Procedure for exchanging the TNC 151 P V Control 38 3 1 3 Procedure for exchanging the
30. PE 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 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 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 IN HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Fault descriptions TNC 151 VDU Display flashing Fault cause X MEASURING SYSTEM DEFECTIVE Y MEASURING SYSTEM DEFECTIVE Z MEASURING SYSTEM DEFECTIVE AXIS 4 MEAS SYSTEM DEFECTIVE Measuring system not connected Cable damaged Glass scale dirty or damaged Scanning head damaged Measuring system supervision damaged EMERGENCY STOP DEFECTIVE Fault in the emergency stop cir
31. PLC I O Board of the PL 100 B 110 B 39 3 2 Board Exchange 40 3 3 Software Exchange 45 3 4 Replacement Parts Loan Exchange Service Units 48 4 Additional Information BE 4 1 Block Diagram Description 50 4 2 Block Diagram TNC 151 55 4 3 Wiring Diagrams 70 4 4 Machine Parameters D 28 EET ERE ee PC EINET ANING l DR JOHANNES HEIDENHAIN GmbH NGA gt 3225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 Page 2 Section 1 1 Use of the Service Manual TNC 151 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 TNC 151 OPERATING MANUAL TNC 151 MOUNTING INSTRUCTIONS AND INTERFACE CIRCUIT CONTROL MACHINE TNC 151 PLC DESCRIPTION The TNC 151 Service Manual is used for the diagnosis 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 toms An integrated built in supervision system and a Burn In Test Program specifically developed for testing the Control can aid in the location of f
32. ain Processor Board IC P11 1C P18 Memory Board Every operating software is specified with an 8 digit Software No example 227 001 06 complete software Id No 227 001 primary software Id No 06 update software index Each of the 17 programmed EPROMs IC P3 IC P19 is specified with an 8 digit Id No example 227 116 CG complete Id No of the Prog EPROM 227 116 primary Id No of the Prog EPROM C position on the board C IC P12 HEXadecimal counting manner G update index The operating software includes o NC software IC P3 IC PB IC P10 1C P19 o PLC software IC P9 TNC 151 A Control with o NC software and o PLC standard software TNC 151 P Control with o NC software and o PLC standard software or PLC custom software SERVICE MANUAL TNC 151 Page 45 Section 3 3 The dialogue language of the TNC 151 is determined by IC P10 located on Main Processor Board and is discernible from the different Id Nos of the programmed EPROMs Following dialogue 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 P9 PLC software The standard PLC program EPROM position IC P9 can be replaced with a custom PLC program for the TNC 151 P IC P3 The export NC Software dif
33. alog voltages are amplified and buffered subsequently 52 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 51 The supervision signals are led to the CLP processor via the CRUIN line Two watch dog monoflops 51 1 are on the analog board These must be triggered separately once every 5ms by the CLP processor 40 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 41 1 A special CRT con troller TMS 9937 41 generates the necessary addresses for the CRT RAM and the character generator IC P19 41 2 So that the data are transferred to the shift register 41 3 in the right sequence Thus signal can be inverted by means of an exclusive or gate 41 4 to generate an inverse video display The video signal the bright dark SERVICE MANUAL TNC 151 Page 53 Section 4 1 signal the horizontal vertical sync signals and an 11V supply are used to operate the screen On the SE board or the PLC interface board the V 24 signals of the handwheel unit HE 310 are connected to the line drivers or respectively to the line receivers 62 A serial interface module 43 on the CLP gra
34. aults 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 permis sible entry values HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SEV MANGAN INS bol D 8225 Traunreut Tel 08669 31 0 Page 3 Section 2 2 1 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 HEIDENHAIN TNC 151 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 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 HEIDENHAIN SERVICE MANUAL TNC 151 DR JOHANNES HEIDENHAIN GmbH Page 4 Section 2 2 2 2 1 D 8225 Traunreut Tel 08669 31 0 Kundendienst 2 2 Flow diagrams for fault location Fault in TNC
35. cro commands 0 0 display Scaling cycle effective for the programmed scaling factor is effective in 2 or 3 axes the 3 main axes X V Z in the working plane Programmed stop with M 06 Programmed stop with M 06 No programmed stop with M 06 the programmed scaling factor is only effective SERVICE MANUAL TNC 151 Page 77 Section 4 4 Temporarily unassigned enter Temporarily unassigned enter 2 Program entry in HEIDENHAIN dialogue Program entry in ISO format Parameters for definition of the V 24 RS 232 C interface bran Standard data interface or atandard data interface Transfer blockvize Transfer blockwise Parameter for definition of the V 24 RS 232 C interface see Programmed stop with M 06 CYCL CALL possible with M 89 CC Call with M 89
36. cted by loading the Burn In test program 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 ae HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst POWER INTERRUPTED EXTERNAL DATA INPUT 6 After completion of a sucessful data transfer the ME unit will rewind the cassette and the VDU will display the question EXTERNAL UNIT CONNECTED Any other display implies either a transmission error or an incorrect faulty test program cassette SERVICE MANUAL TNC 151 Page 27 Section 2 2 6 Loading of Burn In test program Connect ME to V 24 socket of Control Apply mains supply to both units Press kel on ME Wait for display POWER INTERRUPTED following MEMORY TEST Press Pro on Control as often as necessary to obtain display CODE NUMBER Program loads whilst Control displays POWER INTERRUPTED EXTERNAL DATA INPUT Turn over cassette when Control displays EXCHANGE CASSETTE ME START i EXTERNAL DATA INPUT Press Z on ME Remainder of program is read into the Control Fig 7 Loading and Initialization of
37. cuit of the machine for checking routine see Mounting Instructions and Interface Circuit Control Machine manual TNC 151 A TNC 151 P 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 TNC 151 A TNC 151 P Defect in Control machine interface SERVICE MANUAL TNC 151 Page 8 Section 2 2 2 Possible fault location Measuring System Analogue Board Analogue Board PLC I O Board TNC 151 P PLC Interface Board TNC 151 P SE Board TNC 151 A Terminal Board TNC 151 A Machine cams switches reference end position or reference pulse inhibit PLC I O Board TNC 151 P PLC Interface Board TNC 151 P SE Board TNC 151 A Terminal Board TNC 151 A 5 HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MMIUAE ING 292 D 8225 Traunreut Tel 08669 31 0 Page 9 Section 2 2 2 Kundendienst VDU Display flashing Fault cause Possible fault location EMERGENCY STOP PC With standard PLC program faulty reply Terminal board TNC 151 A from output A6 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 GROSS POSITIONING ERROR A Trailing error greater than value entered in MP 174 In the Case of Gross Positioning
38. culated analogue output vol see above tage implied by trailing error is greater than 10 V GROSS POSITIONING ERROR C The analogue output voltage actually neces see above sary to obtain a desired speed deviates from the expected calculated voltage by more than the voltage programmed in MP 234 GROSS POSITIONING ERROR D The actual position at standstill deviates see above from the intended position by more than the distance programmed in MP 169 TNC OPERATING TEMP EXCEEDED Ambient temperature inside Ambient temperature of Control the TNC has exceeded 65 C Fault in the temperature supervision Analogue Board HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 N D 8225 Traunreut Tel 08669 31 0 Page 11 Section 2 2 2 Kundendienst CRT display flashing Fault origin Possible fault location ERROR IN PLC PROGRAM Fault with safety related marker see PLC Description manual TNC 155 A TNC 155 P pages 36 40 Le A Start Key PLC Program Main Processor Board Error with safety related marker oom e B Rapid traverse key We h d EO C Direction latch key 7 WW E v m B D Feed release ui d TM E Start PLC positioning X axis a bt S o o F Start PLC positioning Y axis bg vr 2d G Start PLC positioning Z axis T We e mum H Start PLC positioning IV axis n P x n e um I Direction key X hi Mi 8 J Direction key X co
39. e parts can be ordered from the department Kundendienst Customer Service at HEIDENHAIN Traunreut It is of utmost importance when ordering to give i the Id No ii the name in German and iii the quantity of each part required Telexed order should be sent to the Kundendienst Telex 17 866 982 or Teletex 866 982 SERVICE MANUAL TNC 151 Page 48 Section 3 4 Loan Exchange 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 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
40. e programmed EPROM Id No hexa decimal counting manner The EPROM package index must point in the same direction as the ICs on the board Visually check if the EPROMs are contacting their respective sockets after an exchange SERVICE MANUAL TNC 151 Page 47 Section 3 3 After the software exchange has been concluded the Id Nos of the NC and PLC software have to be changed The description plate for the software numbers is found on the rear of the Control under the type plate Id No NC Software No KAAL V 11 8A 300 208 ZA 50 00 Hr The RAM memory of the Memory Board is unbuffered during the EPROM software exchange The machine parameters and any stored user program are therefore erased For continued operation the machine parameters have to be re entered into memory 1 N TICA IMITA DR JOHANNES HEIDENHAIN GmbH hd D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 4 Replacement Parts Loan Exchange Service Units Units Replacement Parts TNC 151 In general replacement parts are available for all sub assem blies discernible from the wiring diagrams see section 4 3 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 HEIDENHAIN 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 Thes
41. ecognition 73 is immediately effective and causes the overvoltage protection thyristor 73 1 to connect through Thus Ul is short circuited coming directly from the power supply transformer 74 via the rectifier 75 A greater damage at the subsequent electronics is thus inhibited by means of this protective measure SERVICE MANUAL TNC 151 Page 54 Section 4 1 MEIPVENMAIN ea DR JOHANNES HEIDENHAIN bH Gm D 8225 Traunreut Tel 08669 31 0 Kundendienst 4 2 Block Diagram TNC 151 Block Diagram Drawing Number Page Arxengement 4820 EKD 1603300 56 PLC I O Board 4820 EKD 1605100 57 Power Supply 4820 EKD 1605200 58 Terminal Board P Version 4820 EKD 1605000 59 Terminal Board A Version 4820 EKD 1604800 60 PLC Interface Board 4820 EKD 1604900 61 SE 1 0 Baord 4820 EKD 1604700 62 Main Processor Board 4820 EKD 1603400 63 CLP Processor Board 4820 EKD 1603700 64 CLP Graphic Board 4820 EKD 1603800 65 Analog Board TTL Impuls 4820 EKD 1603600 66 Analog Board 4820 EKD 1603500 67 Memory Board 4820 EKD 1603900 68 Memory Board 4820 EKD 1604000 69 SERVICE MANUAL TNC 151 Page 55 Section 4 2 PLC jEin Ausgang RS Netzteil Platine Zeichnungs Nr 4820 E KD 16025 00 Interface Platine Platine P Version Platine A Version GA mupu OE A UJ Tastatur Platine Haupt Rechner Platine Regelk
42. ed 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 07 The test program 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 neccessary to have a set of Burn In Test Adapters Figs 2 to 5 show pictorial and schematic representations of each individual adapter SERVICE MANUAL TNC 151 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 un
43. ergency 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 pressing 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 E after a short delay the VDU will display the input condi tions when only output 0 is being driven high HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst eg INPUTO1234567890123456789 0 10000000000000000000 20 00000000000010000000 40 00000000000000000000 60 0001 i 3 k f b a 1 OUTPUT AO INPUTS EO E32 Subsequent pressing of the key allows successive outputs in ascending order to be driven high or in descending order with the key All outputs can be cleared with the key D Key 7 EXT POT ANALOG OUTPUT TEST Five external relays within the TNC 150 A P Burn In Adapter driven from outputs A16 A20 are used to connect the ana logue outputs X Y Z IV S in turn to the ext pot in put see figs 2 3 pages 22 23 The test is made at three different voltages Key TEST V24 INTERFACE Key 9 TEST 3D SCANNER INTERFACE Checks the interface to the Touch Probe
44. fers from the standard NC Software in EPROM position IC P3 The dot matrix for all VDU displayed characters is contained in IC P19 character generator GR HEIDENHAIN SERVICE MANUAL TNC 151 DR JOHANNES HEIDENHAIN GmbH Page 46 D 8225 Traunreut Tel 08669 31 0 Section 3 3 Kundendienst Illustration left Arrangement of PCBs in the Control Illustration below Arrangement of EPROMs on the various boards Em eim FEE BE PEN EEN DO pm ref 2 Memory Board 224 843 3 Main Processor Board 222 509 4 CLP Processor Board 222 580 230 400 HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Software Exchange Caution When exchanging the software observe the MOS protection procedures 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 Memory Board 2 Main Processor Board 3 CLP Processor Board 4 have to be removed from the assembled Control Thereto lift the board ejector keys and press outwards pull out board from above and lay onto MOS protection mat o Push screwdriver blade carefully between EPROM and socket remove EPROM with extraction tool and place onto MOS protection mat o Insert EPROM into appropriate socket using insertion tool Important When exchanging EPROMs observe the position number second to last digit of th
45. ge Information Note All inputs outputs from the TNC 151 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 tape W s HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 D 8225 Traunreut Tel 08669 31 0 Page 37 Section 3 1 3 1 1 Kundendienst 3 1 Exchanging Control Units 3 1 1 Procedure for exchanging the TNC 151 A E Control 1 Gain access to the rear of the Control 2 Remove the mains supply Ges i 4s ERN 3 Remove the connector box cover plate from the rear of the i a Control 4 Mark the measuring system plugs X Y Z IV Electronic Handwheel and remove them 5 Disconnect the VDU from the Control 6 Disconnect the Handwheel Unit from the Control if present u 6 12 3A 7 Disconnect any external data devices 8 Disconnect connector strips Jl J6 using a screwdriver to prise the connectors apart Do not unscrew individval wires Handwhee oe os 90900000000000 EEE esa BA NG OE NAE a 1 23543 IT prise apart with a screwdriver Remove the faulty Control removing the fixing screws
46. i w Program run interrupted by E N D i For further explanation e vou displays see the corresponding EXTERNAL UNIT CONNECTED section of the written DI rz explahation on pages 29 om O and 30 H ri gt vo Y Respond with m OUO Edo na YN VDU displays 1 REREAD IN PROGRAM XXXX CHECK SUM ERROR Keyboard test already carried out yes no Program run interrupted by EI Error messaae stored yes VDU displays BI SOPTWARE NUMBER XXX Xxx xx JUMP OVER KEYBOARD TEST am Program interrupts ENABLED yes Vim yes Program interrupts ENABLED Program run interrupted by el VDU displays Jump to sequential O 1 OR 2 PC BOARD iis Enter O 1 or 2 tests see page 32 Program run interrupted by EJ Program interrupts ENABLED Calibration of front panel potentiometers DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 HEIDENHAIN Fig 9 Complete initialization of the Burn In test program Kundendienst HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH pu D 8225 Traunreut Tel 08669 31 0 Kundendienst Sequential duration tests Before starting these tests check that all test adapters are correctly connected including the connection to the V 24 inter face socket The following tests are included a b c a e g Key TEST INT POT BATTERY TRIGGER Front pa
47. it the issue of the NC Software can be determined from the NC Software issue number Both these numbers are found on the type plate on the rear of the Control SERVICE MANUAL TNC 151 Page 19 Section 2 2 6 DR JOHANNES HEIDENHAIN GmbH CETT D 8225 Traunreut Tel 08669 31 0 NN TAKEN EATING Application of the Burn In Test Kundendienst Application of Burn In Test Dismantle the Control and VDU from the machine tool Load and run Burn In Test Burn In Test OK Burn In error message on VDU x Defective board send to Heidenhain for repair Ka Board change according to instructions on the VDU Send Control and VDU to Heidenhain for repair Where appropriate ask for loan or exchange unit Control and VDU ready for use again ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Burn In Test Programs for TNC 151 A on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialogue Id No A EET DTM eee TNC 151 A 229 134 99 wes se 06 D 230 600 O1 229 134 95 TNC 151A 229 134 99 swa wee O6 GB 230 601 01 229 134 95 SERVICE MANUAL TNC 151 Page 20 Section 2 2 6 Burn In Test Programs for TNC 151 P on the Philips miniature cassette From Control Control NC Software Test Test Prog Type Id No issue dialogue Id No TNC 151 P 229 136 99 so 06
48. led to the gate arrays 42 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 40 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 50 SERVICE MANUAL TNC 151 Page 52 Section 4 1 The signals from the handwheel if present are shaped via the functional block 53 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 155 AR 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 50 on this analog board whose outputs are directly con nected to the gate arrays 42 on the CLP processor board The supervision signal of the EXE is also buffered 50 and transferred to the CLP processor board The signals of the handwheel are likewise processed 53 as on the normal sine analog board If instead of linear position
49. lij HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH N D 8225 Traunreut Tel 08669 31 0 Kundendienst 3 2 Board Exchange Board Arrangement The TNC 151 consists of three main sections 1 The frontplate Keypad Board assembly 2 The housing Connector Board assembly with five plug in boards namely Memory Board Main Processor Board CLP Processor Board Analogue Board either SE Board TNC 151 A E or PLC Interface Board TNC 151 P V 3 The backplate Power Supply Unit and Terminal Board assembly SERVICE MANUAL TNC 151 Page 40 Section 3 2 Board arrangement TNC 151 A AR P PR TNC 151 E ER V VR PLC 1 0 Board TNC 151 P 224 389 223 691 enn Connector Board 227 267 Terminal Board 228 164 228 166 Power Supply Board 227 601 PLC Interface Board 226 761 with TNC 151 P V SE Board m 227 278 E with TNC 151 A E Analog Board 222 502 223 550 CLP Processor Board e 222 580 229 133 Main Processor Board 222 509 Memory Board p 224 843 230 400 ER Keypad Board 224 825 EN MHEIDENFIJAIINM DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 086 69 31 0 Se MANDAL TNG TAL Section 3 2 Kundendienst Caution Please observe MOS protection measures when exchang Work area requirements ing boards The TNC 151 contains sub assemblies with MOS elements Exchange boards with the same assembly no only Although MOS ICs are equipped with an input protectio
50. lts in the standard PLC program The input E63 is used to indicate an overloaded output to the main processor 30 PL 100B 31 unipolar programmable outputs emergency stop protected against overload 26 unipolar programmable outputs 5 bipolar outputs and emergency stop protected against overload On the PLC I O board a 12V voltage is generated by an external 24V supply On the PLC interface board this 12V voltage is transformed in a 5V voltage for its TTL modules PL 110B ee EE ko EES EINMANN DR JOHANNES HEIDENHAIN GmbH N D 8225 Traunreut Tel 08669 31 0 Kundendienst CLP Processor Graphic Unit Primarily on the CLP processor graphic board Operating system is contained in EPROM IC P3 40 1 32k x 8 The main task is the calculation of the instantaneously intended values of the analog output voltages dependent on the instantaneous actual positions ethe 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 40 2 The measuring system signals are processed on the analog board These signals are amplified at first 50 1 and then subdivided 50 by delaying phase shifted and combining them differently The subdivided 0 degree 90 degrees and RI signals are then
51. m D K Direction key Yt e won 9 L Direction key Y E P x M Direction key Z 5 2 N Direction key Z s ai BE Oo Direction key IV S 2 oom P Direction key IV ii n m om Q Undefined macro called up via PLC marker Kundendienst HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 VDU Display flashing TNC ELECTRONICS DEFECTIVE 0 CRC MID D H BUAWPWNE Om o Cyclic Redundancy Check Macro Instruction Detection Fault cause False CRC CHECK SUM of machine related data exclu ding 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 Processor CLP Processor RAM Overflow interrupt MID interrupt Main Processor Equipped with incorrect language version RAM E FFEFF Main Processor SERVICE MANUAL TNC 151 Page 12 Section 2 2 2 Possible fault location 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 P
52. n diode The assembly no is impressed on every board on the network to eliminate the build up of static charges care must left of the serial no 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 impress with stamp and work personnel must be properly grounded Assembly No Series No A portable MOS HANDLING SET for field service is necessary when exchanging the operating software and or servicing the TNC 151 1 a conductive work surface 2 a wristband that provides an electrical connection between person and conductive work surface 3 a cable that equalizes potential differences between conductive work suface and ground aj HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Exchanging the pluggable boards Unscrew the 5 mounting screws and remove the housing cover Removing the boards Press the board ejector keys outwards and pull out the indi vidual board form the top SERVICE MANUAL TNC 151 Page 42 Section 3 2 Analogue Board Before removing the Analogue Analogue TTL Board pull off and mark the connector plugs for the measuring system inputs square wave signal inputs and the electronic handwheel in put The connector sockets on the board are coded with coding pins Inserting the boa
53. n test programm press Continuation as per figure 9 E Fig 8 Re initialization of a previously loaded Esc l test progr m E S E HEIDENHAIN 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 31 1 2 Beginning with the display EXTERNAL UNIT CONNECTED which refers to the use of an external test computer the operator must respond by pressing EI 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 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 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 a eg Ga vo vo E Fu KE SSS s SERVICE MANUAL TNC 151 Page 29 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
54. n the system SERVICE MANUAL TNC 151 Page 14 Section 2 2 3 Testing of the VDU amp associated circuitry Exchange the VDU Send vDU to HEIDENHAIN for repair Replace original VDU Test 11V supply pins 23 24 cf VDU Socket on rear of TNC w r t pins 21 22 voltage correct Test amp repair PSU section 2 2 4 Test connections from CLP Processor Brd to VDU Socket then replace orig CLP Processor Board Fauit cleared No Exchange VDU AND CLP Processor Board Send entire TNC amp VDU to HEIDENHAIN for repair Send VDU and CLP Processor Board to HEIDENBAIN for repair Order exchange unit if required TNC ready for use Testing of the VDU and associated circuitry E HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst 2 2 4 Testing of the mains supply and 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 voitages at various points on the Power Supply Board The diagram below and the table opposite show the locations of the test points solder ter minals on the Power Supply Board and the respective nominal and actual test voltages under load black OV TTL brown 12 Processor supply red 5V TTL grey 15V Switching reg blue OV Display U
55. nel potentiometers must be set to 100 2 Key 0 EPROM TEST CPU The check sums of all EPROMs accessible to the Main Processor Board CPU are checked Key 1 RAMTEST CPU BOARD Checks the RAM on the Main Processor Board Key 2 RAMTEST MEMORY BOARD Checks the RAM on the Memory Board This test must not be interrupted by a mains failure Key 3 TEST PC RAM Checks the RAM where the PLC data is held markers inputs outputs timers counters etc Key 4 TEST STATIC RAM CLP PROCESSOR BOARD Key PC INSTRUCT DECODER ACCU FF TEST The circuitry used for decoding and carrying out the PLC instructions is tested SERVICE MANUAL TNC 151 Page 32 Section 2 2 6 h Key 6 INPUT OUTPUT TEST 1 PC BOARD only TNC 151 P The PLC I O Board outputs are resistively loaded and connec ted to the inputs by means of the PC 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 PLC BOARD OUTPUT or input FAILURE INPUT 01234567890123456789 0 01111111111111111111 20 1111111 1111 01111111 40 111111111111 1111111 60 1111 BURN IN TIME x x HRS always a zero Input 31 is used to monitor a 20 ms monostable pulse genera ted on the Em
56. nit green 15V Analogue Board yellow 45V Switching reg white 11V Display Unit green white Reset yellow white 22V Display brown white 4 2V Heater brown white 21V Mains transf sec voltage 21V Mains transf sec voltage 2 1V L Mains transf 2 1V 7 sec voltage no connection mern ti NA bt Dm Pine OD SU UN PR 10 11 12 not used with TNC 151 Signal designations for the plug and test points SERVICE MANUAL TNC 151 Page 15 Section 2 2 4 Power Supply Board Connector on Power Supply Fuses Fl and F2 not used on TNC 151 Test points on the Power Supply Board ri uw ri o Z E dw Se Q Hog Uno bop K MO amp d o W Pa Ww DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Wm HEIDENHAIN Kundendienst Procedure for testing the Power Supply Unit Disconnect mains _ EL S pig E M No Adjust as necessary No Replace as necessary ee WEE Voltage selector correct Yes Correct fuse present an intact Yes en i Remove backwall Disconnect PSU connector from Connector Board Restore mains Disconnect transformer secondary from Power Supply Board terminals 1 2 3 amp 4 Sec voltages OK Possible transformer fault x Reconnect transformer secondaries to Power Supply Board hominal PSU voltages ATTENTION return defective The voltages
57. nt panel 216 394 Geh use kompl Housing assy 225 037 Geh use Tastatur Vorsatz ISO format keypad 224 843 Pl Speicher 3160 S tze Memory Brd 3160 Blk 230 400 Pl Speicher 1280 S tze Memory Brd 1280 Blk 222 502 P1 Analogteil Sinus Analogue Brd Sinewave 223 550 Pl Analogteil TTL Analogue Brd TTL 222 509 Platine Hauptrechner Main Processor Brd 222 580 Pl Regelkreisrechner CLP Processor Brd 227 601 Platine Netzteil PSU Board 212 387 Platine Entst r Mains Filter Board Page 49 Section 3 4 MEG LIVIA IN DR JOHANNES HEIDENHAIN GmbH N 0 6225 Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 Page 50 Section 4 4 1 4 Additional Information 4 1 Block Diagram Description General The TNC 155 block diagram shows in simplified form the inter nal functional units of the control their relationship to the various boards and their interconnections The graphic layout of the diagram and the way it is included in single sheets the representation of any of the TNC 155 models A AR P PR simplified representation of functional processes Numbers enclosed in dashes inform about the board and its functional unit e g 50 1 bL Subdivision of functional unit Functional Unit Board Simplified Description of the TNC 155 Block Diagram Keypad Board 1 Memory Board 2 Main Processor Board 3 C
58. ory Board Memory Board Memory Board Memory Board Memory Board Memory Board CLP Processor Board CLP Processor Board CLP Processor Board export version CLP Processor Board export version Main Processor Board Eu FILIPINA HIN DR JOHANNES HEIDENHAIN GmbH NGA gt 3225 Traunreut Tel 08669 31 0 Kundendienst 2 2 3 Testing of the VDU and associated circuitry The first objective is to determine whether 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 asscociated circuitry in which case repairs may be possible without returning the unit The Display Units BE 111 and BE 211 are powered 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 when 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 i
59. phic 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 the PLC interface board 63 and are evaluated via the counter module 42 on the CLP processor graphic board EN FEIUBENFALHN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Power Supply Unit 5V are generated for the TTL modules via the forward converter 70 The flyback regulator 70 1 inductively coupled with the flow converter generates 15V for the operation amplifier The 12V supply voltage for the V 24 interface is generated with the help of the 15V by means of a linear regulator 70 2 11V are generated via the forward converter 70 3 for the TNC 151 BE 111 BE 211 screen which in contrast to tbe TNC 155 BE 411 screen does not have an own power supply unit The switch regulator 70 01 and 70 31 readjust the output voltage load controlled The soft start 71 limits the relatively high switch on current On the power supply board there is moreover a voltage supervision 72 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 operation for a short time If U2 45V exceeds if there is a failure the overvoltage r
60. po kompl i Fr sel lo 46 Flor Pf fe o B ohne Funktion DE 13 maset 9 SV nicht belegen He a H 15 4 30 i 1 om Mu ze 8 asv 3 pegnen i p ped 7 120 luet Synen 38 Tet Danket ma m l f g frei video Ag it 25 di Ao KZ Platine Netzteil D Jose 20 frei P2 KAN 20 mer Sa tre 21 Jav am i 22 5 a Platine PC Interface 2 ov 11 2 frei 23 Tur am Gnd aik aai 2 ar EE a er La E 12 rei 24 e 26 fV Bogscbem zur BE 24 pol kompl si 28 Ov Bidschurm bl p o HH 3L SE A Y fans se d al ME 16 pol kompl i Bd oe Platine Stecker a gei en bine Sika pu aa Futrer 10 5 frer H Kite Ha DIA Sats 12 5 620SR 174 HA H Fate he nhi S z Ag 4 LS ha J5 325 e lo PI H P2 de e JA E Platine Analogtei ab EM Pil H ES SE S 4 wos es Bloe nati i E Spannungsw hler m Sicherung EES i Pi Ri Rechner Si latine me i er o JG e rp i i Te ales f nl ra ma EE 7 D 3 ye e al pr aT 4 1 tt Butikk a E B in b i 8 Wee Platine Speicher l d i 1 Entst r t Netzteil kompl I nm e sere amt A 2 a y hal EH E ve no ay al re I AA 4 Z a mm gh H3 jth or ov TE MT T t tt Netzklemme kompl e m Dal Ferner 062 F TE A Te TL ws sa L N M sene gt fate uoo ES te n SARA y Iv mye PT Des leo f ved Ban one Tastatur vo2 Iw poso E Pi rmi El zc Lar P2 E CH CH ETE rm Es a FE L
61. proach speed 53 Q 1 10 m min Acceleration 0 001 1 5 mi SE EM Position supervision eraseable 0 001 30 mm Position supervision emergency stop Position window X Y Z Axis sequence for reference point approach i m 3 um x e m om wow Speed pre control Output of tool numbers o No output Output only when tool number changes H Output of toot number with e too call No output of spindle rpm Coded output only when rpm changes Coded output of all rpms S Analogue voltage output Gear switching signal only when gear ratio changes 4 S Analogue voltage output Output of gear swithcing signal with every tool call Analogue ad output without gear Output of spmdie speeds codes or as S analogue voltage WN O Ho NP rpm coge limit Oscillatio _ when accelerating 0 01 0 999 Display resolution LO tm A Sym 7 internal potentiometer for override and manual feed t external potentiometer for override and manual feed 2 internal potentiometer for override external potentioma External feed rate potentiometer D time rotation change of spindle in tapping cycle Bil io dd Ja Lea GE DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst o kei ky dese borse OP 2 3 got 29 on ish procedure fo reference point o fo en 7 omi volue voltage fc re EES
62. rds 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 Board When exchanging these boards insert program EPROM s IC P3 and IC P19 on the CLP Processor Board and IC P4 to IC P10 on the Main Processor Board Memory Board During the exchange or removal of the Memory 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 Memory Board plug in the relevant EPROMs EPROM IC P11 to IC P18 paying particular attention to their correct location and orientation ES HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH SERVICE MANUAL TNC 151 SUBA 0 5225 Traunreut Tel 08669 31 0 Page 43 Section 3 2 Kundendienst Exchanging the Keypad Board Remove the 6 cross head fixing screws from the frontplate Tilt the frontplate outwards f Remove connectors J13 feedrate override potentiometer and J14 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 P1 to P8 from the Keypad Board Remove the Keypad Board P9 is not used with the TNC 151 m G ft DE KC a TY i menbra o d 4 p
63. reis Analogteil Speicher RECHNEN Platine _ Platine Platine TNC 151 3160 S tze TTL Eing nge 4 5 Regelkreis Grafik Platine TNC 155 Speicher Platine Si Eing nge 1280 S tze i inus Eingange INC 151 Analogteil Platine Anordnung der Blockschalt bilder und Platinen f r TNC 151 155 2 Lee eeh ne do s EE c CRU Adress i Bus Interface Platine EN NI zu 2 externen Referenzimpuls Sperre X Y 2 IV Referenzimpuls Sperre PL Ein Ausg Platine zu PLC interface Platne CRUIN2 von der 2 PLC Ein Ausg Platine CRUIN 2 zu L Interface Platine CRUIN 1 zu ___PAC Interface Platine _ 1 63 Eing nge E1 zu 2 PLC Ein Ausg Platine pj Maschinen Schnittstelle Leitungs ma e et 31 Ausg nge treiber CRUOUT CRUCLK von DU Inter face Platine din a Reset 7 Strom NOT AUS zu 2 PLC berwachung Ein Ausg Platine NOT AUS von PLC Inter face Platine NOT AUS nn m a Blockschaltbild TNC 151 155 Zeichnungs Nr 4820 E KO 1604500 Extern PLC Ein Ausgang Platine 15V 70 1 Sof istart Ugef 1 Sperrwandler UH Netz trans formator Gleich tichter Flu wandler 70 mit Tiefpat filter Leistungs schalter Schalt regler TL 494 spannungs er kennung Uber wa t FluAwandler 70 3 mit Tiefpaf filter
64. rocessor 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 Zu HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst VDU Display flashing CHECK SUM ERROR XX00 XX02 XX04 XXOA XXOB XXOC XX10 XX17 XX18 XX1A XX1C XX1F XX20 XX21 XX22 XX23 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 CRC CLP the CRC CRC CLP n n n n w Ui n CHECK SUM Processor operating CHECK SUM CHECK SUM Processor ating program CRC CHECK SUM with EPROM J co x with EPROM with EPROM with EPROM with EPROM o o with EPROM with EPROM with EPROM with EPROM with EPROM with EPROM N A KH a D D D vv vo Oo u error in RAM area on the Board in which a part of program is stored error with EPROM 3 error in the RAM area on the Board where part of the oper is stored error with PLC RAM PLC Marker 2815 is set SERVICE MANUAL TNC 151 Page 13 Section 2 2 2 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 Mem
65. tep 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 TEST INT POT BATTERY TRIGGER OVERRIDE POT ADJUST 100 SP ROT SPEED ADJUST 100 If necessary the caps of the 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 foa Ce ux Gara CALL ALL for example cause restarts at various points during the initialization routine as shown in figs 8 and 9 System re boot EXTERNAL UNIT CONNECTED ES CAL JUMP OVER KEYBOARD TEST CALL O 1 OR 2 PC BOARD TEST INT POT BATTERY TRIGGER OVERRIDE POT ADJUST 100 SP ROT SPEED ADJUST 100 a SERVICE MANUAL TNC 151 Page 30 Section 2 2 6 Other interrupts are also possible these are described in the following section Re initialiration of Load ng the Burn In ri DN existing Burn In test test program w o program see fig 8 Ae age fig 7 ri s NG T UT E o Sg pA Y Program interrupts E DISABLED
66. ternal electronics a TNC OPERATING TEMP EXCEEDED b EXCHANGE BUFFER BATTERY c TNC ELECTRONICS DEFECTIVE 0 3 A K Example of fault with measuring system X MEASURING SYSTEM DEFECTIVE Example of fault on machine tool GROSS POSITIONING ERROR A SERVICE MANUAL TNC 151 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 ASIS 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 O 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 A non flashing error message can be cleared by pressing the CE key on the TNC after which normal operation may resume list of error messages is given on page 7 IN HEIDENHAIN SERVICE MANUAL TNC 151 DR JOHANNES HEIDENHAIN GmbH i D 8225 Traunreut Tel 08669 31 0 Page 6 Section 2 2 2 Kundendienst Error message EXCHANGE BUFFER BATTERY Partic
67. 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 2 IV are inhibited on the analog board 50 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 61 and 60 ZEE MEDEN MAIN Y 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 DAC 52 1 digi tal analog converter These voltages are compared with the adjusted values of the override and feed potentiometers 52 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 DAC are allocated to the single axes by means of five sample and hold circuits 52 2 The five individual an
68. ular mention should also be made about the implications of the instruction to exchange the buffer battery If the dialogue 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 Flashing The battery needs to have TEC 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 Not flashing Error Message Harmless error no Emergency Stop eg User or programming error Serious fault Emergency Stop eg X MEASURING SYSTEM DEFECTIVE Switch off Control and remedy
69. ulty Control removing the fixing screws if not already removed in 1 11 Install the new Control check the voltage selector posi tion 12 Check the fuse rating see type plate 13 Reconnect all cables previously removed 14 Obtain from the type plate the Control s Id No NC and PLC Software Nos and write them in the machine handbook 15 Refit the connector box cover plate 16 Turn on the mains voltage 17 Reprogram the machine parameters 18 TNC is now ready to use NIE LP EM AAA DR JOHANNES HEIDENHAIN GmbH MA D 8225 Traunreut Tel 08669 31 0 oe MANUAL TNC 151 age Kundendienst Section 3 1 3 3 1 3 Procedure for exchanging the PLC 1 0 Board of the PL 100 B 110 B Remove the fixing screws of the heatsink cover plate Remove the heatsink cover plate Disconnect the TNC 151 connecting cable 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 RUNE LI is amor hai NC Y ST g DEE 14 ONS Sa SE BONS TTL m BIER be Ionen s mm Ee Di AD y 1 Ea 1 E og ats 7 a La 2 5 b A20 A21 H 1 AG m e A29 5 sap Output for current supervision tor bipolar Outputs a
70. y of analogue output DAC ANALOG OUTPUT LINEARITY Battery voltage check TEST BATTERY VOLTAGE text in brackets appears on VDU these tests are not suitable for use see following explanations i HEIDENHAIN DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Kundendienst Key 2 Analogue output voltage The performance of the analogue output circuitry can be checked by connecting a DVM to each of the analogue outputs eg X axis Ji pinl w s t pin 2 and selecting this test Using the keys voltage increments of 2 44mV 24 4mV 244mV and 2 44V respec tively can be summed at at each of the analogue outputs X Y Z IV S eg if the X key is pushed 5 times the Y key 3 times and the IV key once the output voltage should read 5 x 2 44 mV 3 x 24 4 mV 1x 2 44 V 2 5254 V The polarity of the output can be reversed using the key YA The output can be cleared using the key o Key 5 10V analogue output The analogue outputs should generate their maximum output of 10V The polarity can be reversed as in test 2 Key 7 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 Page 35 Section 2 2 6 EN HEIDENHAIN SERVICE MANUAL TNC 151 oed DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 0 Page 36 Section 3 Kundendienst 3 Exchan

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