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HEIDENHAIN TNC151B, Service Instructions Manual

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HEIDENHAIN TNC151B Service Instructions Manual Download Page 89

Summary of Contents for TNC151B

Page 1: ...further developments of its TNC Controls It is therefore possible that details of your Control may differ slightly from those described herein If that is the case please order a suitably revised issue...

Page 2: ...ng of the Power Supply Unit 15 2 2 5 Testing of the measuring systems and wiring 17 2 2 6 Burn In Test 18 3 Exchange Information 3 1 Exchanging Control units 3 1 1 Procedure for exchanging the TNC 151...

Page 3: ...nd Interface Circuit Control Machine PLC Description SERVICE MANUAL TNC 151 155 Page 2 Section 1 The TNC 151 155 Service Manual is used for the diagnosis localisation and remedying of faults on TNC co...

Page 4: ...form the procedure for exam ining the complete installation In addition the HEIDENWGN TNC 151 155 Contouring ContrOl includes an extensive integrated supervision system for the avoidance of entry ope...

Page 5: ...N GmbH D 8225 Traunteut Tel 08669 31 O Kundendienst SERVICE MANUAL TNC 151 155 Page 4 Section 2 2 2 2 l 2 2 Flow diagrams for fault location 2 2 1 Fault diagnosis for the complete installation Control...

Page 6: ...EXCEEDED b EXCHANGE BUFFER BATTERY c TNC ELECTRONICS DEFECTIVE O 3 A K example of fault with measuring system X MEASURING SYSTEM DEFECTIVE example of fault on machine tool GROSS POSITIONING ERROR A Th...

Page 7: ...wards The battery needs to have IEC designation LR 6 and must be of the leak proof type We especially recommend the use of VARTA Alkaline batteries type 4006 With discharged or missing buffer batterie...

Page 8: ...4 EXCHANGE BUFFER BATTERY TRANSFERRED DATA INCORRECT ME CASSETTE MISSING ME CASSETTE LOClcED NE WRONG MODE SELECTED ME WRONG PROGRAM DATA ME CASSETTE EMPTY ME PROGRAM INCOMPLETE ME TAPE END WRONG PROG...

Page 9: ...ng system supervision damaged Fault in the emergency stop circuit of the machine for checking routine see Mounting Instructions and Interface Circuit Control Machine manual Defect in Control s interna...

Page 10: ...or the continuous po sition supervision determined by MP 57 see Mounting Instructions and Interface Circuit Control Machine manual Relationship between output voltage and traversed distance outside of...

Page 11: ...trailing error is greater than 10 V The analog output voltage required to obtain a desired speed deviates more from the calcu lated voltage than the voltage programmed in MP 234 The actual position at...

Page 12: ...ositioning X Direction Latch Key or incremental positioning Yt Feed Release or incremental positioning Y Start PLC Positioning X axis or incremental positioning Zt Start PLC Positioning Y axis or incr...

Page 13: ...ault cause Error with non erasable marker see also PLC Description Directional Key Zt Directional Key Z Directional Key IV or supplementary axis to be changed to another axis M 2590 and M 2591 Directi...

Page 14: ...Processor CLP Processor False instruction display mode Main Processor CLP Processor CLP Processor RAM Overflow interrupt MID interrupt Main Processor Equipped with incorrect language version RAM EOOO...

Page 15: ...error in RAM area on the CLP Processor Graphics Board in which a part of the operating program is stored CRC CHECK SUM error with EPROM 2 CRC CHECK SUM error in the RAM area on the CLP Processor Grap...

Page 16: ...ed 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...

Page 17: ...e fault is not due to the detective power supply it is likely to be due to the CLP Graphics Board which contains the control circuitry for the Display Unit This can be verified by exchanging the board...

Page 18: ...points on The Power Supply Board under load Test Data Old Power Supply Board 227 601 I for TNC 151 155 The diagram below and the table opposite show the locations of the test points solder terminals o...

Page 19: ...le below show the locations of the test points solder terminals on the new Power Supply Board 230 802 and the respective nominal and actual test voltages under load Previous INC 155 Controls may be fi...

Page 20: ...r return defective board unit to DR JOHANNES HEIDENHAIN for return where appropriate order y ge...

Page 21: ......

Page 22: ...se 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 Sup...

Page 23: ...I...

Page 24: ...st Programs for TNC 155 B F Burn 111 Test Programs for TNC 155 Q W on the Philips miniature cassette on the Philips miniature cassette Control Control Type Id No FIXIUI NC Software Test issue dialog T...

Page 25: ...ins thb procedure for testing older TNC 151 155 versions and is therefore to be used as a guide only for the newer TNC 151 155 controls described in this manual An updated section pertaining to the ne...

Page 26: ...DENHAIN GmbH D 8225Traunreut Tel O8669 31 O Kundendianat Fig 1 Interconnections of Burn In Adapters and TNC 151 155 B F 1 0 I TNC 151 B F SERVICE MANUAL TNC 151 155 Page 21 Section 2 2 6 a TNC 151 B F...

Page 27: ...Fig 1 Interconnections of Burn In Adapters and TM 151 155 Q w BE 211 111 i 0 0 TNC 151 a w I I TNC 151 a w SERVICE MANUAL TNC 151 155 Page 21 1 Section 2 2 6 TNC 155 Q W r I a TNC 151 Q W b TNC 155 Q...

Page 28: ...HtlUtNHAlN DR JOHANNES HEIDENWN GmbH D 8225Traunreut Tel 08669 31 0 Kundendienst SERVICE MANUAL TNC 151 155 Page 22 Section 2 2 6 Fig 2 Burn In Adapter TNC 151 155 A n Id No 233 514 ZY...

Page 29: ...JOHANNES HEIDENHAJN GmbH D 8225 Traunreut Tel 08669 31 O SERVICE MANUAL lWC 151 155 Paqe 22 1 Kundendienst Se ion 2 2 6 Fig 2 1 Burn In Adapter TNC 151 155 A II Id No 233 514 ZY wiring wo w ill3 _ il...

Page 30: ...lltlUtNllAlN DR JOHANNES HElDENHAlN GmbH D 8225Traunreut Tel O8669 31 O Kundendienst SERVICE MANUAL TNC 151 155 Page 23 Section 2 2 6 Fig 3 Burn In Adapter TNC 151 155 P II Id No 233 513 ZY...

Page 31: ...1 CIIJCNI IAIN Dy JOHANNES HEIDENHAJN GmbH D 8225 Traunreut Tel 06669 31 O SERVICE MANUAL TNC 151 155 Page 23 1 Kundendienst Section 2 2 6 Fig 3 1 Burn In Adapter TNC 151 155 P n Id No 233 513 ZY wiri...

Page 32: ...ncluclunnllu DR JOHANNES HEIDENHAIN GmbH D 8225 Traunreut Tel 08669 31 O Kundendienst SERVICE MANUAL mC 151 155 Page 24 Section 2 2 6 Fig 4 PLC Load Adapter Id No 224 873 ZY...

Page 33: ...ICE MANUAL TNC 151 155 Page 24 1 Kundendienst Section 2 2 6 Fig 4 1 PLC Load Adapter Id No 224 873 ZY wiring Additional circuitry for overload standard circuitry with unipolar facility bipolar switch...

Page 34: ...n the Burn In test program is entered by pressing the following keys El es oftea 1 lnceeeely to abteia a b b s CODE NUMBER a and then flgrrors in entering these numbers can be correcteB I gsessing jg...

Page 35: ...ERRUPTED EXTERNAL DATA INPUT 6 After completion of a sucessful data transfer the MB unit will rewind the cassette and the VDU will display the question EXTERNAL UNIT CONNECTED Any other display implie...

Page 36: ...order to restart the Burn In test program The Control will automatically car out a memory check This test takes approx 17 set during which time the dialogue MEMORY TEST will be displayed on the VDU Up...

Page 37: ...dot on the VDU will be replaced with a If an incorrect code is received the keyboard test will start again from the beginning will appear on the VDU and the test program must be reloaded from the ME u...

Page 38: ...moved the securing screws slackened and the knobs realigned and tightened in the 100 position 7 At the beginning of the initialization procedure inter ruptions of the program are inhibited After compl...

Page 39: ......

Page 40: ...upwards depending on RAMS equipped During this test no power interruption should occur e Key El TEST PC RAN Range EOOOH to FFFFH through CRU addressing TESTSTATIC RAM CLP PROCESSOR BOARD Range DSOOH t...

Page 41: ...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 El after a short delay the VDU will display the input condi tions when only...

Page 42: ...RIAL HANDWHEEL INPUT Checks the interface to the HE 310 Handwheel Unit k 1 m n To aid in locating an I O fault each out ut can be driven individually By pressing the key Q after a short delay the VDU...

Page 43: ...the following keys rii following keys q q With a Battery Trlqqer fault both flash In all other cases several LEDs will flash Through pressing the respective key each individual test can be restarted A...

Page 44: ...on the VDU With TNC 155 only A graphics display consisting of a square grid with a circle in the centre can be displayed by pressing the key marked iI Similarly the NC and PLC software numbers can be...

Page 45: ...and hold amplifier can by selected to either 5ms or 5OGms using them key Key q 1ov analog output The analog outputs should generate their maximum output of 1OV The polarity can be reversed as in test...

Page 46: ...connected to circuits which have voltages conforming to WE S 73 S8 Do not disconnect or connect plugs under power NC machines also need protection and installation safety as required for manually ope...

Page 47: ...Handwheel Unit from the Control if present 7 Disconnect any external data devices 8 Disconnect connector strips Jl J6 using a screwdriver to prise the connectors apart Do not unscrew individual wires...

Page 48: ...ector strips Jl J3 using a 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 wise apart with a screwdriv...

Page 49: ...e the fixing screws of the heatsink cover plate 2 Remove the heatsink cover plate 3 Disconnect the TNC 151 155 connecting cable 4 Disconnect connector strips 51 39 using a screw driver to psise the co...

Page 50: ...Processor Board CLP Processor Graphics Board Analog Board either SE Board TNC 151 155 B F or PLC Interface Board TNC 151 155 Q W 3 The backplate Power Supply Unit and Terminal Board assembly Board ar...

Page 51: ...p of static charges care must be taken when handling these elements The following requirements in the work area must be met Prior to working with MOS components or with assemblies con taining MOS elem...

Page 52: ...ith coding pins Inserting the boards The connectors of the boards are coded incorrect insertion is therefore avoided Press the board firmly into the Connec tor Board using the ejector keys tilted inwa...

Page 53: ...le override potentiometer from the Connector Board Remove the ribbon cable connector PlO from the Keypad Board Remove the 7 cross head fixing screws which secure the Key pad Board to the frontplate Pu...

Page 54: ...e ribbon cable connector Pl from the Connector Board see diagram Remove the voltage supply plug PZ from the Connector Board see diagram Exchanging the Connector Board Remove the 2 cross head fixing sc...

Page 55: ...s o NC software IC PZ IC P5 o PLC software IC P6 TNC 151 155 B Control with 0 NC software and o PLC standard software TNC 151 155 Q Control with o NC software end o PL C standard software or PLC custo...

Page 56: ...1 nElUENHAlN m DR JOHANNES HEIDENWN GmbH D 8225 Traunreut Tel 08669 31 O Kundendianst SERVICE MANUAL PNC 151 155 Page 46 Section 3 3 TNC 1511155 TNC 151 TNC155...

Page 57: ...ion tool and place onto MOS protection mat 0 Insert EPROMinto appropriate socket using insertion tool Igortant When exchanging EPROMs observe the position number second to last digit of the programmed...

Page 58: ...66 982 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 dur...

Page 59: ...Board 232 264 Main Processor Baord 227 601 Power Supply Board old 212 387 Mains Filter Board 217 532 Battery Holder Assembly 228 168 Potentiometer Assembly 202 370 Mains Voltage Selector with Integra...

Page 60: ...W Type or respectively QR WR Type Power Supply Board 6 Terminal Board 7 The functional processes of the control are divided between two microprocessor systems each comprising Microprocessor TMS 9995 P...

Page 61: ...LC filter 71 as protection against the oscillation of analog outputs The inputs d outputs are loaded on an external PLC I O boards e g PL 1OOB or respectively PL 100B which is driven by the main proc...

Page 62: ...olled by a supervision circuit 4O SERVICE MANUALTNC 151 155 Page 52 Section 4 1 The signals from the handwheel if present are shaped via the functional block 43 and are also processed by the CLP pr JC...

Page 63: ...RAM and the character generator IC Pl 31 2 so that the data are transferred to the shift register 31 3 in the right sequence Thus signal can be inverted by means of an exclusive or gate 31 4 to genera...

Page 64: ...upled with the flow converter generates 15V for the operation ampli fier The 12V supply voltage for the V 24 interface is generated with the help of the 15V by menas of a linear regulator 70 2 llV are...

Page 65: ...wer Supply 4820 EKD 1602000 58 Terminal Board P Q Version 4820 EKD 1601900 59 Terminal Board A B Version 4820 EKD 1601800 60 PLC Interface Board 4820 EKD 1601600 61 SE I O Bawd 4820 EKD 1601500 62 Mai...

Page 66: ...External i I PLC il Input Output I I Board I 3 OR OR OR SE Input IOutput Board Power Terminal SUPPlY Board Unit I A B Version 1 6 7 Connector Board Drawing No 4820 E KD 16009 00...

Page 67: ...verload output Drivers and Current Sense Drawing No 4820 E KD 16017 00 li sEH E2 7 Input Ports ParalleL to Serial Conv r I to PLC Interface Board I PLC cI f c Boa d _ CRUIN 1 to PLC Interface Boarc d...

Page 68: ...tor I 2 I Power I Forward Converter 70 Switch 1 0 5 v I with Low Pass Filter I f RS 232 C OP NW t4OS LogM OP At4P RS 232 C TTL Logic _ 1 I Power I Forward Converter7aJ Yu3 Switch 1 0 11 v I with Low P...

Page 69: ...e Filter I Analogue Outputs Analogue Outputs I CRU Adress Bus Reference Pulse Inhibit CRUOUTICRUCLK Reset EMERGENCY STOP Drawing No r 4820 E KD 16019 00 I I to Analogue Board 15V from Power Supply ov...

Page 70: ...o Analogue Board 71 L I i ov l l2V LC Voltage 15V from Power Supply Filter Regulator Anologue Outputs Analogue Outputs from Analogue Board 70 1 Fuse Resistor 23x 470 EMERGENCY STOP EMERGENCY STOP Draw...

Page 71: ...ress Bus 2 from tlain Processor Brd I 2 Y Ref Pulse Inhibit to Analogue Board 1 3 I 531 to Gate Arrays ITouch 1 of CLP Board I face I N JdAuswahlJ 1 i i TS I to from Main Processor Brd CRU Data Bus EM...

Page 72: ...d 24 Relays EMERGENCY STOP Ii Y Ref Pulse Inhibit toAnologue Board 9 I 51 j EMERGENCY STOF c E L 24 Inputs s coupled lnpu ts and t 3 lc I riI I L _u h 53 to Gate Art r of CLP Boa I I I rui uuel xru Co...

Page 73: ...s Bus I AS Al5 24 v 24 IRs232c Inter face 20 20 20 1 20 1 l4kx8 l4kx8 Main not mapped not mapped I I Processor CPU TMS 9995 64kx8 64kx8 EPROM 1 IC P3 to SEIPLC Interface Board Standard Data Bus I I CR...

Page 74: ...PLC 31 2 EPROM IC PI 7 8k x 8 Char GM Video ontrolle TMS 1937 NL Gate Arrays Signal Fast RAM 2 xX8 Jai tfree s 9YY r I Reset I I I I II II II I II I I I m I CRU Data Bus 7 i t 77 Standard Data Bus Blo...

Page 75: ...ne Address Bus CRU P i h 777 7nnni 1161 30 33 CLP Processor CPU TMS 9995 Reset 131 181 8kx8 31 6 31 2 31 3 c from Touch 1 Probe on fi kraahicsl K Standard Data Bus Drawing No 4820 EKO 16012 00 fro Ana...

Page 76: ...Processor Board II from Main Proc Brd CRU Address BUS Ref Pulse Inhibit from SElPLC Interf Brd t t I I jDifferen l 11x YV I vers Ii11 CHU Uata Bus from CLP Processor Board 1 A 1 42 Emergency stop Draw...

Page 77: ...PLC _ F Measuring Systems from Main Proc Brd CRU Address Bus to CLP Board Shaper E Puke43 i il Handwheel CRU Data Bus from CLP Process1 Drawing No 4820 E KD 16013 00 Dr B 1 from Main Proc Brd CRU Data...

Page 78: ...ram TNC 151 B Wiring diagram TNC 151 Q Wiring diagram TNC 155 B Wiring diagram TNC 155 Q SERVICE MANUAL T NC 151 155 Page 68 Section 4 3 Drawing NO 232 239 00 Drawing No 232 240 00 Drawing No 239 292...

Page 79: ...ignation A or B or C 2 10 IV 11 X 12 1 G 20 fold 2 10 fold Y 13 max traversing speed max traversing speed 2 14 16 m mini 12 m mini IV 15 X 16 0 Plus direction 1 4 Minus direction Y 17 2 18 with correc...

Page 80: ...econtrolled mode emergency stop 57 Position window X Y Z 58 Axis sequence for reference points approach 59 Speed pre control 60 Input values 1 000 t1 000 mm 1 000 tl OOO I angular axis 1 000 1 000 mm...

Page 81: ...m Parameter 61 62 61 68 0 a off 1 on 69 0 off 1 k on 70 0 9 999 VI 71 0 65 535 72 0 4 no axis inhibited 73 Input values 0 NO output 1 Output only when tool number changes 2 k Output of every tool numb...

Page 82: ...axes Display and transducer supervision Display and transducer supervision for inhibited axes Transducer supervision Input Xl x2 x3 x4 x5 The switching off of the transducer supervision is valid for i...

Page 83: ...g on Change from program run block sequence to program run single block when processing continuous con tours according to counting mode for angular axes IV and V if they function as position displays...

Page 84: ...om parameters 4 to 7 Ramp gradient for S Analog 168 Standstill supervision 169 Programming station 170 Handwheel and measuring probe Parameter 110 to 125 126 to 156 157 171 Input values 0 65 535 in un...

Page 85: ...xis 188 TV axis I 189 Programming of rpm S 0 permitted voltage value of MP 184 may be less Display of current spindle rpm before spindle 190 0 g S0 permitted 1 p SQ not permitted I 191 1 0 p off 1 p o...

Page 86: ...ISO Programming I Blockwise Transfer 218 ASCII code for data input Blockwise Transfer ASCII code for data output Blockwise Transfer ASCII code 219 220 for the beginning and the end of the command blo...

Page 87: ...c Representation of graphic in three planes Rotating the coordinate system of machining plane Activation and function of spindle axis Kv factor for spindle axis 238 Parameter 236 237 Input values 0 12...

Page 88: ...or distance coded linear transducers X 242 Y 243 Z 244 IV 245 Position window for spindle axis 246 Hysteresis for electronic handwheel 241 Spindle rpm for spindle orientation 248 Setting of 16 markers...

Page 89: ...2 Heasuring system input X3 IV 256 0 X4 _ 4 2 Measuring system input X4 V 251 0 2 x5 5 P Measuring system input X5 Input 0 0 Standard allocation Spindle rpm if marker 2501 is set 258 99 999 999 U rai...

Page 90: ..._ l 12 I 11 I 10 I i 9 I 8 I 1 Y Y Y Y Y Y Y Y Y Y 7 12 7 72 r 2 _ 1 72r 1 12 J2 3 JL J5 I Plo tine Klemmleiste j Pla tine 7 L SE i Flonschdose BlJ Y J2 9 I _ Z 13 9 1 IV I PLO1 JL P 56 T J13 Handrad...

Page 91: ...tine Stecker r _ ___ Pla tine Tas ta fur PI0 L N Netzklemme kompl...

Page 92: ...PC EinlAusgonspla tine IJlO Platine Klemmleiste gti a d Platine PC Interface r rr a 6srr ro 1 1 ME Nanschdose BU J 7Lpol kompl IZGN rer T Jl RJ lgr I R I 3 I I Z J3 r L Handrad J9 P3...

Page 93: ...ndrod NOT AUS Klemme I 1 7 Kupplung l w kompl I I I I Netzteil yf f Sponnungswbhier m Sicheru g m 720 10 Y TI OIP 2w 2iQ2l o v O o BOA Gatine 1 Entst I I _ I __ 2s Ez PI Sfecker L N 4 Netzklemme kompl...

Page 94: ...r Y Y Y Y Y Y Y Y Y r 12 t 72 __ I 12 _ I 1 I 11 _ I Jl J2 J3 JL JS Platine Klemmleis te ME Nanschdose BU J ILpol kompl f p i J pLol eeei r I Handrad J9...

Page 95: ...Kupplung 72pol kompl I p_ ZiE i 0 5 ii__ I Platine Stecker E Platine Tas to tur p A PI0 Platine I Netzteil Netzklemme kompl...

Page 96: ...in IAusgangsplatine P2 J JI J2 Plotine Klemmleiste PI ___ ___ I 32 i Kobel V8 floch BE 6 rnranoirii r PC Inter f9ce A L1 x i i Uf MEFlons 3 7 IL 8 rre 2 i rer 3 i re rc 5 RL5 6 DSR 7 re PlOl X 1 Y 2 J...

Page 97: ...I...

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