HEIDENHAIN TNC 155 Manuel utilisateur

HEIDENHAIN

DRJOHANNES HElDENHAlN GmbH

D-8225 Traunreut ‘Tel. (08669) 31-O

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 diffu slightly from those

described herein. If that is the case, please order a suitably

revised issue of the Service Manual.

Copying/Duplication

This manual is provided subject to the condition that no part

of it shall be reproduced in any form or by any means without

our prior consent in writing.

Issue: 01/87

ncIlJelunnllu

DR. JOHANNES HEIDENHAIN GmbH

D-8225 Traunreut ‘Tel. (08669) 31-O

SERVICE MANUALTNC 155

Page 1

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

2.2.1 Fault diagnosis for the complete installation

2.2.2 Use of the integrated supervision system

2.2.3 Testing of the VDU and associated circuitry

2.2.4 Testing of the mains supply and the Power Supply Unit

2.2.5 Testing of the measuring systems and wiring

2.2.6 Burn-In Test

" 4

" 5

II 14

n 15

" 17

" 18

3. Exchange Information " 36

3.1 Exchanging control units " 37

3.1.1 Procedure for exchanging the TNC 155 A/E Control 1' 37

3.1.2 Procedure for exchanging the TNC 155 P/V ContrOl " 38

3.1.3 Procedure for exchanging the PLC I/O Board of the PL 100 B/110 B so 39

3.2 Board exchange " 40

3.3 Software exchange " 45

3.4 Replacement parts, Loan/Exchange/Service Units " 48

4. Additional Information n 50

4.1 Block Diaoran Descri&ion " 50

4.2 Block Diagram TNC 155 " 55

4.3 Wiring Diagrams " 70

4.4 Machine Parameters " 75

Kundendienst

1. Use of the Sesvice Manual TNC 155

In order to determine the fault condition on a NC machine,

a fundamental knowledge of the machine and the drives is

necessary, as well as 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 155 OPERATING MANUAL

.TNC 155 MOUNTING INSTRUCTIONS AND INTERFACE CIRCUIT CONTROL-

MACHINE

.TNC 155 PLC-DESCRIPTION

SERVICE MANUAL TNC 155

Page 2

Section 1

The TNC 155 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 flowdiagrams enables

the user to pinpoint the source of a fault from its symp-

tams .

An integrated supervision

system

and a Burn-In Test Program

specifically developed for testing the Control can aid in

the location of faults.

Important guidance for the exchange of entire Controls,

individual.boards, or software is given in section 3,

Exchange Information.

Section 4, Additional Information, contains a block dia-

gram of the Control, a brief description of the internal

electronics, 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

SERVICE MANUAL TNC 155

D-8225 Traunreut .Tel.(O8669)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 155 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

fault localizing and in the dynamic testing of the Control's

hardware (see section 2.2.6).

HEIDENHAIN

DR. JOHANNES HEIDENHAN GmbH

D-8225 Traunreut .Tel. (08669) 31-O

Kundendienst

2.2

Flow diagrams for fault location *auk i" Tnc

2.2.1 Fault diagnosis for the complete installation

(Control/Measuring System/Machine-tool)

SERVICE MANUAL TNC 155

Page 4

Section 2.2/2.2-l

neIuelunnllu

DR.JOHANNES HEIDENHAIN GmbH

D-8225Traunreut.Tel.108669)31-0

Kundendienst

2.2.2 Use of the integrated supervision system

The TNC 155 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

displayed, indi-

cating (in abbreviated form) the nature of the problem.

example of operator-errors:

a) KEY NON-FUNCTIONAL

ENTRY VALUE INCORRECT

example of fault with TNC internal electronics:

a) TNC OPERATING TEMP. EXCEEDED

b) EXCHANGE BUFFER BATTERY

c) TNC ELECTRONICS DEFECTIVE O...3/A...K

example of fault with measuring system:

X-MEASURING SYSTEM DEFECTIVE

example of fault on machine-tool:

GROSS POSITIONING ERROR A

SERVICE MANUAL TNC 155

Page 5

Section 2.2.2

The system distinguishes between what are considered to be

harmless errors and serious faults, in that faults are shown

as flashing displays. Examples of faults are measuring system

faults, drive faults and faults in the TNC's internal elec-

tronics. The occurrence of a fault leads to the machine being

switched off via the emergency-stop contactor. The fault must

then be rectified before the TNC is switched on again.

Flashing fault messages TNC 155

AXIS X/Y/Z/4 MEAS. SYSTEM DEFECTIVE

EMERGENCY STOP DEFECTIVE

WRONG REFERENCE POINT

EMERGENCY STOP PLC

GROSS POSITIONING ERROR A/B/C/D

TNC OPERATING TEMP. EXCEEDED

ERROR IN PLC PROGRAM A...Q

TNC ELECTRONICS DEFECTIVE O...3/A...K

CHECK SUM ERROR XXOO...XXFF

The significance of these fault messages is explained on

pages 8 to 13

non-flashing) error message can be cleared by pressing the

key on the TNC, after which normal operation may resume.

ist of error messages is given on page 7.

HEIDENHAIN

DR. JOH4NNE.S HEIOENHLUN GmbH

D-8225Traunreut ‘Tel. (08669) 31-O

Use of the integrated supervision system.

SERVICE MANUAL TNC 155

Page 6

Section 2.2.2

Error message "EXCHANGE BUFFER BATTERY"

Particular mention should also be made about the implications

of the instruction to exchange the buffer battery:

If the 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).

The battery needs to have IEC designation "LR 6" and must be

of the leak-proof type. We especially recommend the use of

VARTA Alkaline batteries type "4006". With discharged (or

missing) buffer batteries, the memory for the machine para-

meters and for the user-program will be supported only as long

as the mains remains switched on. Continued operation is still

possible but the memory contents will become erased in the

event of a mains failure. Please note that the TNC has to be

switched on when exchanging the buffer batteries. If a mains

failure occurs during a battery change (or when the battery is

discharged or missing), the reentry of the machine para-

meters and the user-program will be necessary.

HEIDENHAIN

DR. JOHANNES HEIDENHAIN GmbH

D-8225

Traunreut ‘Tel. (08669) 31-O

SERVICE MANUAL TNC 155

Page 7

Section 2.2.2

Kundendienst

Error messages TNC 155

The meanings of many of these error messages are explained in:

(i) Operating Manual TNC 155 A/TNC 155 P

(ii) Mounting Instructions and Interface Circuit Control-Machine TNC 155 A/TNC 155 P

FEY NON-FUNCTIONAL

PROGRAM MEMORY EXCEEDED

SEARCH ADDRESS MISSING

TOOL DEF '$ NOT PERMITTED

PROGRAM NUMBER ON TAPE ALLOCATED

JUMP TO LABEL 0 NOT PERMITTED

ENTRY VALUE INCORRECT

CC-BLOCK MISSING

CIRCLE END POS. INCORRECT

TOOL DEF MISSING

TOOL CALL

MISSING

LABEL NUMBER NOT ALLOCATED

EXCESSIVE SUPROGRAMMING

ANGLE REFERENCE MISSING

PLANE WRONGLY DEFINED

TOOL RADIUS TOO LARGE

ROUNDING RADIUS TOO LARGE

PATH OFFSET WRONGLY STARTED

PATH OFFSET WRONGLY ENDED

ROUNDING-OFF UNDFINSD

ROUNDING-OFF NOT PERMITTED

AXIS DOUBLE PROGRAMMED

WRONG RF'M

NO EDITING OF RUNNING PGM

RADIUS COMP. UNDEFINED

LIMIT SWITCH X+

LIMIT SWITCH X-

LIMIT SWITCH Y+

LIMIT SWITCH Y-

LIMIT SWITCH AXIS Z+

LIMIT SWITCH AXIS Z-

LIMIT SWITCH AXIS 4+

LIMIT SWITCH AXIS 4-

EXCHANGE BUFFER BATTERY

TRANSFERRED DATA INCORReCT

ME: CASSETTE MISSING

NE: CASSETTE LOCKED

MB: WRONG MODE SELECTED

ME: WRONG PROGRAM DATA

ME: CASSETTE EMPTY

NE: PROGRAM INCOMPLETE

ME: TAPE END

WRONG PROGRAM DATA

MACHINE PARAMETER INCOMPLETE

EXT. IN-/OUTPUT NOT READY

MIRROR IMAGE ON TOOL AXIS

WRONG AXIS PROGRAMMED

WRONG SIGN PROGRAMMED

SPINDEL ROTATES MISSING

SLOT WIDTH 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

TOOLNUMBER 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

BLCCKNUNBERALREADY 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

CBAMFERNOTALLOWED

HEIDENHAIN

DFI.JOHANNES HEIDENHAIN GmbH

D-8225 Traunreut .Tel. (08669) 31-O

Kundendienst

Fault descriptions TNC 155

VDU Display (flashing)

X-MEASURING SYSTEM DEFECTIVE

Y-MEASURING SYSTEM DEFECTIVE

Z-MEASURING SYSTEM DEFECTIVE

AXIS 4 MEAS. SYSTEM DEFECTIVE

EMERGENCY STOP DEFECTIVE

WRONG REFERENCE POINT

SERVICE MANUAL TNC 155

Page 8

Section 2.2.2

Fault

cause

.Measuring system not connected

.Cable damaged

.Glass scale dirty or damaged

.Scanning head damaged

.Measuring system supervision damaged

.Fault in the emergency stop

circuit of the machine (for checking

routine

see Mounting

Instructions and

Interface Circuit Control-Machine

manual TNC 155

A/TNC 155

-Defect in Control's internal Emergency

Stop supervision

.Traversed-over reference point lies

outside of the reference point end

position (also

see Mounting

Instruc-

tions and Interface Circuit Control-

Machine TNC 155 A/TNC 155 P)

.Defect in Control/machine interface

Possible fault location

Measuring system

Analogue Board

PLC I/O Board

(TNC 155

PLC Interface Board (TNC 155 P)

SE Board (TNC 155 A)

Terminal Board VTNC 155 A)

Machine (cams/switches

"reference end-position" or "reference

pulse inhibit")

PLC I/O Board PrNc 155 P)

PLC Interface Board (TNC 155 P)

SE Board VJ?NC 155 A)

Terminal Board (TNC 155 A)

Kundendienst

SERVICE MANUALTNC 155

Page 9

Section 2.2.2

VDU Display (flashing) Fault cause Possible fault location

EMERGENCY-STOPPC

GROSSPOSITIONING ERRORA

With standard PIG program, faulty reply

from output A6 ("Lock for spindle on") to

input E20 ("reply: Lock for spindle on")

Fault message EMERGENCY-STOPPC

appears only when no additional PLC marker

is set for the fault message

.Trailing error greater than value

entered in MP 174.

(see Mounting Instructions and Interface

Circuit Control-Machine manual TNC 155 A/

TNC 155 P)

.Deviation from the intended position at

standstill greater than the value entered

in MP 169

(see Mounting Instructions

and Interface

Circuit Control-Machine manual TNC 155 A/

TNC 155 P)

.Exceeding the range for the continuous po-

sition supervision determined by MP 57.

(see Mounting Instructions and Interface

Circuit Control-Machine manual TNC 155 A/

TNC 155 P)

.Relationship between output voltage and

traversed distance outside of the defined

tolerance.

.Defect in the pulse counting section (Con-

trol circuitry) after the transducer signal

supervision

Terminal board (TNC 155 A)

In the Case of Gross Positioning Errors

A/B/C/D the fault could lie with any

element in the closed loop servo system.

ie Control hardware (CLP-Graphics Brd.),

II II (Analogue Brd.),

servo amplifier (offset voltages),

1, I (gain too low),

motor,

tacho,

measuring

system,

external forces acting on drives,

inappropriate MP values programmed.

Aid:

1. Program MP 54 (acceleration) as

small as possible.

2. Adjust rapid traverse (as small a

trailing error as possible).

3. Gradually increase MP 54.

If this does not help:

fault in the Control hardware (closed

loop) or in the machine

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