heidenhain TNC 351, TNC 355 Service Manual

HEIDENHAIN

DRJOHANNES HEIDENHAIN Gmbti

D-8225Traunreut~ ?B(O8669) 31-O

*

SERVICE MANUAL *

TNC 35X/355

Subject to Change/Further Dovelopmontn DR. JOHANNES HEIDENHAIN is constantly working on technically improving its units. It is therefore possible that details of your Control may differ slightly from those described herein. order a suitably revised issue of the Service Manual.

If that is the case please

Copying/Duplication This

manual

shall be reproduced in any form or in writing.

Issue: 06/92

is provided

subject

to the condition that no part of it

by

any means without our prior consent

HEIDENHAIN

DRJOHANNES HEIDENHAJN GmbH

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

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Contents

SERVICE NAMUAL TNC 3511355

Page 1

Page

1. Bow to use the Service Manual

2.

Error Messages

2.1 Possible Causes for Error Messages

3. Fault Hessages and their Causes

4.

LOGIC Unit LE 351/355

4.1 Designation of the LOGIC Unit

4.2 Hardware Components of the LOGIC Unit

4.3 Connector Layout LE 351/355

4.4 PROCESSOR Board

4.5 CLP PROCESSOR Board

4.6 Grounding Diagram

5. Kxternal Supply

5.1 Requirements

5.2 Supply for the NC-Part

5.3 Testing the POWER SUPPLY Board Assembly

5.4 24V-DC Supply for the PLC-Part

5.5 Buffer Battery

of

the External Supply

6. KEYBOARD Unit TE 351/355

6.1 Overview

6.2 Circuit Diagram of the KEYBOARD Unit

6.3 Testing the KEYBOARD Unit

6.4 Key Matrix

I.

DISPLAY Unit BE 2121412

7.1 Display for TNC 351

7.2 Display for TNC 355

7.3 Testing the Display

8. Measuring Systems

8.1 Error Messages

8.2 Possible Error Cause

8.3 Testing the Measuring

Systems

9. Bandwheel

9.1 Overview

9.2 Testing the Handwheel

10.

3D-Touch Probe

10.1 Overview

10.2 Error Messages

3

4

1

8 13 13 14 15 22 23

24 25 25 26 29

32 34 35 35 36 37

38 41

41

41 42 44 44

44

46 46 46 47

41

48

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drives and errors in data processing). The control opens the contact "Control ready" in the case of significant errors. This results in a EMERGENCY-STOP of the machine. The state “EMERGENCY-STOP” can only be eliminated again by switching off the main switch provided that the error cause was eliminated before.

Flashing display

FAULTY DATA PROCESSING

Possible fault cause

PROCESSOR Board

0

II II

1

II II

2

II II

3

II II

4

II II

A

CLP PROCESSOR Board

B

II II

C

II II

D

PROCESSOR or CLP PROCESSOR Board

E

II II II II

F

CLP PROCESSOR Board

G

PROCESSOR Board

H

II II

I

II II

K

Machine Parameter *

L

* Enable (selection) of a function via machine parameters which are not

integrated in the software. If the error message “FAULTY DATA PROCESSING

W ( = identification letter,

see above!) occurs repeatedly return the compl. LOGIC UNIT to HEIDENHAIN for repair. Indicate also the error message and the identification letter.

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SERVICE MANUAL TNC 351/355

Page 9

Flashing display

ERROR IN PLC-PROGRAM . . .._

A

B

C

D

E

F

G

Fault cause

Fault with non-erasable marker

(see also PLC-Description)

Start Key

or incremental positioning xt Rapid Traverse

Key

or incremental positioning XDirection Latch Key

or incremental positioning Yt Feed Release

or incremental positioning YStart PLC Positioning X-axis

or incremental positioning Zt Start PLC Positioning Y-axis

or incremental positioning ZStart PLC Positioning Z-axis

or incremental positioning

IV+

H

I

J

K

L

M

N

0

P

Start PLC Positioning IV-axis or incremental positioning IV-

Directional key Xt or incremental positioning Vt

Directional key Xor incremental positioning V-

Directional key Yt or start-PLC-positioning axis V

Directional key YDirectional key Zt

or directional key V+ Directional key Z-

or directional key VDirectional key IV+

or supplementary axis to be changed

to

M2590

and M2591

Directional Key IVor Start PLC Positioning S-axis

Q

Non-defined macro called up via PLC markers

Possible location of fault:

PLC Program, PROCESSOR Board, PL 300 (PLC POWER I/O Board Assembly), external keys,

switch or wiring

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SERVICE NANUAL TNC 351/355

Page 10

Flashing display

/GROSS POSITIONING ERROR A 1

/GROSS POSITIONING ERROR B 1

GROSS POSITIONING ERROR C

GROSS POSITIONING ERROR D

Fault cause

Position (trailing error) supervision

- Speed precontrol operation: Exceeding position supervision determined by

machine parameter 57.

- Trailing error operation: Exceeding trailing error supervision

determined by machine parameter 174.

Supervision of analog voltage limit

- The nominal value of the voltage calcu-

lated by the control reached the f 10

volt limit (only with speed precontrol).

Move8ent supervision

- The voltage difference calculated by the control reached the limit programmed in

machine parameter 234.

Standstill supervision

- The position deviation from the nominal position of an axis at standstill is greater than programmed in machine parameter 169.

- When positioning beyond the target point programmed the value of the nominal position is greater than programmed

in machine parameter 169.

GROSS POSITIONING ERROR E

Possible location of error with the error message “GROSS POSITIONING ERROR

A/B/C/D/E":

component of the closed loop. e.g. :

- control error (e.g. CLP PROCESSOR Board)

- excessive offset voltage at servo amplifier

- wrong speed adjustment at servo amplifier

- supervision of servo amplifier is effective (e.g. current supervision)

- electrical defect of servo amplifier

- motor defective, tacho, measuring system or cabling

- mechanical defect (bearing, spindle or guidance error)

- excessive mechanical forces on drive

With “Gross Positioning Error” the error can be due to any

Supervision of offset voltage

- The offset voltage limit of 100 mV was reached with an automatic offset adjustment by machine parameter 252.

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SERVICE KANUAL TNC 351/355 Page 11

Flashing display

TRANSDUCER X DEFECTIVE A

TRANSDUCER X DEFECTIVE B

WRONG REFERENCE POINT

I

1

Fault cause

Fault code: A = signal amplitude fault

B = signal frequency fault

- Measuring system not connected

- Cable damaged

- Glass scale dirty or damaged

- Scanning head damaged

- Measuring system supervision defective (CLP PROCESSOR Board)

Supervision of measuring systems, see section a.3

Wrong distance of reference mark with transducers having distance-coded reference marks

(counting error caused by measuring system

or LOGIC Unit).

TNC OPERATING TEMP. EXCEEDED

EMERGENCY STOP DEFECTIVE

IEMERGENCY STOP PLC

PLC: ERROR 00

to

PLC: ERROR 99

1) Instead of PLC: ERROR 00 . . . 99, also another dialog may appear with a customized PLC-program. Detailled information can be obtained from the

machine manufacturer.

Temperature in the inner side of the LOGIC Unit greater than t65OC.

- Fault with the supervision routine for the

I

I,

1,

output "Control Ready" when switching on machine (see section 14.3).

The error message only appears if marker 2815 is set without additional markers

CM2924 - M3023).

Marker 2924 to and marker 2815 was set Marker 3023

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Flashing display

Fault cause

X X 0 0 CRC-checksum *

71 location of fault

correct checksum

SERVICE MANUAL TNC 351/355

Page 12

Possible

fault location

CHECK-SUM ERROR

xx00 1

xx10

xx20

XX30

xx31

XX40

XX42

xx41

xx43

CRC-checksum error with EPROM 3

RAM

PROCESSOR Board

CLP PROCESSOR Board

II II

XXE9

PROCESSOR Board

XXEA

* CRC = Cyclic Redundancy Check (cyclic block check when data is transmitted) If the error message "CHECKSUM ERROR XXXX" occurs repeatedly return the compl.

LOGIC UNIT for repair and indicate the checksum error.

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SERVICE MANUAL TNC 351/355 Page 13

4,

LOGIC Unit LE

35x/355

Logic Unit without PLC Power I/O Board Assembly (PL 300)

4.1 Desiunation of the LOGIC Unit

Logic Board with PLC Power

I/O Board Assembly (PL 300)

type and program label of older

Logic Units

type and program labels of new Logic Units

type label

CLP PROCESSOR Board PROCESSOR Board

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SERVICE NANUAL TNC 3511355 Page 14

The LOGIC UNIT consists of the following assemblies:

- POWER SUPPLY ASSEMBLY

- PLC PROCESSOR Board

- PROCESSOR Board

- PL 300 (= PLC-Power Supply Board, only with

Q/W/S/Y-Version)

The following tables show the inserted assemblies for the various LOGIC UNITS.

4.2.1 TNC 355 Assembly Overview, new Bardware Version (connecting sockets marked with colours)

Ig355C/G Is355SpI IE355Wa1 IE355 WYR

254819.. 254a-a..

249 516 . .

24!3 517 . .

249652.. x x x x x x

a49663..

x x

249828 . . x x

249 a23 . .

RmER SUPPLY Asmy

2364a-407

231 659 . .

x x

x

x x x x

x x

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4.2.2 TNC 351/355 Assembly Overview, old Hardware Version

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oa! 332 ltCE.5 (M +S nC 355 M M: 355 M + S

SERVICE MANUAL TNC 351/355

Page 14.1

xz 355 m la 355 n/p IB 355 p/w la 355 a/F la 355 Q/n

2.36482 . . x3766( . .

F7+oIsmBoARD

235635.. I x 23793a.. x

cLPpRocEsscRBoARD

235 769 I. x 238289 . . 239 863 ,. 242 878 . . x

245922 . . x x

2.3608492

I n

r7 x

PL 300

237 659 . .

x = fmn first delivery

* = fw prcdwticm ade K7 (7/89)

x x x x

*

x

x x

* *

2.38324.. 242aea.. 242407.. 246m.. 24se55..

x x x

I

x x

x

x x

IE 355 C/G lx 355 s/Y

x x

x

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SERVICE MANUAL TWC 351/355 Page 15

4.3.1 Connector layout of LE 351/355 B/P/Q/Y LOGIC WITS

Power

SUPPlY

Closed loop board

PRXeSSCN

board

Closed loop:

Xl = Encoder 1

X2 = Encoder 2

Standard allocation

X3 = Encoder 3

X4 = Encoder 4 X5 = Encoder 5 I X6 = Electronic handwheel HR 150/HR 250 X7 = Touch probe system X8 = Nominal value output for X, Y. Z. IV. S (V) X9 = Visual display unit BE 4128 X10 = Reference pulse inhibitor

X11 =Test I/O 1) S = Signal ground

(switchover via machine

parameters 253 257)

Color cde 1)

Red Blue

Yellow

Red

1) only with Logic Units from 9/89

Processor:

x21 = PLC-output X22 = PLC-input X23 = Keyboard unit TE 355 X24 = Power supply 24 V- for PLC

X26 = Data interface RS-232.C/V.24 X27 = Machine operating panel

Power supply:

X31 = Power supply 24 V- for LE

Red

Yellow

Blue

Red Green

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SERVICE KANUAL TNC 351/355

Page 15.1

Traunreut ‘Tel. (08669) 31-O

4.3.2

Connector

Power SuPPlY

layout of LE 355 C/G/S/Y LOGIC UNITS

Closed loop board

Processor board

Closed loop:

Xl = Encoder 1

X2

= Encoder 2

X3

= Encoder 3

X4 = Encoder 4

X5 = Encoder 5

X6

= Encoder S

X7 = Electronic handwheel HR 150/HR 250

X8 = Nominal value output for X. Y. Z. IV. V. S

Standard allocation

,

(switchover via machine parameters 253 257)

C&Jr

code 1)

Red X9 = Visual display unit BE 4128 X10 = Reference pulse inhibitor Xl 1 = Handwheel with axis selection keys 1) Xl 2 = Touch probe system TS 120 (TS lW511)

B = Operational ground

Processor:

x21 = PLC-output X22 = PLC-input X23 = Keyboard unit TE 355

X24

= Power supply 24 V- for PLC

X26

= Data interface RS-232.W.24

X27 = Machine operating panel

Power supply:

Blue

Yellow

Red

Yellow

Red Yellow Blue

Red

Green

1) only with Logic Units from 9/89

X31 = Power supply 24 V- for LE

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SERVICE HANUAL TNC 3511355 Page 15.2

4.3.3

Connector layout

Power Closed

SUPPlY

loop board

of

LE 355-R LOGIC UNITS

PRXeSSOr

board

Closed loop:

Xl = Encoder 1 Xl 3 = Encoder 2, 3. 4 X5 = Encoder 5

X6 = Encoder S X7 = Electronic handwheel HR 150/HR 250 X8 = Nominal value output for X, Y. Z. IV. V. S

X9 = Visual display unit BE 4126

Xl 0 = Reference pulse inhibitor

Color

code

Standard allocation Blue (switchover via machine parameters 253 257)

Red

Blue

Yellow

Xl 1 = Handwheel with axis selection keys

Xl 2 = Touch probe system TS 120 ITS W/511)

8 = Operational ground Processor: x21 = PLC-output X22 = PLC-input X23 = TNC-keyboard unit TE 355

X24 = Power supply 24 V- for PLC

X26 = Data interface RS-232~C/V.24

X27 = Machine operating panel

Power supply:

X31 = Power supply 24 V- for LE

Red Yellow

Red

Yellow

Blue

Red Green

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SERVICE MANUAL TNC 351/355

Page 16

4.3.4

Connector

&$2&&f~inpltl.2.3,4

Flanged socket rnth P-pin female insert

x5Qaderinplt5

scluarerave~*~

Flanged socket with la-pin feaaJ.e insert

sigoal designatim

89

layout of the TNC 351/355 B/F/Q/W CLP PROCESSOR Roard

w.

z

1

x7lbudtPrcaesystem IQnwd socket with 7-pin flanged socket

siQnaldesignatim

ui 1

x8 IlLmiml value altplt fcu x,Y,z,IV,w,s Flaged socket with U-pin female insert

no.

iis % 8% n0t presmt

t5 v bnsor line)* +5 v (UP,)

8; gymline)*

I Shield = housing *Thesensorliaeiscunnect&inthe

wit with the pertinent supply line.

X6ElectrmiCBanhheel HR l50l250

FJ.anged socket with P-pin female insert

! i ;

i2 2

9 (via spring)

xPBE4l2visual~tit

Flanged socket with S-pin female insert

ks,gwldesignatjm

FEY*-

, ,

Kh?c

Hsnc BRIGHT/m

E shield = connector hous’

xl0referempulseinait

Flanged socket with P-pin female insert

9

g

“g 3 to ,14,&5

do not assign

110.

1

do not assign

I

* ~%i$%fo~5h%~: , 2%%: : :

..,

242 408

. .

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SERVICE MANUAL TNC 351/355 Page 16.1

4.3.5 Connector layouts for LE 355 ClGfS1Yf.R CLP PROCESSOR BOARD

xl2lSl2@TarhPrcbsSystmmSlJlrrS5ll calyticabledapter)

Flanged socket with 15-pin female/m& insert

sigrmldesigna~ ID.

X%X6mccderinplt 5, 6

square-wave input

0V-shield 1

Standby signal start 4

seepage16 X5

I

t15v +15v (rp) 6

Ft3 - ;I

~BRl50/250ElebmicBimdrdreel

Trigger signal 9

Trigger signals

see page 16 X6

Donotassign 2, 11 to 15

3 5

10

XRlmxiJml valueanplt fcrX,Y, 2, IV, v, s

seepage16 X8

x9BE422vhalDisplaylbit

see page 16 X9

xl0 ref-

pulseildlibit

seepage16 Xl0

xll-uithaxisswi-keys

Flangadsccketwith g-pin female/male insert

signal~ticm

M. 0v 2 t5v

3

t12v 4

-15v

ml7 RXD

Don&assign

5 6

1

1,

8, 9

Flauged socket with 25-pin female insert

deeguatico

$?

uas Uat

2: lLj

Yi" Iy)-

4 coder4

14 :2

2 3 "

& 17 5 G iiz

6 7

coder3

zi Da2 Uee Ov

iiz us iiz Dal Da2 use

i&T

0-J Do mt assign Outer shield

L

!8 19 20

I-

21 10

11 12 coder2 22 23 24 9 i-

2. 13

-ins

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4.3.6 Connector layout of PROCESSOR BOARD

x21

PLC.output

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SERVICE HANUAL TNC 351/355

Page 17

X22 WC-input

Flange socket. female (37-p&) Contact No.

1 2 3 A2 31 4 A3 31 5 A4 ” 6 7 A6 3’ 6 9 10 A9 11 12 All 13 A12 14

15 Al4 16 A15 17 Al6 18 Al7 19 A16

20 A19 21 A20 22 A21 23 A22 24 A23 25 28 A25 21 27 A26 ‘I 26 A27 21 29 A26 ” 30 A29 21

31 A30 ”

32.33 34 Control Operational

35. 36. 37 24 V via etiernal EMERGENCY STOP

Housing External screen

” n required. the suppiygme for me disconnmible oY,p”ts Cal be assigned

10 mnne”orX24. pin 1

“naldisconnenible via external EMERGENCY STOP

110. b.23 are dirconnenlble Yia enem* EMERGENCY STOP

” 00 A7 d”Plicafsd on x*7. Mashine oczer~ti”P Panel

Allocation

A0 3 Al 3’

A5 ‘I

A7 31 A6

A10

Al3

A24 *’

do not assign

disconnetiible (PLC ‘I)

Flange socket. female 137-p&)

6 j E5 7

8

9 1 E8 10 I E9

15 1 El4 16 I El5 17 / El6 16 1 El7

19 I El8 20 1 El9 21

22 1 E21 23 1 E22

29 E26 30 E29 31 E30

35,36. 37 1 0” (PLC)“HCUSi”g Exlernal Screen

I E6

) E7

I

I E20

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SERVICE BABUAL TNC 351/355 Page 18

Kundendienat

X23 KEYBOARD Unit TE 351/355 Flanged socket connector (37-pin) Pin no.

1 2

3 4

5 6 7

8

9 10

11

12 13 14

15 16 17 18 19

20

21 22 23 24 25 26

77 28

29 30

Assignment RLO

RLl RL2

RL3 , for key matrix RL4 RL5

RL6 RL7 El28 El29 El30 El31 El32 El33 El34 El35 El36 El37 El38 OUT0 OUT1 OUT2 OUT3 , for key matrix OUT4 OUT5 OUT6

r-mT7 El39

El40

t15V (supply for keys on Machine Operating Panel)

31 32

33 34 35 36 37

housing

El41 El42 El43

Spindle Override (wiper) Feed Override (wiper)

t12V Override Potentiometer

0V Override Potentiometer

outer shield

-

X24 PLC Supply Terminal block

Terminal no. IAssianment 1

1t24V disconnectable via Iexternal EMERGENCY-STOP'

2

-4

1t24V not disconnectable lfiV2)

I) The supply can be optionally assigned

to connector X21, pin 35, 36, 37.

*) 0V can be optionally assigned to

connector X22, pin 35, 36, 37.

X26 Data Interface RS-232-C

Flanged socket, connector (25-pin)

Pin no. 1

A55ignment

shield 2 RxD 3 TxD 4 CTS

5 RTS 6 DTR 7 GND 8 to 19 do not assign

21 to 25 housing

Ido not assign Iouter shield

PLC-inputs El28 . ..E140 from Hachine Operating Panel

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Flanged socket. cOnneCtor UT-pin, This connection is used *hen the

assipned inputs on the TE 355 are : insufficient.

SERVICE MANUAL TNC 351/355 Page 19

1

2

3 I 4 5 6

1

El28

i El29

El30

!

El31

/

El32

I

E133

7 i El34 8

12 13

14 15

16

1

El35

j

Et39

! El40 / El41

E142

1

El43

28 29

30 31

32 33

34 35 36

37

A2 A3

I A4 / A5

A.6

! 117 I 0 " IPLCI

i 0 V (PLCI

-24 " IPLC)

I +24" IPLCi

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4.3.1 Connector Layout of the PLC POUER I/O Board Assembly PL 300

SERVICE HANUAL TNC 351/355 Page 20

[’ 1

c 1 r 1 [ 1

[I c I

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4.3.8 Connector Layouts of the TE 351/355 KEYBOARD Unit

Page 21

SERVICE IMNIJAL TNC 351/355

Xl For conneotion of the machine operating panel

Flange socket female (25.pole)

contact NO. , Allocation

1

2 1 El39 3 / El39

4 1 El37

5 1 El36

7 El34

8 El33

15” 16” 17” 16 to 21 22

23 24 26

1 El40

I

+12 V (override potentiometer) Feed rate override potentiometer (wiper)

Spindle override potentiometer (wiper) do not assign +15 V (Supply for bunons of machine

operating panel)

El43 El42 F141

X2 Far connection of the logic unit LE 365

Flange socket, male (37.pole)

Contact No. I Allocation

6 7

8 9

10 11 12 13 14 15 16 17 18 19 20

22 23 24 25 26 21

27 28

29

30

RL5 RL6

RL7 I El29

El29 El30 El31 El32 El33 El34 El35 El36

El37

El38

OUT0

OUT2 OUT3 OUT4 OUT5 OUT6 OUT1

OUT7 1 El39

El40 +15 V ISupply for buttons of machine

operating mnell

for key matrix

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4.4 PROCRSSOR Board

4.4.1 Interface

- 57 PLC-inputs

- 32 PLC-outputs

- Keyboard Unit

- Machine Operating Panel

- V. 24-interface

4.4.2 Supervision

- Program memory

- Data Processing

- PLC-program

- Acknowledgement Emergency-stop

SERVICE HANUAL TNC 351/355 Page 22

4.4.3 Storage

- NC-Programs

- PLC-Program

- Machine parameters

- List of compensation values

- Operating program

4.5 CAP PROCXSSOR Board

4.5.1 Interface

- Encoder inputs

- Reference pulse inhibit

- Electronic Handwheel

- 3D-Touch Probe

- Analog outputs

- Display

4.5.2 Supervision

- Measuring systems

- Temperature

- Buffer battery

- Data processing

- Program memory

- Axis positions (closed loop)

4.5.3

Storage

- Operating program

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SERVICE HANUAL TNC 351/355 Page 23

Notes

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SERVICE MANUAL TNC 351/355

Page 24

Traunreut.Tel.(08669)31-0

4.6.1 Logic Unit

without grounding terminal

.

-

\r’ Y

r

-

<

-

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SERVICE NANUAL TNC 351/355

Page 24.1

4.6.2

Logic

Unit

with grounding terminal

I

k

I

I I I 1 -

-.-.-.----.

”

T

.

V'