HEIDENHAIN TNC 415 User Manual

Service Manual

TNC 415B/425

11/06

Kundendienst/Service

* SERVICE MANUAL *

TNC 415B / 425

Changes/Developments

We are constantly working on technical improvements of our products.

For this reason, details described in this manual may differ slightly from your control. In this case, please order a revised service manual from us.

Duplication

This manual is provided subject to the condition that no part of it shall be duplicated in any form without our prior consent.

Issue 11/2006
valid for the software versions	TNC 415B/425:	NC Software 259 93*	(Standard)
	TNC 415F/425E:	NC Software 259 94*	(Export)
	TNC 415B/425:	NC Software 280 54*	(Special Software)
	TNC 415F/425E:	NC Software 280 56*	(Export)

Contents Service Manual TNC 415B/425

How to use this Service Manual

Minor Error Messages

Major Error Messages and their Causes Hardware Components TNC 415B/425 Logic Unit LE 415B/425

Connector Designation and Pin Layout

Block Diagrams

Board Description

Grounding Diagrams TNC 415B/425

Power Supply

Keyboard Unit TE 400/410

Visual Display Unit BC 110/B

Encoders

Electric Handwheels

3D-Touch Probes

Data Interfaces

Data Input and Output

Analogue Outputs

PLC Inputs and Outputs

Test Units

Exchange Instructions

Machine Parameter List

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

	SERVICE MANUAL TNC 415B/425
	Page 1
	Issue: 20.08.95
Table of Contents
		Page
1.	How to Use this Service Manual................................................................................	3
2.	Minor Error Messages ...................................................................................................	4
2.1	Causes of Minor Error Messages ........................................................................................	5
3.	Major Error Messages and their Causes ..................................................................	7
4.	Hardware Components TNC 415B/425....................................................................	16
5.	Logic Unit LE 415B/425 ...............................................................................................	17
5.1	Designation of the Logic Unit LE 415B/F............................................................................	17
5.2	Designation of the Logic Unit LE 425/E..............................................................................	18
5.3	Hardware Components of the Logic Unit LE 415B/425......................................................	19
6.	Connector Designation and Pin Layout ..................................................................	20
6.1	Connectors on the Logic Unit LE 415B/425 .......................................................................	20
6.2	Connectors on the PLC I/O Boards.....................................................................................	28
6.3	Connectors on the Keyboard Units.....................................................................................	39
6.4	Connectors on the Visual Display Units..............................................................................	43
7.	Block Diagrams..............................................................................................................	45
8.	Board Description .........................................................................................................	47
9.	Grounding Diagram TNC 415/B.................................................................................	48
10.	Power Supply .................................................................................................................	51
10.1	External Power Supply Requirements ................................................................................	51
10.2	Power Supply of the NC .....................................................................................................	53
10.3	Checking the Power Supply Unit ........................................................................................	55
10.4	Power Supply of the PLC....................................................................................................	58
10.5	Buffer Battery ...................................................................................................................	61.1
11.	Keyboard Unit TE 400/410..........................................................................................	62
11.1	Overview ............................................................................................................................	62
11.2	Checking the Keyboard Unit ...............................................................................................	64
12.	Visual Display Unit BC 110/B.....................................................................................	73
12.1	Overview ............................................................................................................................	73
12.2	Checking the Visual Display Unit ........................................................................................	73
13.	Encoders ..........................................................................................................................	76
13.1	Error Messages for Axes with Analogue Speed Controller ................................................	76
13.2	Error Messages for Axes with Integral Digital Speed Controller ........................................	78
13.3	Electrical Inspection of an Encoder.....................................................................................	80
14.	Electronic Handwheels ................................................................................................	81
14.1	Handwheel HR 130/330......................................................................................................	81
14.2	Handwheel HR 332............................................................................................................	82
14.3	Error Messages ..................................................................................................................	83

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		Page
15.	3D-Touch Probes ...........................................................................................................	84
15.1	Overview ............................................................................................................................	84
15.2	Error Messages ..................................................................................................................	85
16.	Data Interfaces ..............................................................................................................	87
16.1	Operating Modes of the Data Interfaces ............................................................................	87
16.2	Machine Parameters for the Data Interfaces......................................................................	89
16.3	Error Messages ..................................................................................................................	90
16.4	Wiring Diagrams of the Data Interfaces..............................................................................	95
17.	Data Input and Output.................................................................................................	97
17.1	Data Transfer Menu............................................................................................................	97
17.2	Overview of Files for TNC 415B/425 ..................................................................................	99
17.3	External Data Output ..........................................................................................................	99
17.4	Downloading External Data ...............................................................................................	110
18.	Analogue Outputs ........................................................................................................	120
18.1	Specifications.....................................................................................................................	120
18.2	Checking the Analogue Outputs........................................................................................	120
18.3	Switching Over the Position Display..................................................................................	124
18.4	Adjustment of the Feed Rate ............................................................................................	125
18.5	Offset Adjustment .............................................................................................................	126
18.6	Oscilloscope Function........................................................................................................	129
19.	PLC Inputs and Outputs .............................................................................................	133
19.1	PLC Inputs .........................................................................................................................	133
19.2	PLC Outputs ......................................................................................................................	133
19.3	Checking the PLC Inputs and Outputs ..............................................................................	134
19.4	Diagnosis Possibilities in the PLC Mode............................................................................	137
19.5	Compiling the PLC Program...............................................................................................	142
19.6	Output "Control Ready for Operation" and Acknowledgement for Test
	" Control Ready for Operation " ..........................................................................................	143
20.	Test Units .......................................................................................................................	145
20.1	Test Unit for the PLC Inputs and Outputs .........................................................................	145
20.2	Universal Measuring Adapter.............................................................................................	145
20.3	Encoder Diagnostic Set .....................................................................................................	147
21.	Exchange Instructions ................................................................................................	148
21.1	Important Notes.................................................................................................................	148
21.2	Exchanging the Logic Unit .................................................................................................	154
21.3	Exchanging the Processor Board.......................................................................................	156
21.4	Exchanging the CLP Board ................................................................................................	158
21.5	Exchanging the PLC Graphics Board .................................................................................	161
21.6	Exchanging the Power Supply Unit ...................................................................................	163
21.7	Exchanging the PLC I/O Boards.........................................................................................	165
21.8	Exchanging the EPROMs ..................................................................................................	169
22.	Machine Parameter List .............................................................................................	170

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1. How to Use this Service Manual

The service manual TNC 415B/425 can be used to diagnose, locate and eliminate errors on machine tools controlled by TNC.

In order to correctly judge the problems in an NC-controlled machine tool, fundamental knowledge of the machine tool and its drives as well as their interaction with the control and the measuring systems is required. Incorrect behaviour of the machine tool can also result from improper use of the control, NC-programming errors and incorrect or not properly optimized machine parameters.

For further information in this respect please refer to the

∙Documentation of the machine tool manufacturer

∙Operating Manual (HEIDENHAIN)

∙Technical Manual (HEIDENHAIN).

The Technical Manual is not enclosed with every control. In general, it is only supplied to the machine tool manufacturer and is updated by HEIDENHAIN, Traunreut. Therefore, it is absolutely necessary to contact the machine tool manufacturer, if errors occur that are due to a machine parameter or to the interface of the control. Support will, however, also be provided by the HEIDENHAIN service department and agencies. Telephone numbers, addresses and telex/fax numbers can be found on the back side of the cover page and the back side of the service manual.

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Issue: 20.08.95

2. Minor Error Messages

TNC 415B/425 features a comprehensive integral monitoring system to avoid input and operation errors, to locate errors and technical defects of the entire equipment (TNC, measuring systems, machine tool, cables etc.). The monitoring system is a fixed component of the TNC hardware and software; it is always active when the control is switched on. If a technical defect or an operation error is detected, an error message in plain language is displayed on the screen.

To erase minor error messages, press CE .

Further error messages are described in the

∙Operating Manual TNC 407/415B/425

∙Technical Manual TNC 407/415/425

∙Documentation by the machine tool manufacturer

∙Operating Instructions FE 401 B.

Error Message	Sec.
AXIS DOUBLE PROGRAMMED	15.2
START POSITION INCORRECT	15.2
TOUCH POINT INACCESSIBLE	15.2
RANGE EXCEEDED	15.2
OPERATING PARAMETERS ERASED	2.1
BAUD RATE NOT POSSIBLE	16.3
CYCL PARAMETER INCORRECT	15.2
FAULTY RANGE DATA	15.2
ROTATION NOT PERMITTED	15.2
DATA MEDIUM MISSING	16.3
DATA MEDIUM EMPTY	16.3
DATA MEDIUM WRITE-PROTECTED	16.3
LIMIT SWITCH <AXIS>	2.1
PLANE WRONGLY DEFINED	15.2
EMERGENCY STOP	19.6
EXT. IN-/OUTPUT NOT READY	16.3
ERR: 001	16.3
ERR: 002	16.3
ERR: 003	16.3
ERR: 004	16.3
ERR: 005	16.3
ERR: 006	16.3
ERR: 007	16.3
ERR: 010	16.3
ERR: 011	16.3
ERR: 012	16.3
ERR: 013	16.3
ERR: 014	16.3
ERR: 015	16.3
ERR: 016	16.3
ERR: 017	16.3
ERR: 018	16.3
ERR: 100	16.3
ERR: 101	16.3

Error Message	Sec.
ERR: 102	16.3
ERR: 103	16.3
ERR: 104	16.3
ERR: 105	16.3
ERR: 106	16.3
ERR: 107	16.3
ERR: 108	16.3
ERR: 109	16.3
PROGRAM DATA ERRONEOUS	16.3
WRONG OPERATING MODE	16.3
WRONG AXIS PROGRAMMED	15.2
HANDWHEEL ?	14.3
HANDWHEEL DEFECTIVE	14.3
ME: TAPE END	16.3
SCALING FACTOR NOT PERMITTED	15.2
PLC PROGRAM NOT TRANSLATED	2.1
PLC: ERROR <00 to 99>	2.1
POSITIONING ERROR	2.1
PROGRAM INCOMPLETE	16.3
POWER INTERRUPTED	2.1
INTERFACE ALREADY ASSIGNED	16.3
RELAY EXT. DC VOLTAGE MISSING	19.6
STYLUS ALREADY IN CONTACT	15.2
PROBE SYSTEM NOT READY	15.2
EXCHANGE TOUCH PROBE BATTERY	15.2
TRANSFERRED VALUE ERRONEOUS X	16.3
TRANSFERRED DATA INCORRECT X	16.3
TIME LIMIT EXCEEDED	15.2

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2.1 Causes of Minor Error Messages

OPERATING PARAMETERS ERASED

-With new and exchange controls, the machine parameters are always erased

-Defective buffer batteries, accumulator or capacitor

-RAM error on the processor board

-Software exchanged

LIMIT SWITCH <AXIS>

-"Manual" Operating Mode

The preset software limit switch has been reached during traverse with the axis address keys.

-"Automatic" Operating Mode

The calculated position of the current block is beyond the software limit switch range or beyond the additional limit (set with the MOD function <AXIS LIMIT>). The positioning is not performed.

Machine Parameters for the Software Limit Switches

	X+	X-	Y+	Y-	Z+	Z-
Default setting	910.0	920.0	910.1	920.1	910.2	920.2
Activation via PLC 1)	911.0	921.0	911.1	921.1	911.2	921.2
Activation via PLC 1)	912.0	922.0	912.1	922.1	912.2	922.2

	IV+	IV-	V+	V-
Default setting	910.3	920.3	910.4	920.4
Activation via PLC 1)	911.3	921.3	911.4	921.4
Activation via PLC 1)	912.3	922.3	912.4	922.4

1) PLC markers M 2816 and M 2817

POWER INTERRUPTED

-After a reset signal of the power supply (e.g. line voltage drops)

-Important machine parameters may have been changed:

e.g. MP 210, MP 410.3, MP 730, MP 3240.1, MP 7210, MP 7310

POSITIONING ERROR

-The servo lag monitor set in the machine parameters 1410.X or 1710.X has responded. (Check the run-in behaviour of the axis; readjust, if necessary.)

PLC PROGRAM NOT TRANSLATED

- After editing, the PLC program must be compiled (translated) anew.

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PLC: ERROR 00	marker	2924
to	to		— set
PLC: ERROR 99	marker	3023

-Instead of PLC: ERROR 00 to 99 another dialogue may be displayed with customized PLC programs. For further information please contact your machine tool manufacturer.

NOTES

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Issue: 20.08.95

3. Major Error Messages and their Causes

The integrated monitoring system distinguishes between minor and gross errors. Gross errors are characterized by a blinking display (e.g. malfunctions of the encoders, of the drives and data processing errors).

If a gross error occurs, the control opens the contact "Control Ready for Operation". This causes an emergency stop of the machine tool.

		END
By switching off the main switch or by pressing			, the emergency stop state can be reset, provided that
the error cause has been eliminated.
Display (blinking)			Error Cause
			X = 0	CRC sum control data incorrect
	PROCESSOR CHECK ERROR YX
			1	CRC sum machine parameters incorrect
			2	Check sum NC-memory incorrect
			3	Test plane incomplete / will not run
			4	Crosstalk between data bits in RAM
			5	Crosstalk between addresses in RAM
			6	Stack overflow
			7	CRC sum PLC program ASCII
			8	CRC sum PLC program OP-Code
			9	CRC sum test section
			A	Software error
			B	Wrong interrupt
				Differentiation with register V0:
				08	bus error
				0C	address error
				10	illegal instruction
				14	division by 0
				18	error output for CHK command
					(check range)
				20	error output for TRAPV command
					(trap on overflow)
				24	privilege infringement (supervisor
					command in the user mode)
				28	emulator trap
				2C	emulator trap
				30	-
				34	-
				38	-
				3C	interrupt vector not initialized
				40	interrupt vector not initialized
				44	interrupt vector not initialized
				48	interrupt vector not initialized
				4C	-
				50	-
				54	-
				58	-
				5C	-
				60	false interrupt (with priority 0)
				64-7C		interrupt auto-vector 4-7,
						user interrupt $100-$3FC
				94-BC		TRAP #5 - #15

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Display (blinking)			Error Cause
			C	Time slice overflow
	PROCESSOR CHECK ERROR YX
	(continued)		D	Command stack overflow control loop
			E	Wrong command main processor
			F	Wrong display mode main processor
			G	Wrong boot command
			H	Verify error with boot command "load"
			I	Wrong supplementary command with boot
			J	command "test"
				Boot logon not successful
			K	EPROM comparison CLP
			L	Wrong command CLP processor
			M	Operating voltage beyond tolerance range
			N	No PLC texts in PLC chip
			O	Axis 4 and/or 5 paraxial with export version
			P	Inhibited software function activated
			Q	(function without software enable module)
				TNC 415 without CLP or geometry CPU
			R	The control attempted to start a
				PLC positioning (M2704 to M2708),
				a datum shift (M2716) or to switch the
				range (M2816 and M2817), although
				MP7440/bit 2 was set or MP3030 ≤ 1.
			Y =	CPU number	1 = main processor
					2 = geometry processor
					3 = CLP processor

If the error message PROCESSOR CHECK ERROR XY (XY = code; see above) comes up repeatedly, send the complete logic unit to HEIDENHAIN for repair. Please indicate the error message and the code.

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Page 9

Issue: 28.10.00

Display (blinking)			Error Cause
			XX = 1A	NC start	complement missing
	ERROR IN PLC-PROGRAM XX
			1B	Rapid traverse	complement missing
			1C	Axis address key latch	complement missing
			1D	Feed enable	complement missing
			1E	PLC positioning X 1)	complement missing
			1F	PLC positioning Y 1)	complement missing
			1G	PLC positioning Z 1)	complement missing
			1H	PLC positioning IV 1)	complement missing
			1I	Axis address key X+	complement missing
			1J	Axis address key X-	complement missing
			1K	Axis address key Y+	complement missing
			1L	Axis address key Y-	complement missing
			1M	Axis address key Z+	complement missing
			1N	Axis address key Z-	complement missing
			1O	Axis address key IV+	complement missing
			1P	Axis address key IV-	complement missing
			1Q	More than one of the markers
				M2485...M2487 (M03, M04,
			1R	M05) are set simultaneously
				More than one of the
				functions "PLC Positioning"
				(M2704 to M2708), "Datum
				Shift" (M2716) or "Q-Para-
				meter Transfer" are activated
			2A	simultaneously.
				Jog increment pos. X+	complement missing
			2B	Jog increment pos. X-	complement missing
			2C	Jog increment pos. Y+	complement missing
			2D	Jog increment pos. Y-	complement missing
			2E	Jog increment pos. Z+	complement missing
			2F	Jog increment pos. Z-	complement missing
			2G	Jog increment pos. IV+	complement missing
			2H	Jog increment pos. IV-	complement missing
			2I	Jog increment pos. V+	complement missing
			2K	Jog increment pos. V-	complement missing
			2L		complement missing
			2M	Axis address key V+	complement missing
			2N	Axis address key V-	complement missing
			2P	PLC positioning V	complement missing
			50	Excessive nesting (too many modules nested inside
				one another)
			51	Stack underflow (an attempt to acquire data from the
			52	STACK, although it was empty)
				Stack overflow (an attempt to load too many data
			53	onto the STACK)
				Time-out (the permissible program run-time has been
				exceeded by more than twice. Check the structure of
			54	the subprogram)
				CASE arguments are larger than the number of
			55	entries in the table
				No access to error texts / dialogue texts

1) Only active with compatibility mode TNC 355

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Display (blinking)			Error Cause
			X =	7	Called label not defined
	ERROR IN PLC-PROGRAM X
				8	No end-program condition found (the program does
					not contain an EM instruction, or it contains a JP
				9	instruction without a LBL instruction following.)
					Program is too long (RAM overflow) (insufficient
					memory for the program code to be generated.)
			XX =	10	Assign with parenthesis (an =, S, SN, R, RN or PS
	ERROR IN PLC-PROGRAM XX
					instruction has been programmed, although arithmetic
				11	parenthesis are open)
					Excessive nesting of parentheses (more than 16
				12	parentheses are open)
					Jump within a gating sequence (unconditional jump
					has been programmed, although the gating sequence
				13	was not closed with an Assign)
					"Close Parenthesis" without "Open Parenthesis" (a
					"Close Parenthesis" command was programmed,
				14	although no parentheses were open)
					Label within parentheses (a LBL instruction has been
				15	programmed, although parentheses are open)
					Label within a gating sequence (a LBL instruction has
					been programmed, although the previous gating was
				16	not closed with an Assign)
					Jump within parentheses (a jump instruction has been
				17	programmed, although parentheses are open)
					Parentheses open at the end of a block (an EM
					instruction has been programmed, although
				18	parentheses are open)
					Label defined twice
				19	Logic Assign missing (a Word Assign or gating has
					been programmed, although the previous Logic-gating
				20	was not closed with a Assign)
					Logic Assign missing (a Word instruction has been
					programmed, although the previous Logic-gating was
				21	not closed with an Assign)
					Word accumulator not loaded (a Word Assign or
					gating has been programmed, although the Logic
				22	accumulator does not contain a definite value)
					Logic accumulator not loaded (a Logic has been
					programmed, although the Logic accumulator does
					not contain a definite value)

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Display (blinking)			Error Cause
			23	Accumulators not loaded on "Open Parentheses"
	ERROR IN PLC-PROGRAM XX
				(an A[, AN[, O[, ON[, XON[ command has been
(continued)
				programmed, although neither the word nor the logic
			24	accumulator has been gated or loaded)
				Incorrect type of parentheses result (a different type
				has been calculated in the parentheses from that which
				was defined in the "Open Parentheses" command, i.e.
			25	logic instead of word or vice versa)
				Conditional jump with incorrect logic accumulator
				(a conditional jump has been programmed, although the
			26	logic accumulator does not contain a definite value)
				Empty CASE instruction
			27	"END-CASE" missing

NOTES

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Error Messages GROSS POSITIONING ERROR:

Axes with Analogue Speed Controller

Display (blinking)			Error Cause
			Positioning (Servo Lag) Monitoring
	GROSS POSITIONING ERROR
	<AXIS> YA		- Operation with feed forward control:
			position monitoring range exceeded
			(range defined in MP1420.X)
			- Operation with servo lag:
			servo lag monitoring range exceeded
			(range defined in MP1720.X)
			- Operation with gantry axes:
			positions of master and slave axes deviate by more than
			the value set in MP855.X. (displayed axis = slave axis)
			Monitoring of the Analogue Voltage Limit
	GROSS POSITIONING ERROR
			- The nominal voltage calculated by the control has
	<AXIS> YB
			reached its limit of ± 10 V (± 20 V for spindle).
			(only with feed forward control)
	GROSS POSITIONING ERROR		Movement Monitoring
	<AXIS> YC
			- The path actually traversed in a certain time is less than
			¼ of or more than 4x the nominal value calculated by the
			control. (can be influenced via MP1140.x)
	GROSS POSITIONING ERROR		Standstill Monitoring
	<AXIS> YD
			- The deviation from the nominal position of an axis in
			standstill has exceeded the value programmed in the
			machine parameter MP1110.x.
	GROSS POSITIONING ERROR		Monitoring of the Offset Voltage
	<AXIS> YE
			- The offset voltage limit of 100mV has been reached
			during an automatic offset adjustment with MP1220.
			(see section 18.5)
			Y = CPU number	1 = main processor
				2 = geometry processor
				3 = CLP processor
Error Location

When the error message GROSS POSITIONING ERROR is displayed, the error may be located in any element of the closed loop.

e.g.- Error in control (e.g. CLP board)

-Excessive offset voltage at the servo amplifier

-Incorrect speed adjustment at the servo amplifier

-Monitoring function of servo amplifier has responded (e.g. monitoring of current intensity)

-Electrical defect at the servo amplifier

-Mechanical error (bearing, spindle, guides)

-Excessive mechanical forces on a drive

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Error Messages GROSS POSITIONING ERROR:

Axes with Integrated Digital Speed Controller

Display (blinking)			Error Cause
			Positioning (Servo Lag) Monitoring
	GROSS POSITIONING ERROR
	<AXIS> YA		- Operation with feed forward control:
			position monitoring range exceeded
			(range defined in MP1420.X)
			- Operation with servo lag:
			servo lag monitoring range exceeded
			(range defined in MP1720.X)
			- Operation with gantry axes:
			positions of master and slave axes deviate by more than
			the value set in MP855.X. (displayed axis = slave axis)
			Monitoring of the Analogue Voltage Limit
	GROSS POSITIONING ERROR
			- The nominal voltage calculated by the control has
	<AXIS> YB
			reached its limit of ± 10 V (± 20 V for spindle).
			(only with feed forward control)
	GROSS POSITIONING ERROR		Movement Monitoring
	<AXIS> YC
			- The difference between the path information of the
			position encoder (LS) and that of the speed encoder
			(ROD) has reached the tolerance limit defined in
			MP1970.x.
	GROSS POSITIONING ERROR		Standstill Monitoring
	<AXIS> YD
			- The deviation from the nominal position of an axis in
			standstill has exceeded the value programmed in the
			machine parameter MP1110.x.
	GROSS POSITIONING ERROR		Monitoring of the Offset Voltage
	<AXIS> YE
			- The offset voltage limit of 100mV has been reached
			during an automatic offset adjustment with MP1220.
			(see section 18.5)
	GROSS POSITIONING ERROR		Monitoring of the Integrated Digital Speed
	<AXIS> YF
			Controller
			- The monitoring limit of the integrated speed controller
			(MP1910.x) has responded.

Y = CPU number	1	= main processor
	2	= geometry processor
	3	= CLP processor

Error Location

When the error message GROSS POSITIONING ERROR is displayed, the error may be located in any element of the closed loop.

e.g.: - Error in control (e.g. CLP board)

-Excessive offset voltage at the servo amplifier

-Monitoring function of servo amplifier has responded (e.g. monitoring of current intensity)

-Electrical defect at the servo amplifier

-Motor, tachometer, encoder or cabling defective

-Mechanical error (bearing, spindle, guides)

- Excessive mechanical forces on a drive

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Display (blinking)			Error Cause
	ENCODER <AXIS> DEFECTIVE YA		Signal amplitude error		position encoder
	ENCODER <AXIS> ` DEFECTIVE YA		Signal amplitude error		speed encoder
	ENCODER <AXIS> DEFECTIVE YB		Signal frequency error		position encoder
	ENCODER <AXIS> ` DEFECTIVE YB		Signal frequency error		speed encoder
	ENCODER <AXIS> DEFECTIVE YC		Error with distance-coded scale		position encoder
			Error with distance-coded scale		speed encoder
	ENCODER <AXIS> `DEFECTIVE YC
			Y = CPU number	1 = main processor
				2 = geometry processor
			Error Causes:	3 = CLP processor

-Encoder not connected

-Cable damaged

-Glass scale contaminated or damaged

-Scanning head defective

-Encoder monitoring system defective

		Checking the encoders: see section 13
		Wrong reference mark spacing entered with distance-
WRONG REFERENCE POINT
		coded linear encoders (counting error caused by the
		measuring system or the logic unit)
TNC OPERATING TEMP. EXCEEDED		Temperature inside the logic unit has exceeded + 70°C
EMERG. STOP DEFECTIVE YX
		YX = 1(	1. emergency stop test
		1) 2. emergency stop test
		1.	3. emergency stop test
		- Error during the test routine "Control ready for operation"
		when the machine is switched on (see section 19.4)
EMERGENCY STOP PLC		This error message is only generated, if the marker 2815
		is set without additional marker (M2924 - M3023).

							SERVICE MANUAL TNC 415B/425
							Page 15
							Issue: 20.08.95
Display (blinking)				Error Cause
			1)	marker	2924
	PLC: Error 00
	to			to				— and marker 2815 set
			1)	marker	3023
	PLC: Error 99
				TNC 407:
	CHECK SUM ERROR YX				1A		CRC sum main processor EPROM chips 1/2
					1B		CRC sum main processor EPROM chips 3/4
					1D		CRC sum PLC chip
					1X		Check sum calculation
				TNC 415A:
					YA		CRC sum main processor EPROM chips 1 to 4
					YC		CRC sum geometry processor EPROM chips 5/6
					YD		CRC sum PLC chip
					YE		CRC sum GEM chip 7
					YR		CRC sum CLP boot chip
					1X		Check sum calculation
				TNC 415B,
				TNC 425:	YA		CRC sum main processor EPROM chips 1/2
					YB		CRC sum main processor EPROM chips 3/4
					YC		CRC sum geometry processor EPROM chips 5/6
					YD		CRC sum PLC chip
					YE		CRC sum GEM chip 7
					YR		CRC sum CLP boot chip
					1X		Check sum calculation
				Y =			CPU number
								1 = main processor
								2 = geometry processor
								3 = CLP processor

1)Instead of PLC: ERROR 00 ... 99 another dialogue may be displayed with customized PLC programs. For further information, please contact your machine tool manufacturer.

CRC = Cyclic Redundancy Check (during data transfer)

If the error message CHECK SUM ERROR YX comes up repeatedly, send the complete logic unit to HEIDENHAIN for repair. Please indicate the check sum error.

SERVICE MANUAL TNC 415B/425

Page 16

Issue: 20.08.95

4. Hardware Components TNC 415B/425

TNC
Component			TNC 415 B		TNC 425
LOGIC UNIT LE 415 B/F6)
Id.No. 267 223 --			x
LOGIC UNIT LE 425/E6(7)
Id.No. 267 214 --					x
VISUAL DISPLAY UNIT BC 110/B
Id.No. 260 520 -- (BC 110B)			x		x
Id.No. 254 740 -- (BC 110)			x 5)		x 5)
KEYBOARD UNIT TE 400
Id.No. 250 517 --			x		x
KEYBOARD UNIT TE 410 (customized version)
Id.No. 258 645 --			x		x
Id.No. 264 105 --			x		x
PLC I/O BOARD PA 110 (option)2)
Id.No. 262 651 --			x		x
PLC I/O BOARD PL 400 (option)1)
Id.No. 255 855 --			x		x
PLC I/O BOARD PL 405 (option)4)
Id.No. 263 371 21			x		x
PLC I/O BOARD PL 410 (option)3)
Id.No. 263 371 --			x		x

1)only digital part (64 PLC inputs / 32 PLC outputs)

2)only analogue part

3)version 01: 64 PLC inputs / 23 PLC outputs and analogue part version 11: 64 PLC inputs / 23 PLC outputs, no analogue part

4)only digital part: (32 PLC inputs / 16 PLC outputs)

5)superseded by BC 110B

6)F/E: export versions of the controls (different software; hardware identical)

7)TNC 425: control with integral digital speed controller (see section 18.2)

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Issue: 20.08.95

5. LOGIC UNIT LE 415B/425

5.1 Designation of the Logic Unit LE 415B/F

ID plate and		ID plate of
PGM label		processor board
of logic unit

ID plate of	ID plate of
CLP board	PLC graphics board

LE 415F = export version of LE 415B

SERVICE MANUAL TNC 415B/425

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Issue: 20.08.95

5.2 Designation of the Logic Unit LE 425/E

ID plate and		ID plate of
PGM label		processor board
of logic unit

ID plate of	ID plate of
CLP board	PLC graphics board

LE 425E= export version of LE 425

SERVICE MANUAL TNC 415B/425

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Issue: 20.08.95

5.3 Hardware Components of the LOGIC UNIT LE 415B/425

Board Overview LE 415B/F

		TNC 415B/F
	LE 415B/F	LE 415B/F	LE 415B/F
Board	267 223 --	267 223 3-	267 223 4-

PROCESSOR BOARD

Id.No. 268 553 01

x

x

x

PLC GRAPHICS BOARD

Id.No. 257 954	02	x	x
Id.No. 257 954	03*			x

CLP BOARD

Id.No. 275 705 01	x
Id.No. 275 705 02		x	x

Board Overview LE 425/E

			TNC 425/E
	LE 425/E	LE 425/E	LE 425/E	LE 425/E	LE 425/E
Board	267 214 1-	267 214 2-	267 214 3-	267 214 4-	267 214 5-

PROCESSOR BOARD

Id.No. 268 553 01

x

x

x

x

x

PLC GRAPHICS BOARD

Id.No. 257 954	02	x	x	x	x
Id.No. 257 954	03*					x

CLP BOARD

Id.No. 265 401 01	x
Id.No. 268 927 01		x
Id.No. 275 711 01			x
Id.No. 275 711 02				x	x

* +24V supply voltage of the operating panel (routed via X46) cannot be switched off with EMERG. STOP.

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Issue: 20.08.95

6. Connector Designation and Pin Layout

6.1 Connectors on the LOGIC UNIT LE 415B/425

6.1.1 Connector Designation LOGIC UNIT LE 415B/425

LE 415B

Power	CLP	PLC	Processor
Supply	Board	Graphics	Board
		Board

CLP board

X1 = measuring system 1 ( )

X2 = measuring system 2 ( )

X3 = measuring system 3 ( )

X4 = measuring system 4 ( )

X5 = measuring system 5 ( )

X6 = measuring system S ( )

X8 = nominal value output 1, 2, 3, 4, 5, S

X12 = triggering touch probe

X14 = measuring touch probe

B = signal ground

PLC graphics board

X41	= PLC output
X42	= PLC input
X43	= visual display unit (BC)
X44	= 24V power supply for PLC
X45	= TNC keyboard unit (TE)
X46	= machine operating panel
X47	= PLC I/O board

Processor board

X21 = RS-232-C data interface

X22 = RS-422 data interface

X23 = electronic handwheel

X31 = 24Vpower supply for NC

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Issue: 20.08.95

LE 425

Power	CLP	PLC	Processor
Supply	Board	Graphics	Board
		Board

CLP Board
X1	= encoder 1 ( )
X2	= encoder 2 ( )
X3	= encoder 3 ( )
X4	= encoder 4 ( )
X5	= encoder 5 ( )					)
X6	= encoder S (
X8	= nominal value output 1, 2, 3, 4, 5, S
X12	= touch trigger probe
X14	= measuring touch probe
X15	= encoder / speed
X16	= encoder / speed
X17	= encoder / speed
X18	= encoder / speed
X19	= encoder / speed
X20	= reserved
B	= signal ground
PLC Graphics Board
X41	= PLC output
X42	= PLC input
X43	= visual display unit (BC)
X44	= 24 V power supply for PLC
X45	= TNC operating panel (TE)
X46	= machine operating panel
X47	= PLC I/O interface

Processor Board

X21 = V.24/RS-232-C data interface

X22 = V.11/RS-422 data interface

X23 = electronic handwheel

X31 = 24Vpower supply for NC

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Issue: 14.11.06

6.1.2 Pin Layout: POWER SUPPLY LE 415B/425

X31 Power Supply (NC) terminal strip (pluggable) 2-pin

Pin No.	Assignment
1	+ 24 V
2	0V

6.1.3 Pin Layout: CLP Board LE 415 B

X1,X2,X3,X4,X5 Encoders 1,2,3,4,5 (Position)

sinusoidal input, current interface 7-16µA

flange socket with female insert (9-pin, Conei)

Pin No.	Assignment
1	0°+
2	0°-
5	90°+
6	90°-
7	RP+
8	RP-
3	+ 5 (Up)
4	0 V (Uusable comp.)
9	internal shield
housing	external shield = housing

X8 Nominal Value Output 1,2,3,4,5,S flange socket with female insert

(15-pin, D-SUB)

Pin No.	Signal Designation
1	analogue output 1
3	analogue output 2
5	analogue output 3
7	analogue output 4
4	analogue output 5
8	analogue output spindle
9	0V analogue output 1
11	0V analogue output 2
13	0V analogue output 3
14	0V analogue output 4
6	0V analogue output 5
15	0V analogue output spindle
housing	external shield = housing
2,10,12	do not assign

X6 Spindle Encoder (Position)

square-wave encoder (TTL)

flange socket with female insert (12-pin, Conei)

Pin No.	Signal Designation
5	Ua1
6	-Ua1
8	Ua2
1	-Ua2
3	Ua0
4	-Ua0
7	-UaS
(2)	+ 5V (sense)
12	+ 5V (Up)
(11)	0 V (sense)
10	0 V (Uusable comp.)
9 (via spring)	shield = housing

X12 Touch Trigger Probe

flange socket with female insert

(15-pin, D-SUB)

Pin No.	Signal Designation
1	internal shield
3	standby
4	start
5	+ 15V
6	+ 5V (Up)
7	-battery warning
8	0 V (Uusable comp.)
9	trigger signal
10	-trigger signal 1)
2, 11 to 15	not assigned

1) stylus at rest = high level

X14 Measuring Touch Probe

flange socket with female insert (25-pin, D-SUB)

Pin No.	Assignment
17	0° +
4	0° -
16	90° +
3	90° -
14	RP +
2	RP -
15	+ 5V
1	0V
21	0° +
8	0° -
20	90° +
7	90° -
18	RP +
6	RP -
19	+ 5V
5	0 V
25	0°+
12	0°-
24	90°+
11	90°-
22	RP +
10	RP -
23	+ 5V
9	0V
13	shield

6.1.4 Pin Layout: CLP Board LE 425

X1, X2, X3, X4, X5 Encoder 1, 2, 3, 4, 5 (Position)

sinusoidal input

current interface 7 - 16µA

flange socket with female insert (9-pin, D-SUB)

Pin No.	Assignment
6	0° +
1	0° -
8	90° +
3	90° -
9	RP +
5	RP -
7	+ 5V (UP)
2	0V (UN)
3	internal shield
housing	external shield = housing

X8 Nominal Value Output 1, 2, 3, 4, 5, S see CLP board LE 415 B

X14 Measuring Touch Probe see CLP board LE 415 B

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X6 Spindle Encoder (Position)

square-wave input (TTL)

flange socket with female insert (15-pin, D-SUB)

Pin No.	Assignment
1	Ua1
9	-Ua1
3	Ua2
11	-Ua2
14	Ua0
7	-Ua0
13	-UaS
12	+ 5V sense
10	0V sense
4	+ 5V (UP)
2	0V (UN)
5, 6, 8, 15	not assigned
housing	external shield = housing

X12 Touch Trigger Probe

see CLP board LE 415 B

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Issue: 20.08.95

X15, X16, X17, X18, X19 Encoder 1,2,3,4,5 (Speed) sinusoidal input,

voltage interface 1Vpp

flange socket with female insert (15-pin, D-SUB)

Pin No.	Assignment
1	A+
9	A-
3	B+
11	B-
14	R +
7	R -
4	+ 5V (UP)
2	0V (UN)
(12)	+ 5V sense
(10)	0V sense
5,6,8,13,15	do not assign
housing	external shield = housing

6.1.5 Pin Layout: PLC Graphics Board LE 415B/425

X44 Power Supply (PLC) terminal strip (pluggable) 3-pin

.

Pin No.	Assignment
1	+ 24V_A can be switched off via
	EMERG. STOP
2	+ 24V cannot be switched off
	via EMERG. STOP
3	0V

X41 PLC Output

flange socket with female insert (37-pin, D-SUB)

Pin No.	Assignment
1	O0
2	O1
3	O2
4	O3
5	O4
6	O5
7	O6
8	O7
9	O8
10	O9
11	O10
12	O11
13	O12
14	O13
15	O14
16	O15
17	O16
18	O17
19	O18
20	O19

Pin No.	Assignment
21	O20
22	O21
23	O22
24	O23
25	O24 2)
26	O25 2)
27	O26 2)
28	O27 2)
29	O28 2)
30	O29 2)
31	O30 2)
32	do not assign
33	0V (PLC) 1)
34	control ready for operation 2)
35,36,37	+24V_A PLC 3)
housing	external shield

1)0 V PLC reference potential for testing

2)cannot be switched off with ext. EMERG. STOP

3)+ 24V_A PLC power supply for testing

(can be switched off)

X42 PLC Input

flange socket with female insert (37-pin, D-SUB)

X45 TNC Operating Panel (TE)

flange socket with female insert (37-pin, D-SUB)

SERVICE MANUAL TNC 415B/425

Pin No.	Assignment
1	I0
2	I1
3	I2
4	I3 acknowledgement for test
	"control ready for operation"
5	I4
6	I5
7	I6
8	I7
9	I8
10	I9
11	I10
12	I11
13	I12
14	I13
15	I14
16	I15
17	I16
18	I17
19	I18
20	I19
21	I20
22	I21
23	I22
24	I23
25	I24
26	I25
27	I26
28	I27
29	I28
30	I29
31	I30
32	I31
33,34	do not assign
35,36,37	0V PLC 1)
housing	external shield = housing

1) external reference potential for PLC supply

X43 Visual Display Unit (BC 110/B) flange socket with female insert (15-pin, D-SUB)

Pin No.	Assignment
1,8,11	GND
2 to 6,12,13	do not assign
7	R signal
9	V SYNC
10	H SYNC
14	G signal
15	B signal

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Issue: 20.08.95

Pin No.	Assignment
1	RL0
2	RL1
3	RL2
4	RL3
5	RL4
6	RL5
7	RL6
8	RL7
9	RL8
10	RL9
11	RL10
12	RL11
13	RL12
14	RL13
15	RL14
16	RL15	key matrix
17	RL16
18	RL17
19	RL18
20	SL0
21	SL1
22	SL2
23	SL3
24	SL4
25	SL5
26	SL6
27	SL7
28	RL19
29	RL20
30	do not assign
31	RL21
32	RL22	key matrix
33	RL23
34	spindle override (wiper)
35	feed override (wiper)
36	- 5V override potentiometer
37	0V override potentiometer
housing	external shield = housing

X46 Machine Operating Panel

flange socket with female insert (37-pin, D-SUB)

Pin No.	Assignment
1	I128
2	I129
3	I130
4	I131
5	I132
6	I133
7	I134
8	I135
9	I136
10	I137
11	I138
12	I139
13	I140
14	I141
15	I142
16	I143
17	I144
18	I145
19	I146
20	I147
21	I148
22	I149
23	I150
24	I151
25	I152
26	O0 1)
27	O1 1)
28	O2 1)
29	O3 1)
30	O4 1)
31	O5 1)
32	O6 1)
33	O7 1)
34	0 V (PLC) 2)
35	0 V (PLC) 2)
36	+ 24V PLC 3)	4)
37	+ 24V PLC 3)	4)

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Issue: 20.08.95

X47 PLC Expansion Interface

12V interface

flange socket with male insert(25-pin, D-SUB)

Pin No.	Assignment
1,2,3	0 V * 1
4	serial IN 2
5,6,17,18	not assigned
7	-RESET
8	-WRITE EXTERN
9	WRITE EXTERN
10	-O5
11	-O3
12	-O1
13	shield
14,15,16	+ 12V * 1
19	serial IN 1
20	EMERGENCY STOP
21	-serial OUT
22	serial OUT
23	-O4
24	-O2
25	-O0

1)O0...O7 simultaneously at X21 (PLC output)

2)0V PLC reference potential for testing

3)+ 24 V PLC supply voltage routed via fuse for the inputs I128 to I152

4)PLC board version 01/02: + 24V_A can be switched off PLC board version 03: + 24V cannot be switched off

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Issue: 20.08.95

6.1.6 Pin Layout: Processor Board LE 415B/425

X21 V.24/RS-232 Data Interface

flange socket with female insert (25-pin, D-SUB)

Pin No.	Assignment
1	shield
2	RxD
3	TxD
4	CTS
5	RTS
6	DTR
7	GND (0 V * 2)
8 to 19	not assigned
20	DSR
21 to 25	not assigned
housing	external shield = housing

X23 Handwheel Interface (serial)

flange socket with female insert (9-pin, D-SUB)

X22 V.11/RS-422 Data Interface

flange socket with female insert (15-pin, D-SUB)

Pin No.	Assignment
1	shield
2	RxD
3	CTS
4	TxD
5	RTS
6	DSR
7	DTR
8	GND
9	-RxD
10	-CTS
11	-TxD
12	-RTS
13	-DSR
14	-DTR
15	do not assign

Pin No.	Assignment HR 130/330	Assignment HR 332
1,3,5	not assigned	not assigned
4	+ 12V	+ 12V
2	0 V	0 V
6	DTR	DTR
9	not assigned	not assigned
8	RXD	RXD
7	do not assign	TXD
housing	external shield = housing	external shield = housing