TNC 320 Service Manual

Service Manual
TNC 320
January 2008
638142_00_a_01.pdf 2 11.12.2007 08:07:01
Contents 1 Safety Precautions ................................................................................................................. 7
2 How to Use this Service Manual .......................................................................................... 9
2.1 About this Manual ........................................................................................................... 9
2.2 Other Documentation.................................................................................................... 10
2.3 Support .......................................................................................................................... 10
2.4 Safety ............................................................................................................................ 10
3 Code Numbers ..................................................................................................................... 11
3.1 Introduction ................................................................................................................... 11
3.2 Overview ....................................................................................................................... 11
3.3 Notes on Entering the Code Numbers .......................................................................... 12
4 Error Messages .................................................................................................................... 15
4.1 Introduction ................................................................................................................... 15
4.2 Error Window ............................................................................................................... 16
4.3 List of NC Error Messages ............................................................................................ 20
5 Errors..................................................................................................................................... 25
5.1 Introduction ................................................................................................................... 25
5.2 Overview of Possible Errors .......................................................................................... 25
6 Procedures and Tips for Error Diagnosis ........................................................................... 29
6.1 Introduction ................................................................................................................... 29
6.2 Sequence for Finding Errors in the Control Loop .......................................................... 29
6.3 Error Localization by Process of Interchange ................................................................ 31
6.4 Error Localization by Process of Exclusion .................................................................... 31
6.5 Notes and Tips............................................................................................................... 33
7 Logs and Service Files ......................................................................................................... 35
7.1 General .......................................................................................................................... 35
7.2 Calling the Logs ............................................................................................................. 36
7.3 Settings for the Logs ..................................................................................................... 37
7.4 Saving Service Files....................................................................................................... 38
7.5 Evaluating the Service Files........................................................................................... 40
8 Diagnosis with the Online Monitor (OLM) ........................................................................ 41
8.1 Introduction ................................................................................................................... 41
8.2 OLM Operation.............................................................................................................. 41
8.3 Screen Layout................................................................................................................ 42
8.3.1 Variable display .................................................................................................... 42
8.3.2 Units .................................................................................................................... 43
8.3.3 Status display ....................................................................................................... 43
8.4 Using the OLM for Troubleshooting.............................................................................. 44
9 Integrated Oscilloscope....................................................................................................... 45
9.1 Introduction ................................................................................................................... 45
9.2 Activation and Settings.................................................................................................. 45
9.3 Recording Signals .......................................................................................................... 50
9.4 Analyzing Recordings .................................................................................................... 52
9.5 Saving and Loading Recordings..................................................................................... 54
10 PLC Diagnostics ................................................................................................................ 55
10.1 Introduction ................................................................................................................. 55
10.2 Diagnosis Options in the PLC Mode ........................................................................... 58
10.2.1 The API DATA Function ..................................................................................... 58
10.2.2 The WATCH LIST Function ................................................................................ 60
10.2.3 The TABLE Function .......................................................................................... 63
10.2.4 The TRACE Function .......................................................................................... 67
10.2.5 PLC Diagnostics with the Integrated Oscilloscope ............................................ 68
10.3 The COMPILE Function............................................................................................... 71
10.4 Calling the PLC Error Table for Diagnosis.................................................................... 72
January 2008 HEIDENHAIN Service Manual TNC 320

10.5 Overviews ................................................................................................................... 74
10.6 Specifications .............................................................................................................. 85
10.6.1 PLC Inputs ......................................................................................................... 85
10.6.2 Analog Inputs ..................................................................................................... 86
10.6.3 Inputs for Pt 100 Thermistors ............................................................................ 86
10.6.4 PLC Outputs ...................................................................................................... 87
11 Memory Card and File Manager of the TNC 320............................................................. 89
11.1 Introduction ................................................................................................................. 89
11.2 Memory-Card Test .................................................................................................... 90
11.3 Setting the System Time............................................................................................. 90
11.4 File Management in the TNC Partition ........................................................................ 91
11.5 File Management in the PLC Partition......................................................................... 93
12 Data Backup ....................................................................................................................... 97
12.1 Introduction ................................................................................................................. 97
12.2 Connection Setup ........................................................................................................ 99
12.2.1 Via USB .............................................................................................................. 99
12.2.2 Via Ethernet ..................................................................................................... 100
12.2.3 Via serial interface RS 232/V.24 ....................................................................... 106
12.3 Reading In/Out Files and Directories......................................................................... 108
12.4 Data Backup on External Data Medium .................................................................... 113
12.5 Extracting Files from the Backup File ........................................................................ 116
12.6 Restoring Data........................................................................................................... 117
12.7 Cable Overview ......................................................................................................... 119
12.7.1 Ethernet Interface RJ45 Connection ............................................................... 119
12.7.2 RS-232-C / V.24 ............................................................................................... 120
13 Important Features of HEIDENHAIN Components ....................................................... 123
13.1 Hardware Identification ............................................................................................. 123
13.2 Display of System Information .................................................................................. 130
14 Connector Designations and Layouts ........................................................................... 133
14.1 Important Note .......................................................................................................... 133
14.2 MC 320...................................................................................................................... 133
14.2.1 Designation and Position of Connectors ......................................................... 133
14.2.2 ..................................................................................... Pin layouts on MC320: 134
14.3 Encoders ................................................................................................................... 147
14.4 Touch Probe Systems ............................................................................................... 149
14.5 Handwheels .............................................................................................................. 150
14.5.1 HR 410 Portable Handwheel ........................................................................... 150
14.5.2 HR 130 Panel-Mounted Handwheel ................................................................ 151
14.6 PLC Input/Output Units ............................................................................................. 152
14.6.1 Designation and Position of Connectors ......................................................... 152
14.6.2 PL 510 Pin Layout ............................................................................................ 153
14.7 Machine Operating Panel ......................................................................................... 157
14.7.1 Designation and Position of Connectors on MB 420 ....................................... 157
14.7.2 Pin Layouts on MB 420 ................................................................................... 157
15 Power Supply ................................................................................................................... 159
15.1 Power Supply for MC 320 ......................................................................................... 159
15.2 Power Supply for Control-Is-Ready Signal ................................................................. 160
15.3 Buffer Battery ............................................................................................................ 161
15.4 Power Supply for PLC Outputs ................................................................................. 164
15.4.1 General ............................................................................................................ 164
15.4.2 Supply Voltage for PLC Outputs on MC 320 ................................................... 165
15.4.3 Supply Voltage for PLC Outputs on the PL 4xx B ........................................... 167
15.4.4 Supply Voltage for PLC Outputs on PL 510 ..................................................... 169
HEIDENHAIN Service Manual TNC 320

16 Encoder Interface ............................................................................................................ 171
16.1 Position Encoders...................................................................................................... 171
16.1.1 Introduction ...................................................................................................... 171
16.1.2 Configuration Data ........................................................................................... 172
16.1.3 Possible Causes of Errors ................................................................................ 172
16.1.4 Error Codes for Encoders with EnDat Interface .............................................. 173
16.1.5 Troubleshooting ............................................................................................... 174
16.1.6 Corrective Action ............................................................................................. 176
16.1.7 Resetting the Machine Datum ......................................................................... 177
16.1.8 Resetting the Spindle Orientation .................................................................... 179
16.1.9 Investigating Position Encoders ....................................................................... 180
16.2 Speed Encoders ........................................................................................................ 181
17 Reference Run .................................................................................................................. 183
17.1 Definition ................................................................................................................... 183
17.2 Traversing the Reference Marks ............................................................................... 184
17.3 Possible Causes of Errors.......................................................................................... 185
17.4 Deselecting Referencing of Axes .............................................................................. 185
18 Checking the Enables on TNC 320 ................................................................................. 187
18.1 General ...................................................................................................................... 187
18.2 Examination ............................................................................................................... 189
18.2.1 Checking the EMERGENCY STOP chain ......................................................... 189
18.2.2 Checking the Readiness of the Analog Servo Drives ...................................... 194
18.2.3 Checking PLC Operands of the "Axis" Group ................................................... 195
18.2.4 Checking PLC Operands of the "Spindles" Group ............................................ 197
19 Interface to the Analog Drives ........................................................................................ 199
19.1 Introduction ............................................................................................................... 199
19.2 Configuration Data..................................................................................................... 199
19.3 Specifications ............................................................................................................ 199
19.5 Troubleshooting......................................................................................................... 200
19.5.1 Observing the Analog Voltage ......................................................................... 200
19.5.2 Using a Battery Box ......................................................................................... 203
19.5.3 Switching the Analog Channels ...................................................................... 204
19.6 Adjusting the Electrical Offset................................................................................... 206
19.7 Speed Adjustment at Servo Amplifier ....................................................................... 210
19.8 Switching the Position Display for Service Purposes ................................................ 213
20 Flat-Panel Display ............................................................................................................ 215
20.1 Introduction ............................................................................................................... 215
20.3 Troubleshooting......................................................................................................... 216
20.4 Corrective Action ....................................................................................................... 217
21 Operating Keys and Potentiometers.............................................................................. 219
21.1 Introduction ............................................................................................................... 219
21.3 Checking the Keys..................................................................................................... 220
21.4 Checking the Potentiometers.................................................................................... 224
21.5 Key Matrix of MC 320 ............................................................................................... 228
22 Machine Operating Panel ................................................................................................ 235
22.1 Introduction ............................................................................................................... 235
22.3 Checking the Power Supply ...................................................................................... 236
22.4 Checking the Keys..................................................................................................... 237
January 2008 HEIDENHAIN Service Manual TNC 320

22.5 Checking the Outputs ............................................................................................... 238
23 Handwheel........................................................................................................................ 241
23.1 Introduction ............................................................................................................... 241
23.2 Possible Causes of Errors ......................................................................................... 242
23.3 Error Diagnosis at HR 410 Portable Handwheel........................................................ 243
23.4 Deselecting the HR 410 Portable Handwheel ........................................................... 246
23.5 Error Diagnosis at Panel-Mounted Handwheels........................................................ 247
23.5.1 Checking the Switches .................................................................................... 247
24 Touch Probe ..................................................................................................................... 251
24.1 Introduction ............................................................................................................... 251
24.2 Possible Causes of Errors ......................................................................................... 253
24.3 Checking TS 220, TS 440 and TS 640 ....................................................................... 254
25 Exchange of HEIDENHAIN Components........................................................................ 261
25.1 Important Information ............................................................................................... 261
25.2 Exchanging MC 320 .................................................................................................. 264
25.3 Exchanging the CFR Memory Card ........................................................................ 265
25.4 Replacing the Buffer Battery ..................................................................................... 268
25.5 Replacing the Potentiometers ................................................................................... 268
25.6 Exchanging Keyboard Components .......................................................................... 271
25.7 Exchanging Components of the Machine Operating Panel....................................... 275
25.8 Exchanging Other HEIDENHAIN Components ......................................................... 277
26 Loading of Service Packs ................................................................................................ 279
26.1 Introduction ............................................................................................................... 279
26.2 Preparations and Execution ....................................................................................... 280
27 Inspection and Testing Equipment ................................................................................ 283
27.1 Important Notes ........................................................................................................ 283
27.2 Test Adapter .............................................................................................................. 284
27.3 Universal Measuring Adapter .................................................................................... 288
27.4 PWM 9 Encoder Diagnostic Set ................................................................................ 289
27.5 PWT 10/17/18 Mounting Aid ..................................................................................... 291
27.6 IK 215 Adjusting and Testing Package ...................................................................... 292
27.7 Battery Box................................................................................................................ 293
28 Machine Parameters........................................................................................................ 295
28.1 ................................................................................................................ Explanation 295
28.2 The Configuration Editor............................................................................................ 297
1 Annex: Monitoring Functions ............................................................................................... 1
1.1 Introduction ..................................................................................................................... 1
1.2 During Start-Up................................................................................................................ 1
1.3 During Operation ............................................................................................................. 2
1.4 EMERGENCY STOP Monitoring...................................................................................... 3
1.5 ............................................................................Position or Following-Error Monitoring 4
1.6 Movement Monitoring .................................................................................................... 7
1.7 Standstill Monitoring ....................................................................................................... 8
1.8 Positioning Window ........................................................................................................ 9
1.9 Temperature Monitoring ............................................................................................... 11
2 Annex: Principle of Function of the TNC 320 Control....................................................... 13
2.1 Introduction ................................................................................................................... 13
2.2 Block Diagrams with Brief Explanations........................................................................ 13
2.3 Basic Circuit Diagrams ............................................................................................... 16
2.4 Interchange Possibilities on TNC 320............................................................................ 17
HEIDENHAIN Service Manual TNC 320

1 Safety Precautions
DANGER
Ensure that the equipment grounding conductor is continuous!

Interruptions in the equipment grounding conductor may cause damage to persons or
property.
DANGER
Ensure that the main switch of the control is switched off and that connected devices are
not under power when you engage or disengage any connecting elements or connection
clamps.
DANGER
In order to be able to judge the behavior of an NC controlled machine, service engineers

need to have fundamental knowledge of controls, encoders, drives, electronics and
mechanics.
Inappropriate use may cause considerable damage to persons or property.
Caution
HEIDENHAIN assumes no liability for indirect or direct damage caused to persons or

property through incorrect use or operation of the machine.
DANGER
Incorrect or not optimized input values may lead to malfunction of the machine and may
thus cause damage to persons or property.
The machine configuration (config objects and machine parameters) may only be changed
by the machine manufacturer or after consultation with the machine manufacturer!
Uncontrolled movements must be expected.
Caution
Note the safety precautions on the machine (e.g. stickers, signs) and the safety precautions
in the documentation of the machine manufacturer (e.g. operating instructions).
DANGER
Technicians who work on the electrical system of the machine must have the required
technical knowledge and competence!
DANGER
National regulations for power installations must be adhered to!
DANGER
Always secure vertical axes to prevent them from falling down before you perform tests
on these axes!
January 2008 1–7

DANGER
The interfaces for the PLC inputs/outputs, machine operating panel and PL expansion
cards comply with the basic insulation in accordance with IEC 742 EN 50 178.
Only units that comply with the requirements of IEC 742 EN 50 178 for basic insulation
may be connected, otherwise damage to persons or property may be caused.
The maximum mean dc voltage of the PLC inputs is 31 V.
Meaning of the
symbols used in
this manual
DANGER
Failure to comply with this information could result in most serious or fatal injuries,
and/or in substantial material damage.
Caution
Failure to comply with this information could result in injuries and interruptions of
operation, including material damage.
Note
These boxes contain important and useful information.
1–8 HEIDENHAIN Service Manual TNC 320

2 How to Use this Service Manual
2.1 About this Manual

This service manual assists service personnel in the field in diagnosing and correcting errors on
machine tools controlled by TNC 320.
It includes:
Error messages and types of errors that indicate a technical defect
Information on possible error causes
Descriptions of error diagnosis
Application descriptions of the diagnosis tools
Information on corrective action
Data backup instructions
Theoretical explanations of functions and their correlations
The “Overview of Possible Errors” on page 25 includes many references to troubleshooting
descriptions. You will find these descriptions in the chapters of the Service Manual sorted by
topics.
The descriptions comprise the possibilities of servicing the current hardware and software of the
control at the editing date of this manual. The service possibilities of your devices may differ
from those described here. The descriptions also provide information on any peculiarities of the
hardware or software.
This manual is valid for:

TNC 320 with NC software 340551 as of version 02
It is assumed that...
The machine had been working perfectly before the error occurred.
Only original spare parts are used!
Note
Basic knowledge of Windows is required for some of the descriptions in this Service
Manual, e.g. those that deal with the use of a service laptop or PC.
Update service This Service Manual is updated at irregular intervals.

You find the current printable version on our website -->
http://www.heidenhain.de/Services and Documentation/... /SHB TNC 320
You can download a ZIP file which requires a password to be unpacked. Your receive this
password during a HEIDENHAIN service training course or upon request by telephone!
Printed copies of the manual (ring binders) are only distributed to the participants of our service
training courses.
January 2008 2–9

2.2 Other Documentation
For more important information please refer to the following documentation:
Documentation by the machine manufacturer
(circuit diagrams, wiring diagrams, machine manual, etc.)
Manual of the servo manufacturer
HEIDENHAIN TNC 320 User's Manual
HEIDENHAIN TNCguide
HEIDENHAIN mounting instructions
Brochures of the respective HEIDENHAIN products.
Note
Other documentation is available in PDF format for free download from www.heidenhain de.
2.3 Support
Caution
The machine manufacturer must be contacted first for error diagnosis on your machine tool!
However, support will also be provided by the Service Department of HEIDENHAIN Traunreut
or by your HEIDENHAIN agency.
You will find telephone and fax numbers, as well as e-mail addresses, on the back cover of this
Service Manual, or on the HEIDENHAIN website at www.heidenhain.de.
2.4 Safety
DANGER
It is extremely important that you read the safety precautions in chapter 1!

See “Safety Precautions” on page 7.
2 – 10 HEIDENHAIN Service-Handbuch TNC 320

3 Code Numbers
3.1 Introduction
With code numbers …
certain areas of the memory card
certain file types
certain functions
... can be called.
DANGER
Code numbers may only be passed on to and/or be used by trained service technicians.
Inexpert handling may result in a loss of important data, in faulty machine performance and
thus lead to damage or injury to property or persons.
3.2 Overview
Code number Brief description
0 Delete the code numbers entered so far.
Same effect as a restart!
123 Edit the machine parameters the machine tool builder makes available
to the operator.
13852 Commission analog axes.
75368 Offset adjustment for analog axes, .
95148 Edit machine parameters, see page 28 – 295.
531210 Reset the non-volatile PLC operands. Control operation stops.
A restart is required.
555343 Enable special functions for Q parameter programming and
activate the table editor.
654321 Call the OLM area (online monitor), see page 8 – 41.
688379 Integrated oscilloscope, see page 9 – 45.
807667 Select the PLC Programming mode, see page 11 – 93.
857282 Reset the operating times.
NET123 Edit the network settings.
SIK Display of the number of the system identification key and of the enabled
options, see page 25 – 262.
January 2008 3 – 11
3.3 Notes on Entering the Code Numbers
Keep the code numbers confidential!
Code numbers can only be entered in the Programming and Editing mode.
The screen must be blank or the file editor displayed.
The program manager must not be open (pressing the MOD key would activate the
configuration data for the serial interfaces).
Press the MOD key and enter the code number. Conclude your entry by pressing ENTER.
Example:  Select the Programming mode of operation.

Calling the
configuration
 Call the code number window.
editor
 Enter and confirm the code number.
3 – 12 HEIDENHAIN Service Manual TNC 320

There are two ways to enter letters:
 Press the GOTO key. --> A pop-up window appears.
 Now use the numeric keypad to enter the letters or numbers (as when writing an SMS).
Or ...
 Connect a computer keyboard with USB interface to TNC 320 (connector X141 or X142).
Note
The machine manufacturer can define his own code numbers!

In this event the HEIDENHAIN code numbers do not function any longer, or only function to
a limited extent. --> Contact your machine manufacturer!
When certain code numbers are entered, new soft keys are displayed, e.g. CONFIG EDIT, PLC
EDIT, OSCI.
With these soft keys you can now change to the respective areas without having to enter the
code number again.
When you have finished your work do not forget to delete all code-number soft keys (CONFIG
EDIT, PLC EDIT, OSCI, etc.) --> Enter the code number 0, confirm with ENTER or restart the
control!
January 2008 3 – 13
4 Error Messages
4.1 Introduction
TNC 320 features a comprehensive integral monitoring system for the prevention of input or
operation errors, as well as for identification and diagnosis of technical defects on the control
and the connected devices. The monitoring system is an integral component of the TNC
hardware and software and is active as long as the control is switched on. The presence of a
technical fault or an operation error is made known through a plain-language message.
The effect of the monitoring functions is described in the annex. --> see “Annex: Monitoring
Functions” on page 1 – 1
Moreover, the machine manufacturer can define specific PLC error messages.
Type of error PLC error messages

message
Machine-specific error messages
Are defined by the machine manufacturer (e.g. coolant pump defective, protective door
open, etc.)
The machine manufacturer defines how the control reacts to a PLC error message (NC stop,
EMERGENCY STOP, etc.)
The machine manufacturer defines whether the control can still be operated or has to be
rebooted after a PLC error message.
If you have any questions, please contact your machine manufacturer.
NC error messages
Are part of the HEIDENHAIN NC software.
Can be subdivided into error messages that result from operation, programming and machine
applications and those that indicate a technical defect (devices, electronic and mechanical
components, etc.)
HEIDENHAIN defines how the control reacts to an NC error message (NC Stop, EMERGENCY
STOP, etc.)
HEIDENHAIN defines whether the control can still be operated or has to be rebooted after an
NC error message.
If you have any questions, please contact your machine manufacturer and/or HEIDENHAIN.
Operating-system error messages

Often contain the message CHILD PROCESS ERROR.
The control cannot be operated any more and has to be rebooted.
If you have any questions, please contact your machine manufacturer and/or HEIDENHAIN.
Display of an Error messages are displayed...

error message
In the screen header (at the top of the screen) usually in red color.
As a plain-language message.
January 2008 4 – 15
The machine manufacturer can display additional information on PLC error messages in the
small PLC window (above the soft-key row).
Reaction of Display only

the control
The machine does not react. Programs are not stopped.
NC Stop
The axes decelerate at the characteristic curve of the nominal value; normally the contour of
the workpiece is not damaged.
EMERGENCY STOP
Axes and spindle decelerate at the current limit; the machine is supposed to stop as quickly
as possible. The contour of the workpiece is not taken into account and may be damaged.
4.2 Error Window

The control displays one error in the header of the screen. Long and multi-line error messages
are displayed in abbreviated form. Complete information on all pending errors is shown in the
error window.
 Press the ERR KEY to call the error window.
(If you press this key again, the window will close.)
To obtain information on the cause of error and the corrective action, proceed as follows:
 Press the MORE INFORMATION soft key.

With the cursor keys you can select error messages from the error list.
To obtain further details on the error, such as date, time, event class, line of the NC program,
control program reporting the error, etc., proceed as follows:
 Press the INTERNAL INFORMATION soft key.
In the Source: line you can see whether the present error is an NC or a PLC type.
January 2008 4 – 17
Clearing errors To delete an individual error:
 Place the cursor on the entry to be deleted.
 Press the DELETE soft key (or the CE key).
To delete all errors listed in the error window:

 Press the DELETE ALL soft key.
If the error cause is still existing, the corresponding error message will be displayed again.
--> Correct the error!
Note
Some error messages cannot be acknowledged. --> Shut down the control correctly (soft
key OFF) and restart it afterwards.
If this does not work: Switch the power switch of the machine off and on again.
Information on the Error number: Assigned by HEIDENHAIN or by the machine tool builder.
error message Error class: Defines the control’s reaction to this error (see table).
Error text: Describes the error (in one or several lines). If the error occurs while an NC program
is being run, the line of the NC program will also be indicated.
Overview of error handling in the control:
Error class Reaction Display Log file Ack- Error

entry now- group
ledgmt.
Ev_class_2 none x Warning
Ev_class_3 none x Warning
Ev_class_4 none x x Warning
Ev_class_5 none x x x Error
Ev_class_6 Feed stop x x x Error
Ev_class_7 Program abortion x x x Error
Ev_class_8 Program aborts at x x x Error
stable position
Ev_class_9 Emergency stop x x x Error
Ev_class_10 Reset x x x System
error
Ev_class_11 NC Stop x x Error
Ev_class_12 NC Stop x x x Error
Ev_class_13 Program abortion x x Error
Ev_class_14 Reset – without x x x System
output of error text error
(“Processor check
error”)
Ev_class_15 Feed stop x x Error
Ev_class_16 Emergency stop x x Error

Error class Reaction Display Log file Ack- Error
entry now- group
ledgmt.
Ev_class_17 Display informational x x Info
text
Ev_class_18 none x x Warning
Ev_class_19 Program abortion x x x Error
Ev_class_18 is used to report that service files were saved.
Checking logs Error and keystroke logs can be used to examine error messages and keystrokes in their time
sequence. --> see “Logs and Service Files” on page 7 – 35
Saving error Being part of an error log, error messages can be saved to a ZIP file. --> see “Logs and Service
messages Files” on page 7 – 35
January 2008 4 – 19
4.3 List of NC Error Messages
Complete list You can find the complete list of all NC error messages (including operator errors) on the
TNCguide DVD in several languages and sorted by error numbers.
This TNCguide information is also available on our website
http://www.heidenhain.de/Services and Documentation/...
This is the official list of NC error messages which contains all possible errors of HEIDENHAIN
controls that operate with the NC kernel operating system.
It comprises technical error messages as well as error messages related to operation and
handling!
Note
When it is possible and useful you should switch the control off and on again in order to see
whether the error message is generated again afterwards.
Filtered list The list below contains the most important error messages that indicate a technical defect.
A reference will be made, if there are additional descriptions in this Service Manual.
Error Message Possible Cause of Error Measures for Error Diagnosis and/or
Corrective action
Deviation in the switch-on The switch-on position of this axis Check current position
position of axis %2 too large deviates from the last one stored by See ”Troubleshooting” on page 16 –
more than permitted tolerance. 174
See ”Possible Causes of Errors” on See ”Investigating Position Encoders”
page 16 – 172 on page 16 – 180
Amplitude too high at position Noise on signal See ”Troubleshooting” on page 16 –
encoder %1 Scanning head too close to scale 174
For very old encoders: Incandescent See ”Investigating Position Encoders”
lamp too bright (spiral-wound filament on page 16 – 180
short-circuited) Adjust scanning head
See ”Possible Causes of Errors” on
page 16 – 172
Movement monitoring error See "Excessive servo lag in %2" See "Excessive servo lag in %2"
in %2
Input frequency of position Noise on position encoder signals Check the shielding (see “Notes and
encoder %.1s Tips” on page 6 – 33)
Check the encoder signals (see
“Investigating Position Encoders” on
page 16 – 180)
EnDat encoder (%2) reports Connected EnDat encoder or encoder See ”Troubleshooting” on page 16 –
error cable is defective 174
page 16 – 172 on page 16 – 180
EnDat encoder (%2) reports Connected EnDat encoder or encoder See ”Troubleshooting” on page 16 –
wrong position cable is defective 174
page 16 – 172 on page 16 – 180

Corrective action
EMERGENCY STOP EMERGENCY STOP key pressed on Unlock EMERGENCY STOP button
machine operating panel or handwheel Retract axis
Axis is on hardware limit switch Check EMERGENCY STOP chain (see
Wiring interrupted “Checking the EMERGENCY STOP
Relays, safety contactor combinations chain” on page 18 – 189)
defective If "Control is ready“ output is defective
X34 is not powered with 24 V --> Replace MC 320 (see “Exchanging
MC 320” on page 25 – 264)
"Control is ready“ output of MC 320
defective
Processor check error! The 24 V control voltage for the relays Check the +24 V power supply
Relay ext. DC voltage missing is not present. Check the fuses (see “Supply Voltage
The PLC fuses in the MC 320 have for PLC Outputs on MC 320” on page
blown. 15 – 165)
Wiring interrupted
Handwheel? Electronic handwheel not connected Connect a handwheel
Transmission line defective Check the cables
Position encoder %2: Amplitude The amplitude of the position encoder See ”Troubleshooting” on page 16 –
too small signal is too low or the contamination 174
signal is active. See ”Investigating Position Encoders”
See ”Possible Causes of Errors” on on page 16 – 180
page 16 – 172
Position encoder %2 defective Contradiction apparent from See ”Troubleshooting” on page 16 –
comparison of absolute and 174
incremental positions. See ”Investigating Position Encoders”
page 16 – 172
Position encoder %1 defective No signal present See ”Troubleshooting” on page 16 –
See ”Possible Causes of Errors” on 174
page 16 – 172 See ”Investigating Position Encoders”
on page 16 – 180
Position encoder %1 defective EnDat cannot be read See ”Troubleshooting” on page 16 –
(EnDat) See ”Possible Causes of Errors” on 174
on page 16 – 180
Position input %1 measured Position value of position encoder was See ”Troubleshooting” on page 16 –
value not saved (EnDat) not stored 174
Interruption in cable See ”Investigating Position Encoders”
Position encoder defective on page 16 – 180
See ”Possible Causes of Errors” on
page 16 – 172
Position encoder %1 defective No signal present See ”Troubleshooting” on page 16 –
See ”Possible Causes of Errors” on 174
on page 16 – 180
MC +5V out of tolerance The 5 V voltage is raised or lowered by Disconnect or remove all devices (also
errors within or outside the control. USB devices) from the control. If
required, deactivate them in the MP
list. Observe, whether the error
message is repeated. Find the
defective device (see “Error
Localization by Process of Exclusion”
on page 6 – 31)
If the power supply unit in the control is
defective --> replace MC 320
(see “Exchanging MC 320” on page 25
– 264)
MC amplitude too high %2 See "Amplitude too high at position See: "Amplitude too high at position
encoder %1" encoder %1"
January 2008 4 – 21
Corrective action
MC amplitude too low %2 See "Position encoder %2: Amplitude See "Position encoder %2: Amplitude
too small" too small"
MC housing fan defective Rotational speed of the housing fan is Return the MC 320 for repair (see
too low “Exchanging MC 320” on page 25 –
264)
MC NC temperature out of tol. See "Temperature too high (CPU%1 := See "Temperature too high
%2°C)" (CPU%1:= %2 °C)"
Encoder defective %1 Evaluation of ref. marks of distance- See ”Troubleshooting” on page 16 –
coded encoder is faulty 174
page 16 – 172 on page 16 – 180
Encoder %1 defective See "Position encoder %1 defective" See "Position encoder %1 defective"
EMERGENCY STOP defective Relays, safety contactor combinations Replace relays, safety contactor
defective or too slow combinations
Input I3 (X42/4) is permanently at 24 V Check input I3 (see “Checking the
MC 320 defective EMERGENCY STOP chain” on page 18
– 189)
Error in zero pulse distance of Contradiction apparent from See ”Troubleshooting” on page 16 –
encoder %2 comparison of absolute and 174
incremental positions See ”Investigating Position Encoders”
page 16 – 172
Pos. error too large %.1 See "Excessive servo lag in %2" See "Excessive servo lag in %2"
Exchange buffer battery The voltage of the buffer battery is too Replace buffer battery (see “Buffer
low. Battery” on page 15 – 161)
Excessive servo lag in %1 See "Excessive servo lag in %2" See "Excessive servo lag in %2"
Excessive servo lag in %2 Blunt tool See ”Sequence for Finding Errors in
Insufficient lubrication the Control Loop” on page 6 – 29
Machining feed rate too high Reduce machining feed rate
Spindle speed too low Increase spindle speed
Shocks, vibrations Remove shocks, vibrations
Stiffness of mechanical components Carry out offset adjustment (see
“Adjusting the Electrical Offset” on
Excessive offset page 19 – 206)
Incorrect speed adjustment Carry out speed adjustment (see
Speed encoder defective “Speed Adjustment at Servo
Defective carbon brushes Amplifier” on page 19 – 210)
Excessive backlash Check the speed encoder (ask the
manufacturer!)
Coupling system defective (belt, gear,
coupling) Replace carbon brushes
Defect in the mounting of the position Remove backlash
encoder or scanning head Fasten encoder or scanning head
Position encoder or cable defective See ”Investigating Position Encoders”
on page 16 – 180
Signal frequency at position See "Input frequency of position See "Input frequency of position
encoder %1 encoder %1" encoder %1"
Standstill monitoring %2 Shocks, vibrations See ”Sequence for Finding Errors in
Excessive offset the Control Loop” on page 6 – 29
Vertical axes: Poor brake or faulty Remove shocks, vibrations
weight balance Carry out offset adjustment (see
Great mechanical effects during “Adjusting the Electrical Offset” on
machining page 19 – 206)
Replace or repair brake, adjust weight
balance
Check tools

Corrective action
Relay ext. DC voltage missing EMERGENCY STOP key pressed on Unlock EMERGENCY STOP button
machine operating panel or handwheel Retract axis
Axis is on hardware limit switch Check EMERGENCY STOP chain (see
Wiring interrupted “Checking the EMERGENCY STOP
Relays, safety contactor combinations chain” on page 18 – 189)
defective If "Control is ready“ output is defective
X34 is not powered with 24 V --> Replace MC 320 (see “Exchanging
MC 320” on page 25 – 264)
"Control is ready“ output of MC 320
defective
Stylus already in contact Stylus is already deflected at start of Retract touch probe, repeat probing
probing movement Inspect touch probe for damage
See ”Touch Probe” on page 24 – 251
Exchange touch probe battery Battery dead Replace battery
Touch probe not ready Touch probe not connected Connect touch probe
Battery dead Replace battery
Penetration of humidity Dry the touch probe
Touch probe cable defective Replace cable
Cable to transmitter/receiver unit Clean touch probe and transmitter/
defective receiver unit
Contamination of probe and/or Remove obstacle from infrared
transmitter/receiver unit connection
--> No infrared connection Readjust receive range of SE
Obstacle in infrared connection or If the interface to touch probe or
strong shadowing of transmitter or transmitter/receiver unit on the MC is
receiver defective --> Replace MC 320 (see
Several touch probes may be within the “Exchanging MC 320” on page 25 –
receiving range of one SE; the infrared 264)
signals cannot be allocated any more; See ”Touch Probe” on page 24 – 251
faulty operation.
Interface to touch probe or transmitter/
receiver unit on MC defective
Temperature too high (CPU%1 Climate control unit in electrical cabinet Repair or replace climate control unit
:= %2°C) defective Clean the filter pads
Clogged filter pads Replace fan in electrical cabinet
Fans in electrical cabinet defective If the fan in the control is defective
Fan in MC 320 defective ---> Replace MC 320 (see “Exchanging
Temperature sensor in the control MC 320” on page 25 – 264)
defective If the temperature sensor in the control
Unfavorable mounting of components is defective --> Replace MC 320 (see
“Exchanging MC 320” on page 25 –
264)
January 2008 4 – 23
5 Errors
5.1 Introduction
Not all error conditions on the control or machine can be shown by error messages on the
monitor.
Therefore, this chapter gives you an overview of errors with notes and tips on how to proceed.
Static and Errors can be assigned to the categories of static errors (e.g. interruption in the electrical cabinet,
nonstatic errors defective device) and nonstatic errors (e.g., loose connection, shielding problems,
interferences).
Naturally, static errors can be found more easily.
Sporadic and Check whether you can reproduce a certain error on the machine at any time (nonsporadic error).
nonsporadic This assists you in troubleshooting.
errors To investigate sporadic errors e.g. the integrated log files and the integrated oscilloscope are
suited.
5.2 Overview of Possible Errors

The following table shows an overview of specific errors on the machine or control, possible
causes of the errors as well as measures for finding these errors.
The potential measures for finding and correcting the errors are described in more detail in the
corresponding chapters.
Note
Where it is possible and useful, you may switch the control off and on to observe whether
the error is generated again afterwards.
Error Possible Error Cause Measures for Error Diagnosis and/

or Corrective action
The TNC 320 monitor remains Power supply of MC 320 defective Check the MC power supply, see
dark after the machine has been Monitor defective “Power Supply” on page 15 – 159
switched on Defective unit connected to the Check the monitor, see “Flat-Panel
or control (short circuit, humidity etc.) Display” on page 20 – 215
the screen goes blank during
Cable defective Disconnect suspicious devices, see
operation. “Sequence for Finding Errors in the
Control Loop” on page 6 – 29
see “Low voltages and polyfuses”
on page 6 – 33
Axis movement slower than Feed-rate potentiometer defective See ”Checking the Potentiometers”
programmed feed rate Feed rate limited by PLC on page 21 – 224
Touch probe active Check the entry in API DATA/
CHANNEL/
PP_CHNCONTOURFEEDMAX, see
“The API DATA Function” on page
10 – 58
Check the entry in API DATA/
CHANNEL/
PP_CHNTCHPROBEMONITOR, see
“The API DATA Function” on page
10 – 58
January 2008 5 – 25
The control does not boot completely No good contact of memory card Remove and re-insert the memory
(error messages related to the booting Memory card defective card
procedure may be displayed). Replace memory card or MC 320,
see “Exchange of HEIDENHAIN
Components” on page 25 – 261
The message RELAY EXTERNAL DC EMERGENCY STOP chain Check "Control is ready" output and
VOLTAGE MISSING does not disappear, interrupted acknowledgment I3, see “Checking
although the key "Control voltage ON" 24 V power supply from connector the Enables on TNC 320” on page
is pressed. X 34 is missing 18 – 187
MC 320 defective
The Power interrupted message The control does not receive the see “Operating Keys and
cannot be confirmed signal of the CE key Potentiometers” on page 21 – 219
The machine cannot be referenced Interruption between NC Stop key Eliminate the interruption, repair the
after switch-on, or during operation and control (the NC Stop signal is key, etc., see “Machine Operating
neither the axes can be moved nor the low-active) Panel” on page 22 – 235
spindle switched on.
The machine is in the mode Cross Drive system not ready for operation See ”Checking the Readiness of the
over reference points which is Analog Servo Drives” on page 18 –
Alarm from servo 194
neither possible with the NC START
key nor with the axis direction keys. Feed-rate enable missing
See ”Checking the Enables on TNC
NC STOP signal active 320” on page 18 – 187
Inspect NC Stop key
During reference run, the machine The trip dogs for direction reversal See ”Reference Run” on page 17 –
moves to the EMERGENCY STOP limit during reference run are defective 183
switch or to the mechanical stop (for PLC input at TNC 320 or PLC I/O See ”Checking the PLC inputs” on
machines with trip dogs) board (e.g. PL 510) defective page 10 – 63
During reference run, the machine The reference marks of the linear or Check linear scale, angle encoder,
moves to the EMERGENCY STOP limit rotary encoders were not evaluated etc., see “Encoder Interface” on
switch or to the mechanical stop (for The reference marks of the rotary page 16 – 171
machines without trip dogs) encoders in the servo motors were Check servo motor, drive amplifier --
not evaluated > Ask the manufacturer!
The STIB symbol for "Control-in- Axis did not reach the positioning Perform drift adjustment see
operation" (NC START button in status window “Adjusting the Electrical Offset” on
display) remains in place even though Excessive static and sliding friction page 19 – 206
positioning appears to be completed.I (slip & stick ) After axis post/re-optimization
in the automatic operating modes the Excessive offset Check the workpiece
next NC block is not executed; the NC Approach behavior of axis not
program hangs. optimized
Chip in threaded hole; reversal point
is not reached
Axes oscillate; loud noise may be Negative mechanical changes in the Check the mechanics of your
produced machine axes machine; consult your machine
manufacturer
Axis "jolts" Carbon brushes to supply the motor Exchange the carbon brushes
with energy or to pick off the
speedometer are abraded on one
side or used up
Inexplicable drift of the drives (offset Poor shielding or grounding Check the grounding of your
and speed adjustment at the servos machine; consult your machine
are OK) manufacturer
Ensure that all grounding clamps are
secure
See ”Shielding and grounding” on
page 6 – 33
The following error is too high at axis Excessive drift Perform drift adjustment see
standstill. “Adjusting the Electrical Offset” on
page 19 – 206

Various error messages are generated Short circuit of shield potential Check the cables for damage. Check
which, however, are not substantive. (chassis, cable shielding) to the 0 V the machine for correct shielding
potential of the NC power supply (ask the machine manufacturer).
Disconnect the data lines from the
machine.
See ”Shielding and grounding” on
page 6 – 33
NC functions do not function any more Data loss on the memory card in the Check the memory card, see
(the control may have reported that the SYS partition area “Memory-Card Test” on page 11 –
corresponding files have been 90
deleted). Reload the NC software --> Contact
your machine manufacturer.
The number of memory-card errors Defects on the memory card Check the memory card, see
increases. “Memory-Card Test” on page 11 –
90
January 2008 5 – 27
6 Procedures and Tips for Error Diagnosis
6.1 Introduction
The following systematic procedures have proven themselves for error diagnosis at a machine
tool.
They are described below.
Note
Make use of the extensive diagnosis options of TNC 320, such as...
Integrated oscilloscope (see “Integrated Oscilloscope” on page 9 – 45)
PLC diagnosis (see “PLC Diagnostics” on page 10 – 55)
Log files (see “Logs and Service Files” on page 7 – 35)
Online monitor (see “Diagnosis with the Online Monitor (OLM)” on page 8 – 41)
Also note the procedures and tips for error diagnosis at NC-controlled machine tools in
chapter 6.5!
6.2 Sequence for Finding Errors in the Control Loop

To find the cause of errors related to movement, acceleration and standstill (e.g. Excessive
servo lag, Movement monitoring, Standstill monitoring), you should inspect the machine
components in the following sequence:
See flowchart on the next page!
Note
If you need information on lubrication, mechanics, hydraulics, pneumatics, brakes, coupling

system and drives, please contact your machine manufacturer!
Trouble-shooting at the TNC 320 and the connected devices is described in this manual
(e.g. in the chapter "Encoder interface").
Note
In exceptional cases defective measuring systems may be the cause of the above-
mentioned error messages in the control loop. Due to defective electronics or a damaged
cable, constant voltage values are supplied to the control that are within the tolerance range
of the encoder specifications. Consequently, no encoder error message is generated!
To perform an analysis, increase the monitoring limits (e.g. for the following error, see
“Annex: Monitoring Functions” on page 1 – 1) such that a longer distance can be traversed.
Now inspect the encoder signals with an appropriate measuring device (e.g. PWM 9, see
“PWM 9 Encoder Diagnostic Set” on page 27 – 289).
When the axis is moved, the signal must change (sine, cosine)!
Finally, restore the original monitoring tolerances!
January 2008 6 – 29
Flowchart
Procedure in the event of errors in the control loop
Inspection of lubrication, tools, mechanics, e.g.:

- Oil level, lubricating film
- Blunt or damaged tools
- Guideways
- Ball screw
Lubrication, NO Ensure proper lubrication,

tools, mechanics replace defective tools,
OK? correct the mechanical error.
YES
Inspection of hydraulics, pneumatics, brakes with e.g.:

- Weight compensation
- Hirth coupling
- Motor brakes
Hydraulics, NO
Correct error in hydraulics,
pneumatics, brakes
pneumatics, brakes.
OK?
YES
Inspection of coupling system, e.g.:

- Belt tension
- Gear
- Coupling
Coupling NO
Correct errors in
system
coupling system.
OK?
YES
Inspection of drive system, e.g.:

- Motors and cables
- Servo amplifiers
Drive NO
Correct errors in
system
drive system.
OK?
YES
Inspection of control, e.g.:

- Interface to drives
- Interface to encoders
NO
Control and Replace defective control
connected devices OK? or encoders or cables.
YES
Call machine tool manufacturer or a HEIDENHAIN service agency.

6.3 Error Localization by Process of Interchange
For checking machine-tool components that are available more than once (such as encoders,
analog channels, servo amplifiers, motors, etc.) the "interchange method" can be used.
To do this, interfaces or identical devices are interchanged in order to find out, whether the
error "moves".
Example:
Interchange
possibilities
on TNC 320
Interchanging interface assignments of position encoders -->

see “Encoder Interface” on page 16 – 171
Interchanging interface assignments of analog axes -->

see “Interface to the Analog Drives” on page 19 – 199
Interchanging identical servos and motors -->

Ask the machine manufacturer!
6.4 Error Localization by Process of Exclusion

For the "exclusion method" probably defective devices, axes, etc. are disconnected and
deselected in the NC software in order to see, whether the machine works properly afterwards.
The "exclusion method" is useful in the following events:
The monitor remains dark after the machine is switched on -->

see “Troubleshooting” on page 20 – 216
Errors occur that concern the handwheel -->

see “Deselecting the HR 410 Portable Handwheel” on page 23 – 246
Errors occur that concern a certain axis -->

See flowchart on next page "Deselecting an axis"
January 2008 6 – 31
Deselection of an axis
Switch off the machine.
Disconnect the encoder for the axis

concerned and separate
the interface between control and
analog servo amplifier for this axis.
Press the EMERGENCY STOP button and

switch on the machine.
Do not acknowledge the Power interrupted

message but call the MP list.
In the attribute axisMode, select NotActive

for the axis concerned, save the setting and
restart the control.
Do No
The errors are limited to one axis!
error messages continue
Find out the error cause.
to occur?
Yes
The errors are not limited to one axis!

There are other faulty axes / units or
general errors.
Note
The PLC program may prohibit the deselection of individual axes.

--> Ask your machine manufacturer!
Errors occur that do not uniquely refer to a certain axis or connected device.
--> Sequentially deselect the axes or disconnect the devices and deselect them in the
NC software!
Note
If you intend to use the exclusion method for the tool changer, chip conveyor, etc., contact
your machine manufacturer!

6.5 Notes and Tips
Power Where it is possible and useful, you may switch the control off and on to observe whether the
OFF and ON error is generated again afterwards.
What is the cause Ask the operator or technician who worked last with or on the machine about the detailed course
of this error? of events.
Were there any particular incidences such as …
Thunderstorms
Modifications to the machine
Update of NC software
New machining program
Tool breakage
Collision
Power failure
Etc.
The error diagnosis will be easier for you if you ask pointed questions to get precise answers!
Comparison with If identical machines or devices are available, you can compare the functions.
functioning
This can be very helpful for troubleshooting!
machines or
devices
Males and Observe the following instructions for connecting or disconnecting any connectors:
females
Connect and disconnect straightly! Otherwise, the spring contact in the D-sub connectors
could be widened. This may result in contact problems!
Low voltages All units connected to the control are supplied by the control (encoders with long cables
and polyfuses are maybe provided with voltage amplifiers).
The TNC 320 features "polyfuses".
Polyfuses are electronic "self healing" fuses that become highly resistive if an overload occurs
and thus separate defective peripherals (encoders, handwheel, USB devices, touch probes,
machine operating panel) from the low voltages in the control.
Error messages related to the respective device may be displayed afterwards.
Caution
The video signal is switched off, if there is a short-circuit in the power supply of the
handwheel (12 V) or in the 15 V power supply of the touch probe (not the 5 V supply).
--> The screen goes blank!
Shielding and Defective shieldings and groundings may also result in undefined errors or in a malfunction of
grounding the machine (e.g. vibration of axes, poor quality of the workpiece surface). The reason are
compensating currents that are caused by potential differences.
Therefore, check the terminals, shielded cables (the braiding must not contact the 0 V conductor
inside the cable), cover plates, grounding bars, contact plates, etc.
Sources of Also consider possible sources of interference that may have a negative effect on the control
interference and the connected devices.
Interference is mainly produced by capacitive and inductive coupling from electrical conductors
or from device inputs/outputs, such as ...
Strong magnetic fields, e.g. from transformers, electric motors, magnetic clamping tables
Relays, contactors and solenoid valves
January 2008 6 – 33
High-frequency equipment, pulse equipment and stray magnetic fields from switch-mode
power supplies
Adjoining welding facility
Power lines and leads to the above equipment
Make sure that …

There is a minimum distance of 20 cm from the control and its leads to interfering equipment.
There is a minimum distance of 10 cm from the control and its leads to cables that carry
interference signals. For cables in metallic ducting, adequate decoupling can be achieved by
using a grounded separation shield.
The cross section of potential compensating lines is at least 6 mm2.
Note
Contact the machine manufacturer if these conditions are not fulfilled!
Contamination Pay special attention to contaminated units (oil, grease, dust, etc.)!
What could be the reason for the contamination?
Some examples:
Machining of graphite
Coolant or coolant vapor
Defective filter system in the electrical cabinet (filter pads)
Oil or oil vapor
Oil in the compressed-air system
Temperature Use the appropriate equipment to measure, whether the temperature is exceeded.
What could be the reason?
Some examples:
Climate control unit in electrical cabinet defective
Clogged filter pads
Defective fan
Motors and servos overloaded
Defective temperature sensors
Unfavorable mounting of components
DANGER
The permissible ambient temperature during operation is 0 °C to 40 °C.

Any deviation from this will impair the operating safety of the device!
Humidity Check whether humidity has entered the units!

What could be the reason?
Some examples:
Climate control unit in electrical cabinet defective
Coolant or coolant vapor
Condensation of boards due to changes in temperature
Defective tubes, sealings, etc.

7 Logs and Service Files
7.1 General
Logs and service files serve as troubleshooting aids.
The log files comprise the error log, the keystroke log and the service files.
For this purpose errors and system information (system start, system end, etc.) are entered.
All keystrokes and mouseclicks are logged.
Note
The first horizontal soft key (bottom left on the monitor) is entered as HORZSOFTKEY1 in the
keystroke log, the second one as HORZSOFTKEY2, etc.
The arrow keys for switching the horizontal soft-key rows are logged (SOFTKEYSCROLLLEFT
and SOFTKEYSCROLLRIGHT).
Any newly called soft-key row starts with HORZSOFTKEY1.
The first vertical soft key (top right of the screen) is entered as VERTSOFTKEY1 in the log,
the second one as VERTSOFTKEY2, etc.
The arrow key for switching the vertical soft-key rows is logged as SOFTKEYSCROLLUP.
Any newly called soft-key row starts with VERTSOFTKEY1.
All entries show the date and the local time.
Note
The error log also features a counter which is incremented at IPC clock pulse.
This counter is used as time reference for the information in the individual service files.
January 2008 7 – 35
7.2 Calling the Logs
 Press the ERR key to open the error window.
 Press the LOG FILES soft key.
 Now you can open the error log file by pressing the ERROR LOG soft key.
The soft key KEYSTROKE LOG opens the log containing the keystrokes.

7.3 Settings for the Logs
Current and Two files are available for the error log and the keystroke log: the current file and the
previous file previous file.
As soon as the current file is full, it becomes the previous file and the control creates a
new current file.
I.e. if you do not find an error message or a keystroke in the current file:
Press the PREVIOUS FILE soft key.
Search this file for the error message or keystroke.
Setting filters in Use a filter to limit the log file display to the following error groups:
the error log
Information
Warnings
Errors
System errors
Whether the filter is taken into account depends upon the setting of the
FILTER ON / OFF soft key.
 Press this soft key to activate the filter settings.
 Now press the FILTER SETTINGS soft key.
 Press the filter soft keys to obtain the desired display.
 Press the REFRESH soft key.
With the soft key MORE FILTER FUNCTIONS you can ...
Select clients whose errors and error information are to be considered in the log file display.
Select date and time from which you want the log file contents to be displayed.
 Close the dialog box with OK and press the REFRESH soft key again to load the settings.
January 2008 7 – 37
7.4 Saving Service Files
 Press the ERR key to open the error window.
 Press the LOG FILES soft key.
 Press the soft key SAVE SERVICE FILES. --> The files concerned are zipped and
stored in the TNC:\ main directory.
Note
The files that are compressed here comprise the files defined by HEIDENHAIN as well as
all files in the directories PLC:\Service and TNC:\Service (if existing).

Note
Five ZIP files maximum can be generated.

The name of the most recent file is service1.zip.
January 2008 7 – 39
7.5 Evaluating the Service Files
The compressed service files cannot be viewed on the control.
 Read out the required ZIP file (e.g. service1.zip) to an external data medium.
 Decompress the ZIP file.
 Open the log files with a text editor.
 Other files you can e.g. open with EXCEL.
The compressed service file contains a large number of files.

Among these files are the error logs LogFile.log and LogFileSave.log for the current and the
previous file. Open these files with a text editor.
The names of the keystroke logs are keylog.xml, keylog1.xml, keylog2.xml. Open these files
with the XML editor.
In the file _ParamCheck.txt the axis properties are listed next to each other in a table. Open this
file with EXCEL.
The file hardware.sys provides information on the hardware used. Open this file with EXCEL.
Note
For further evaluation in detail send the compressed service files (e.g. service1.zip) to your
machine your machine manufacturer or to a HEIDENHAIN service agency.

8 Diagnosis with the Online Monitor (OLM)
8.1 Introduction
The OLM (OnLine Monitor) is part of the control software and can be used for diagnosing
MC 320.
Software structure
8.2 OLM Operation
Starting and Starting the OLM:

exiting the OLM
 Switch to the Programming operating mode.
 Press the MOD key.
 Enter the code number 654321 for the control to activate the OLM main menu.
Exiting the OLM:

 Change to the main level of the OLM.
 Press the END soft key.
January 2008 8 – 41
8.3 Screen Layout
8.3.1 Variable display

Example of screen layout when variables are displayed:
The OLM lists the variable designations, status designations, etc. in the dark-highlighted
boxes of the “main window.”
The white-highlighted boxes contain the variable values. The OLM displays the values of two
axes or channels.
In the column heading, the axis designation or channel designation defined in the parameters
is shown.
Parameter for axis designation:
System/CfgAxes/axisList(axisId)
Parameters for channel designation for IPO:
ChannelGroup/CfgChannelGroup/Machining/ChannelList
Parameter for channel designation for SimIpo:
ChannelGroup/CfgChannelGroup/Simulation/ChannelList
The term Index n in the column heading means that no axis or no channel is defined for this
index.
The following general data is displayed in the bottom display line:
Connected: Indicates the software or function area to which the OLM is connected.
Ipo
SimIpo
PLC
none: No connection
IpoCounter: Counts the IPO clock pulses
Note: The contents of the IpoCounter are also stored for trace information and error
messages.
Ax/Chn-Number: Logical axis number or channel number (depends on the selected function)
Number at left: Left column
Number at right: Right column

If the number of variables displayed exceeds the capacity of the main window, use PageDown/
PageUp to scroll to the next/previous group of variables. One group consists of eight displayed
variables.
8.3.2 Units
The OLM displays data in the following units:
Linear axes
For position, length, etc: in [mm]
For speed: in [mm/s]
For acceleration: in [mm/s2]
Rotary axes (spindles)
For position, etc: in [°]
For speed: in [°/s]
For acceleration: in [°/s2]
8.3.3 Status display

Example of screen layout for status display:
In the main window, the status of the binary variables is displayed. The status is identified by the
background color and the code letter.
Green or “T”: true
Red or “F”: false
Yellow: Status not defined yet
The information given about the display of variables also applies to the column headings and the
bottom display line.
January 2008 8 – 43
8.4 Using the OLM for Troubleshooting
The use of the online monitor for field service is described in the respective chapters of this
Service Manual.

9 Integrated Oscilloscope
9.1 Introduction
The TNC 320 features an integrated oscilloscope with...
6 channels for recording analog signals
16 channels for recording digital signals
Note
The integrated oscilloscope is a useful aid for investigating errors related to axis
movements.
For example, the comparison of actual to nominal values, such as distance, velocity and
acceleration may provide information about possible error locations and causes.
Note
The integrated oscilloscope also allows for simultaneous recording of analog signals and
PLC signals!
9.2 Activation and Settings

 Switch to the Programming operating mode.
 Enter the code number 688379. --> The control displays the Settings page.
January 2008 9 – 45
Setup for  Press the SELECTION soft key.
analog signals
and PLC signals
In the dialog box, set:
 Type of display: Set the time interval for recording the signals.
YT: Chronological depiction of the channels
YX: Graph of two channels
 Sampling time: Set the time interval for recording the signals.
CC clock: Time interval = 0.6 ms
IPO clock: Time interval = IPO clock = 3 ms
PLC clock: Time interval = PLC clock
(results from System/CfgCycleTimes/plcCount * Ipo clock)
3 000 grid points (events) are stored. The time grid determines the duration of recording.
Examples:
0.6 ms ⋅ 3000 = 1.8 s
3 ms ⋅ 3000 = 9 s
21 ms ⋅ 3000 = 63 s
Note
TNC 320 with analog axes does not feature a CC (digital controller).
Therefore, the smallest reasonable time interval is the 3 ms IPO clock!
Channel 1 to channel 6
Specify the signals to be recorded:
 Assign the channels of the analog signals to be recorded to the respective axes.
 Specify the operand type (B,W,D,I,O,T,C) and the address for the recording of PLC operands.

 Use the SAVED setting to “freeze” the signal last recorded for this channel. This means that
the recorded values remain available on the display. For example, you can use them to record
a reference curve for use in future measurements.
Note
To compare a "SAVED" signal to a newly recorded signal both recordings should be made
with the same trigger conditions!
Otherwise, shifts on the time axis may make signal comparison difficult or impossible.
Trigger conditions:
Specify the trigger conditions in the following input fields:
 Trigger: Set the trigger condition.
Single shot: After pressing the soft key, the next 3000 events are stored.
Free run: The recording is started and ended by soft key. When you press the STOP soft
key, the last 3000 events (maximum) are saved.
Channel 1 to Channel 6: Recording begins when the trigger condition of the selected
channel is fulfilled.
Channel 1 + L to channel 6 + L: Recording begins when the trigger condition of the channel
selected here as well as the trigger conditions of the digital signals (trigger condition “logic”)
are fulfilled. The trigger conditions are AND-gated.
Logic: Recording begins when the trigger condition of the digital signals is fulfilled (trigger
condition “logic”).
 Edge: Set when triggering is to occur:
+: Trigger at rising edge
–: Trigger at falling edge
 Trigger threshold: Enter the trigger threshold (you will find the appropriate units in the signals
table on Page 49).
 Pre-Trigger: Select a value from the selection box.
Recording begins at a time preceding the trigger time point by the value entered here.
The Output and Feed rate F fields are reserved.
January 2008 9 – 47
Special setup for Call the “M, I, O, T, C selection” dialog box:
the PLC signals  Press the SELECT MIOTC soft key.
M, I, O, T, C
Set:
 Operand: Type and number of the PLC operand
M: Marker
I: Input
O: Output
T: Timer
C: Counter
 Trigger:
X: No trigger
0: Trigger at 0-level
1: Trigger at 1-level
The trigger is only taken into consideration if Selection = X is set.
 Selection:
X: Signal is displayed and considered as trigger
Empty field: Signal is not displayed and not considered as trigger
Note
You define the general trigger conditions (“Trigger” input field) and the pre-trigger in the
setup for analog signals.
The trigger condition “logic” is fulfilled when all triggers set in “MIOTC SELECT” are
fulfilled (AND-gating).

Overview of signals
Analog signals Meaning

Off No recording for this channel
SAVED The signal last recorded on this channel is “frozen.”
a act Actual axis acceleration value [mm/s2] or [°/s2].
Calculated from position encoder.
a nom Nominal axis acceleration value [mm/s2] or [°/s2].
v act Actual value of the axis feed rate [mm/min] or [°/min].
Calculated from position encoder
v nom Nominal value of the axis feed rate [mm/min] or [°/min].
Axis feed rate calculated from the difference from the nominal
position values. The following error is not included.
Feed rate F Contouring feed rate [mm/min] or [°/min]
s act Actual position [mm] or [°]
s nom Nominal position [mm] or [°]
s diff Following error of the position controller [mm] or [°]
j act Actual jerk value [mm/s3]. Calculated from position encoder.
j nom Nominal jerk value [mm/s3].
PLCPrePgm The PLC operands (B, W, D, I, O, T, C) are recorded before the
PLC program run. For types B, W and D the contents are
recorded, and for the other types the logical state of the
operands are recorded.
PLCPostPgm The PLC operands (B, W, D, I, O, T, C) are recorded after the
PLC program run. For types B, W and D the contents are
recorded, and for the other types the logical state of the
operands are recorded.
Analog Analog axis/spindle:
Analog voltage = nominal velocity value [V]
Note
For technical reasons the signals Position: A (0° signal of position encoder) and
Position: B (90° signal of position encoder) cannot be recorded with the internal
oscilloscope!
Note
The signals PosDiff, v (n act), v (n nom), I (n int) and I (nom) are reserved for
digital axes.
If v (n act), v (n nom), I (n int) or I (nom) are selected, the following error message
is displayed:
251-0ced WARNING! Error in synchronization of data channels
Digital signals Meaning

M PLC marker
I Input
O Output
T Timer
C Counter
X reserved
Note
The PLC operands are addressed with numbers in the oscilloscope. You get the numerical
addresses from the PLC diagnostic function WATCH LIST.
January 2008 9 – 49
Sampling rate The resolution of the internal oscilloscope is at most 3 ms.
With a scanning frequency of 333 Hz signal frequencies up to 166 Hz can be displayed!
9.3 Recording Signals

 Press the OSCI soft key.
For every channel, the type and resolution of the analog signal are shown in the left status field.
The operand type and address are listed for digital signals.
Starting and To start recording:

stopping the  Press the START soft key.
recording
To stop recording:
 Press the STOP soft key.
Stop display:
 Press the DISPLAY STOP soft key.
Trigger conditions Trigger and pre-trigger conditions:

Trigger = Single shot: 3000 events beginning from the start are recorded.
Trigger = Free run: At most the last 3000 events before the STOP soft key is pressed
are recorded.
Trigger condition defined: The time when recording ends depends on the setting of
the pre-trigger.

Pre-trigger = 0%: 3000 events beginning from the fulfilled trigger condition are recorded.
Pre-trigger = 25% (or 50%, or 75%): 75% (or 50% or 25%) of the 3000 events beginning
from the fulfilled trigger condition are recorded.
Pre-trigger = 100%: Recording is stopped. The last 3000 events before the fulfilled trigger
condition are saved.
Note
If the trigger condition is fulfilled before the corresponding number of events have been
stored when the pre-trigger is set to 25, 50, 75 or 100%, then correspondingly fewer events
are recorded.
Example:
Oscilloscope display with pre-trigger 75 %; the trigger condition is fulfilled immediately when
recording is started.
During recording, the selected signals are continuously displayed. You can freeze the display of
the signals with the DISPLAY STOP soft key. This does not affect the recording of the signals.
The recorded data remain stored until you start recording again or activate another graphic
function.
A fulfilled trigger condition is indicated with a “T” in the status field at right below the display
area.
Hide/show gridlines:
 Press the GRID soft key.
January 2008 9 – 51
9.4 Analyzing Recordings
Recording After recording has completed, the oscilloscope shows the memory contents. The information
completed in the status field below the display area refers to the displayed events. It has the following
meanings (see figure below):
Left number: Time the “leftmost” event was recorded
Right number: Time the “rightmost” event was recorded
The bar symbolizes the displayed range relative to the memory content.
The fulfillment of the trigger condition is designated as “t0” (t=0). Events that were recorded
before the trigger condition was fulfilled are given a negative time. If no trigger condition was
defined, the beginning of the recording is designated as “t0.”
Influence the
signal display Soft keys that influence the signal display:
 Shift the signal downward.
 Shift the signal upward.
 Decrease the vertical resolution.
 Increase the vertical resolution.
 Optimum vertical resolution.

The signal is centered on the zero line and always remains in the display area.
 Undo vertical shifts.
 Invert the signal (multiply by –1).
Shift the The following soft keys influence the entire display range (all signals):
time axis
 Shift the display range to the left.
 Shift the display range to the right.
 Decrease horizontal resolution.
 Increase horizontal resolution.

Analyze an  Use the ARROW UP and ARROW DOWN keys to select the channel to be
individual analyzed.
analog signal The selected channel is indicated with an asterisk (*). At the same time, the cursor is activated
and placed on the selected channel.
Shown in the status field (bottom left) are (see “Cursor information” figure):
Code “t1: .....”: Cursor position in [s], referenced to t0
Code “Cu1: .....”: Signal size at the cursor position
Shifting the cursor:

 Shift the cursor with the ARROW RIGHT and ARROW LEFT keys.
Second cursor  Activate/deactivate second cursor.
The information for the second cursor is relative to the first cursor. It is shown in the status
field (see “Cursor information” figure):
Code “t2: .....”: Cursor position in [s], referenced to the first cursor
Code “Cu2: .....”: Signal referenced to the first cursor position
Cursor information:
January 2008 9 – 53
9.5 Saving and Loading Recordings
You can save the recorded signals and all settings in one file. The file must have the
extension SCO (oscilloscope trace file).
You can load and evaluate saved SCO files in the oscilloscope. HEIDENHAIN also makes
the PC program TNCscopeNT available for evaluating SCO files.
Saving and loading oscilloscope recordings:

Switch to the Saving and Loading mode:
 Press the soft key.
Save the oscilloscope trace file:

 Press the SAVE soft key.
 Enter the path in the “Save As” dialog box.
 Press the OK soft key or button.
Load the oscilloscope trace file:

 Press the LOAD soft key.
 Enter the path in the “Open” dialog box.
 Press the OK soft key or button.

10 PLC Diagnostics
10.1 Introduction
PLC Terminology PLC is a general term from control technology and is the abbreviation for:
Programmable Logic Control.
The PLC is an integral part of a HEIDENHAIN control and is therefore referred to as
Integral PLC.
Tasks of the PLC Interfacing of various types of machines to HEIDENHAIN controls

Assuming control tasks
Note
The machine manufacturer creates the PLC program for the machine or adapts an existing
PLC project to his machine.
DANGER
Changes to the PLC program or to the PLC wiring may influence not only the function
but also the safety of the machine! This may result in damage to property or persons!
Changes to the PLC may only be performed by the machine manufacturer!
Data exchange The PLC has to exchange data with the machine but also with the operating system of the
with the PLC control to be in a position to carry out adaptation and control tasks.
Depending on the type of control, various inputs and outputs are available for data exchange
with the machine.
Data exchange between PLC and NC is implemented over the Application Programmer
Interface (API), a symbolic programming interface.
The familiar previous PLC-NC interface is also available and can be used by the machine
manufacturer, if desired.
PLC error See ”Error Messages” on page 4 – 15

messages
PLC error messages (text, reaction of the control, etc.) are defined by the machine manufacturer.
Calling the  Press the following keys to call the PLC mode:
PLC mode  Select the Programming mode of operation.
 After the code number has been entered, the PLC main menu is displayed.
January 2008 10 – 55
PLC main page
Processing time maximum:

Maximum run time of the PLC program.
The processing time of the PLC (time for one PLC scan) is given as a percentage: 100 % is
a run time of 1 ms.
The maximum cycle time of the sequential program must not exceed 2000 % (= 20 ms).
If it is higher, the control outputs the blinking error message PLC time out..
Processing time current:

The time taken for the latest PLC scan in %.
Code length:
Length of the compiled sequential program in bytes.
Running PGM:
Name of the last compiled PLC program (program in process memory).
During switch-on, the control automatically compiles the program that was selected in process
memory before switch-off.
The files only become active after they have been compiled.
Trace PGM:
Name of the PLC program called last in the Trace mode.
Error table:
Name of the error table used.
Editor PGM:
Name of the program or file in the editor’s main memory.

PLC functions of From the PLC main menu you can use soft keys to access the following PLC functions:
the main menu
Soft key Function

Edit selected file
Compile PLC program
Display states of symbolic operands of the API
Display states of selected operands in tabular format;

operands must be selected from the symbol list
Display the logical states of the PLC operands (M/I/O/T/C/B/W/D).
Display TRACE function
Exit PLC Programming mode
January 2008 10 – 57
10.2 Diagnosis Options in the PLC Mode
TNC 320 provides comprehensive PLC diagnosis options.
Since the PLC program was written by the machine manufacturer, PLC diagnosis often requires
his support.
10.2.1 The API DATA Function

The API DATA function enables the control to display the states or contents of the symbolic
API markers and API double words. This function requires that your PLC program use the
new PLC-API.
Call  Soft key to call the API DATA function
Note
If the machine manufacturer is using the programming interface (API) compatible with
the TNC, the API DATA function is not active or does not provide useful display values.

Soft keys for the API DATA function
Soft key Function

Display the contents of general API markers
Display the contents of the API markers for machining groups
Display channel-specific API data
Display axis-specific API data
Display the API markers that apply to the spindle
Show contents of operands as decimals or hexadecimals
Freeze the screen
Return to previous menu
January 2008 10 – 59
10.2.2 The WATCH LIST Function
The WATCH LIST function enables you to create a table of different operands whose states are
then displayed altogether.
Call  Soft key to call the WATCH LIST function
Note
Create a WATCH LIST with the aid of the machine manufacturer, if necessary.
Meaning of the columns in the WATCH LIST:

MODULE: <Global> for global symbolic operands or path with the name of the *.SRC file in
which the operand is defined
ADDR: Absolute address of the operand
VALUE: Content of the operand
COMMENT: Comment on the operand
Soft keys within the WATCH LIST function:
Soft key Function

Insert a new line above the current line
Delete current line
Display a selection list with all symbolic operands used in the

active PLC program
Navigation
Show contents of operands as decimals or hexadecimals
Save the active WATCH LIST to the memory card
Load the saved WATCH LIST selection from the memory card
(*.WLT file)
Return to the PLC main menu

Display of  Press the WATCH LIST soft key to call the menu of the WATCH LIST function.
symbolic  Press the SYMBOL LIST soft key to open a list box containing all global and local operands used
operands in the in the PLC program.
WATCH LIST  Use the arrow keys to move within the SYMBOL LIST. Press the RIGHT ARROW key to open
a tree structure. Press the LEFT ARROW key to close an open tree structure.
 Use the arrow keys to select the desired operand and press the INSERT soft key to transfer it.
Saving After you have created a WATCH LIST, you can save the settings in a WLT file and call them
WATCH LIST files again at a later date:
 Press the SAVE soft key. --> A new window opens.
 Enter the name for the list to be saved (the file extension must be wlt) and confirm your entry
with OK.
 Your WATCH LIST is saved in the path PLC:\table\ ...
Loading When you call the WATCH LIST function after a restart, the file tmp.wlt is loaded automatically.
WATCH LIST files Now you can call previously saved WATCH LIST files:
 Press the LOAD soft key. --> A new window opens. The saved WATCH LIST files are
displayed.
January 2008 10 – 61
 Use the cursor to select the desired WATCH LIST and confirm it with OK.
 The selected WATCH LIST file is displayed.

10.2.3 The TABLE Function
With the TABLE function you can display the logical states of of the inputs, outputs, markers,
counters, timers, bytes, words, double words and strings in a table.
Call  Call the TABLE function
To select the table for a certain operand type:

 Press the soft key M/I/O/T/C or B/W/D/S.
 Press the soft key for the desired operand type.
Checking the The following describes the testing of PLC inputs and outputs for which the TABLE function can
PLC inputs be very helpful:
 Call the TABLE function
 Display of the inputs
 Observe the logical state of the input to be checked.

 For this purpose measure the voltage for the input to be checked, e.g.
at the terminals in the electrical cabinet to which the signals of X42 are connected
directly at the terminals of the machine operating panel
directly at the terminals of the input/output module PLD 16-8
Assignment --> See “Connector Designations and Layouts” on page 14 – 133
January 2008 10 – 63
Note
An active input is signalled by a yellow LED at the PLD 16-8.
The displayed logical states must be in agreement with the voltage level of each input!
Possible causes If there is a difference (e.g., the voltage level is within the tolerance range but the logical
of error state is 0), it may have the following causes:
Defective input at the MC or the PLC expansion card
Defective cable or connector
Fault in the PLC bus
Note
It is not possible to measure PLC inputs directly at the handwheel or at the cable adapter
for the handwheel!
Note
If the HEIDENHAIN test adapter (or the "Universal Measuring Adapter") is available, you can
connect it between the connectors X42 and X45 of the MC to measure the voltage level of
the input to be checked. --> See “Inspection and Testing Equipment” on page 27 – 283
Checking the  Call the TABLE function

PLC outputs
 Display of the outputs
 Observe the logical state of the output to be checked.

 For this purpose measure the voltage (and possible the current) for the output to be checked,
e.g.
at the terminals in the electrical cabinet to which the signals of X41 are connected
directly at the terminals of the machine operating panel
directly at the terminals of the input/output module PLD 16-8
Assignment --> See “Connector Designations and Layouts” on page 14 – 133
Note
An active output is signalled by a yellow LED at the PLD 16-8.

A red LED at X4/pin1 indicates a short circuit at the output side of a PLD 16-8.
Meaning of the
LEDs on the
PLD 16-8 LED Meaning
Red LED at X4, pin 1 Short circuit of the outputs
Yellow LEDs at X4, X5 and X6 Status of the inputs and outputs
Green LEDs at X6, pin 9 and pin 10 24 V power supply of the outputs

Note
If an output is short-circuited the output voltage is reset. Short-circuit monitoring remains

active. It can be reset with the PLC program of the machine manufacturer or by switching
the machine off and on.
In order to recognize a short circuit, a current of 20 A must be able to flow for approximately
3 ms. If this is not the case (e.g. the 24-V supply limits the current sooner), the short-circuit
monitoring might not become effective.
The displayed logical states must be in agreement with the voltage level of each output!
Troubleshooting If there is a difference (e.g., the logical state is 1, but the voltage level is below the tolerance
limit), proceed as follows:
PLC output defective?
Unplug connecting cable or disconnect wires

and check for short-circuit
Yes
Connecting cable, wires, relay, etc.
Short-circuit?
defective.
No
Reconnect device and

interconnect a current measuring device.
Measure output current during operation.
Yes
Configuration may be faulty;
Output current too high?
contact the machine tool builder!
No
Output board of MC or
PLC expansion board defective,
or interruption in connector,
or interference on a PLC bus
Note
It is not possible to measure PLC outputs directly at the handwheel or at the cable adapter!
January 2008 10 – 65
Note
If the HEIDENHAIN test adapter (or the "Universal Measuring Adapter") is available, you can
connect it between the connectors X41 and X46 of the MC to measure the voltage level of
the output to be checked. --> See “Inspection and Testing Equipment” on page 27 – 283
Measuring circuit
with test adapter
for PLC inputs and
outputs on the MC
DANGER
Do not engage or disengage any connecting elements while the machine is under power!
X41: PLC output

X42: PLC input
X46: Machine operating panel

10.2.4 The TRACE Function
The TRACE function allows to control the logical states of PLC operands (M,I,O,T,C) within
the respective PLC files (statement list).
Furthermore, the contents of bytes, words and double words can be checked.
Call  Soft key to call the TRACE function
The control displays:

The statement list (STL) of the selected PLC program
For every program line, the content of the operand and the accumulator in HEX or decimal
code (selectable by soft key)
The control identifies every cyclically executed command with an asterisk (*).
Use the arrow keys or the GOTO function to select the program section that the control should
display on the screen.
The PLC program to be displayed is chosen with the SELECT MODULE soft key, and must be
the currently active main program or a file integrated with USES.
January 2008 10 – 67
10.2.5 PLC Diagnostics with the Integrated Oscilloscope
The integrated oscilloscope offers the possibility of recording PLC operands as a function of
time. Thus, it can be used as logic diagram!
The following operands can be selected:

Inputs
Outputs
Markers
Bytes
Words
Double words
Moreover, the control signals of timers and counters can be recorded.
Six channels are available for recording.
Call See ”Integrated Oscilloscope” on page 9 – 45
Selecting the You can record the PLC operands B, W, D, M, I, O, T, C.

possible PLC These PLC signals can be recorded simultaneously with analog signals.
operands
 Press the SELECT soft key.
 Set the time resolution to PLC clock.
 For the oscilloscope signal select PLCPrePgm or PLCPostPgm.
 Select s in the operand list. --> In the next column you can then specify the SYMBOL LIST.
 Place the cursor in the next column and press the SYMBOL LISTsoft key.
 Now select the symbolic operand.

Example Oscilloscope display for spindle orientation:
Selecting Here you can only record PLC operands with their possible states (0 or 1).
M, I, O, T, C Up to 16 channels can be selected.
These PLC signals can be recorded simultaneously with analog signals.
 Press the SELECT MIOTC soft key.
 Choose the operand type and number.
January 2008 10 – 69
Note
To display the numerical addresses call the symbol list e.g.in the Watch List function.
--> See “Display of symbolic operands in the WATCH LIST” on page 10 – 61.
 Select a trigger condition.
Note
You define the general trigger conditions (“Trigger” input field) and the pre-trigger in the
setup for analog signals.
The trigger condition “logic” is fulfilled when all triggers set in “M I O T C selection” are
fulfilled (AND-gating).
 In the Selection column mark the signal to be recorded by an X.

 Confirm the settings with OK.
 Start the oscilloscope recording.
Example Oscilloscope display for switching the spindle on and off:

10.3 The COMPILE Function
Compiling a completed PLC program transfers it to the process memory where it can then
become active. The name of the compiled program appears on the PLC main page in the line
RUNNING PGM:
PLC main page
To compile a PLC program:

 Press the COMPILE PLC PGM soft key; the control switches to the program manager.
 Use the arrow keys to select the PLC program to be compiled.
 Press the SELECT soft key.
Note
The compilation of very extensive PLC programs may take some time. Compilation is
completed when the PLC main menu appears on the screen again and values are displayed
under Processing time. If errors occur during the compilation of the program, the control
displays a corresponding message in the PLC main menu.
Caution
Only the main program may be compiled.

If a subprogram was accidentally compiled instead of the PLC main program, an error
message (e.g. Syntax error in PLC program) is generated. In this case the compiler has
detected global modules in this file.
In a PLC main program there are no modules defined as global.
The main program continues to be the sequential program!
January 2008 10 – 71
10.4 Calling the PLC Error Table for Diagnosis
Introduction The machine manufacturer defines the PLC error messages in the PLC ERROR TABLE.
This PLC error table has the extension .PET.
You can open this file to learn more about the PLC error messages!
DANGER
The PET table may only be opened for the purpose of fault diagnosis.
Under no circumstances may the settings be changed, as this will alter the performance of
the machine!
This could lead to damage to property or persons!
Calling the  Enter the PLC code number. --> See “Code Numbers” on page 3 – 11
PET table  Exit the PLC main page with END.
 Call the program management.
 Select the PLC error table (z.B. PLC:\LANGUAGE\ERR_TAB.PET) with the

arrow keys.
 Confirm.
Example of
a PET table
If you place the cursor to the right, you get more information about the PLC error messages.

Description of Column Description
the elements
NR Line number in the table.
The modules select the PLC error message by assigning the line number.
ERROR Error text
There are three ways to specify the error text:
Direct entry of the error text (max. 32 characters).
Line number of the PLC error text file defined in MP_errorText.
(# < line number>)
MARKER The PLC error message can be activated without a module call by setting the
marker defined here. The marker is also set if the error message was activated
through module 9085.
Symbolic operands can also be used as error markers.
0 means no error marker.
RESET 0 = No NC reset upon activation of the error message (no system error).
1 = NC reset upon activation of the error message (system error).
The PLC program stops.
NC_STOP 0 = No NC stop when error message is activated.
1 = NC stop upon activation of the error message (NN_ChnErrorNcStop is set).
NC_CANCEL 0 = No NC stop with INTERNAL STOP when the error message is activated.
1 = NC stop with subsequent INTERNAL STOP upon activation of the error
message (NN_ChnErrorCancel is set).
F_STOP 0 = Feed rate enable is not affected.
1 = Feed rate enable is reset upon activation of the error message
(NN_ChnErrorFStop is set).
EMER_STOP 0 = No EMER. STOP stop when error message is activated.
1 = EMERGENCY STOP upon activation of the error message
(NN_ChnErrorEmergencyStop is set).
CE 0 = Error message can be cleared with the CE key.
1 = Error message cannot be cleared with the CE key.
PRIO A priority from 0 to 2 can be entered for the error message. Priority 0 means
highest priority. Pending PLC error messages are displayed according to their
priority.
WARN_LVL Not evaluated
 Exit the PET table.
Error text file Error texts are defined directly in the PET table (max. 32 characters; not language-sensitive) or
in the error text file. In the error text file, the machine manufacturer defines the error text to be
displayed as well as the information on the cause of error and corrective action.
Error text files are language-sensitive. The path for the error text file is permanently defined:
PLC:\LANGUAGE\EN (or another language abbreviation).
Note
If the # symbol is entered in the ERROR column of the PET table, there is a link to an error
text file in the respective national language.
Ideally the PLC programmer also writes the text of the error message (e.g. # 010 Machine
guard is open!) next to the # symbol with the error number. However, this is not mandatory.
--> The error texts can be found in the corresponding PLC error text file!
January 2008 10 – 73
10.5 Overviews
The following tables are excerpts from the TNC 320 Technical Manual of February 2006.
Instructions The table below provides an overview of all possible PLC commands:
overview
Group of Syntax Function
functions
Loading and saving commands
L Load
LN Load NOT
L– Load two’s complement
LB Load BYTE
LW Load WORD
LD Load DOUBLE WORD
= Assignment
B= Assign BYTE
W= Assign WORT
D= Assign DOPPELWORT
=N Assign NICHT
=– Assign two’s complement
Setting commands
S Set
R Reset
SN Set NOT
RN Reset NOT
Logical operations
A And
AN And NOT
O Or
ON Or NOT
XO Exclusive OR
XON Exclusive OR NOT
Arithmetical commands
+ Addition
– Subtraction
x Multiplication
/ Division
MOD Remainder

functions
Increment
INC Increment operand
INCW Increment word accumulator
INCX Increment index register
Decrement
DEC Decrement operand
DECW Decrement word accumulator
DECX Decrement index register
Comparisons
== Equal to
< Less than
> Greater than
<= Less than or equal to
>= Greater than or equal to
<> Not equal to
Parenthetical expression in logical operations
A[ ] And [ ]
AN[ ] And NOT [ ]
O[ ] Or [ ]
ON[ ] Or NOT [ ]
XO[ ] Exclusive or [ ]
XON[ ] Exclusive OR NOT [ ]
Parenthetical expressions with arithmetical instructions
+[ ] Addition [ ]
–[ ] Subtraction [ ]
x[ ] Multiplication [ ]
/[ ] Division [ ]
MOD[ ] Remainder [ ]
Parenthetical expressions in comparisons
==[ ] Equal to [ ]
<[ ] Less than [ ]
>[ ] Greater than [ ]
<=[ ] Less than or equal to [ ]
>=[ ] Greater than or equal to [ ]
<>[ ] Not equal to [ ]
Shifting commands
<< Shift left
>> Shift right
Bit commands
BS Bit set
BC Bit clear
BT Bit test
January 2008 10 – 75
functions
Stack operations
PS Push data onto the data stack
PL Pull data from the data stack
PSL Push logic accumulator onto the data stack
PSW Push word accumulator onto the data stack
PLL Pull logic accumulator from the data stack
PLW Pull word accumulator from the data stack
Jump commands
JP Unconditional jump
JPT Jump if logic accumulator = 1
JPF Jump if logic accumulator = 0
CM Call module
CMT Call module if logic accumulator = 1
CMF Call module if logic accumulator = 0
EM End of module, program end
EMT End of module if logic accumulator = 1
EMF End of module if logic accumulator = 0
LBL Label

Operand The machine manufacturer probably uses the new expanded API (i.e. the symbolic
overview PLC operands) in his PLC program. For a list of the symbolic PLC operands predefined
(old TNC API) by HEIDENHAIN. See “Operand overview (new TNC API)” on page 10 – 78.
If the old TNC API is used, the operands from the table below are valid:
Operand Abbreviation Address range

Markers M (marker) M0 to M9999
M0 to M999 are free; they are deleted only after
entering the code number 531210, not during a reset
(nonvolatile range); the range can be reduced in the
*.CFG file of the PLC compiler.
M1000 to M3999 are free; they are deleted during
reset.
M4000 to M5999 are reserved for the NC-PLC
interface if you are using the old TNC-API. (M4800
to M4999 are deleted before the first run of the
PLC program, e.g. after compilation or restarting).
They are freely usable if you are using the new
symbolic API.
M6000 to M9999 are free; they are deleted during
reset.
Input I (input) I0 to I31 (X42)
I128 to I152 (X46 machine operating panel)
I64 to I127 (first PL input/output unit)
I192 to I255 (second PL)
I256 to I319 (third PL)
I320 to I383 (fourth PL)
Output O (output) O0 to O30 (X41)
O32 to O62 (first PL)
O64 to O94 (second PL)
O128 to O158 (third PL)
O160 to O190 (fourth PL)
Counter C (counter) Set counter: C0 to C47
Counter contents: C48 to C95
Counter pulse release: C96 to C143
Timer T (timer) Timer start: T0 to T47
Timer is running: T48 to T95 and T96 to T999
Bytes B (byte) B0 to B9999 (8 bits)
Words W (word) B0 to B255 are free; depending on the definition in
the *.CFG file of the PLC compiler, the defined range
Double word D (double word)
is deleted only after entering the code number
531210, not during reset (nonvolatile range). If no
range is defined in the *.CFG file, B0 to B127 is the
nonvolatile range.
B256 to B2047 are reserved for the NC-PLC interface
if you are using the old TNC-API. They are freely
usable if you are using the new symbolic API.
B2048 to B9999 are free; they are deleted during
reset.
Constant K -2 147 483 647 to +2 147 483 647
String S S0 to S99
January 2008 10 – 77
Operand PLC operands of the “general data” group
overview
(new TNC API)
Markers Description SW
version
General – Control configuration
D NN_GenOmgCount Number of configured groups of operating
modes
D NN_GenChnCount Number of configured machining channels
D NN_GenAxCount Number of configured logical axes (including
spindles)
D NN_GenSpiCount Number of configured spindles
General – Control status
D NN_GenOmgManual Selected operating mode group for manual
operation
D NN_GenChnManual Selected machining channel for manual
control
D NN_GenSpiManual Selected spindle for manual control
M NN_GenCycleAfterPowerOn 1. PLC scan after power on
(M4172)
M NN_GenCycleAfterPlcStop 1. PLC scan after interruption of the PLC
program
(M4173)
M NN_GenCycleAfterReConfig 1. PLC scan after changing of the
configuration data
(M4174)
M NN_GenNcInitialized Control is being initialized (after start-up
cycles)
(M4184)
M NN_GenNcEmergencyStop Control in “external emergency stop” state
(M4178)
General – Error handling
M NN_GenApiModuleError An error occurred when using an API
module.
(M4203)
D NN_GenApiModuleError Error code that appeared when using an API
Code module.
(W1022)
General – Key information
D NP_GenKeyCode Code of the depressed key
(W274)
D NP_GenModCode Code of the code number last entered
(D276)
M PP_AxHandwheelLocked Disable handwheel motion
(M4576)
D NP_GenSoftkeyHori Code of the horizontal soft key last pressed
(W302)
D NP_GenSoftkeyVert Code of the vertical soft key last pressed
(W304)
General – Touch probe
M NN_GenTchProbeReady Touch probe: Ready (hardware signal)
(M4050)
M NN_GenTchProbeDeflected Touch probe: Stylus deflected (hardware
signal)
(M4052)

version
M NN_GenTchProbeBatteryLow Touch probe: Weak battery (hardware
signal)
(M4054)
M NN_GenTchProbeX13 Touch probe: X13 active (if 0, then X12
active)
(M4060)
General – Safe control
M NN_GenSafetyInputs Safety oriented: Inputs 0 to 15 bit-encoded
(M4264)
M NN_GenSafetyStopActive Safety oriented: Stop is activated
(M4280)
M NN_GenSafetyPermButtons Safety-oriented: Both permissive buttons
Pressed are pressed
(M4281)
M NN_GenSafetyStartCutout Safety-oriented: Beginning of the test
Channel channel
(M4282)
M NN_GenSafetyCutout Safety-oriented: Switch off, since no switch-
off test was performed
(M4283)
M NN_GenSafetyFeedLimit Safety-oriented: Limitation of the feed rate
Active or spindle infeed active
(M4284)
January 2008 10 – 79
PLC Operands of the “Operating Mode Group” Group
version
OMG – Configuration
D NN_OmgChnCount Number of machining channels for this
group of operating modes
D NN_OmgChn Array of the machining channels for this
group of operating modes
OMG – Operating modes
M NN_OmgManual Manual Operation operating mode
(M4150)
M NN_OmgHandwheel Electronic Handwheel operating mode
(M4151)
M NN_OmgMdi Positioning with Manual Data Input
operating mode
(M4152)
M NN_OmgProgramSingle Program Run, Single Block operating mode
(M4153)
M NN_OmgProgramRun Program Run, Full Sequence operating
mode
(M4154)
M NN_OmgProgramReference Reference operating mode
(M4155)
M NN_OmgProgramDiagnosis Diagnosis operating mode
M NN_OmgJogIncrement Jog Increment operating mode
(M4579)
OMG – Program run
M PP_OmgNcStart NC start for all machining channels of this
operating mode group
M PP_OmgNCStop NC stop for all machining channels of this
operating mode group

PLC Operands of the “Machining Channels” Group
version
Channel – Configuration
D NN_ChnAxisCount Number of axes of this machining channel
D NN_ChnAxis Array of the axes of this machining channel
Channel – Error handling
M NN_ChnErrorWarning Error or warning occurred
M NN_ChnErrorFStop Feed stopped because of an error
(M4220)
M NN_ChnErrorNCStop NC stop due to an error
(M4221)
M NN_ChnErrorCancel Program canceled because of an error
(M4223)
M NN_ChnErrorEmergency Emergency stop because of an error
Stop
(M4222)
M NN_ChnErrorReset Reset because of an error
Channel – Program run

M PP_ChnNcStart NC start or Cycle on
(M4564)
M PP_ChnNCStop NC stop or Cycle off
(M4560)
M PP_ChnNcStartExtern External request for NC start
Request
M PP_ChnNCStopExtern NC stop or Cycle off
M NN_ChnControlInOperation Control is in operation
(M4176)
M NN_ChnProgStoppedAsync Asynchronous NC program interruption
M NN_ChnProgStopped NC program interruption
M NN_ChnProgCancel NC program cancellation
M NN_ChnProgEnd NC program end is reached
M NN_ChnAutostart Autostart function: Request for program
start
(M4182)
M NN_ChnAutostartTime Autostart function – Request for program
Expired start
M PN_ChnAutostartEnable Enabling the autostart
(M4586)
M NN_ChnBlockScan Mid-program startup (or block scan) active
(M4158)
M NN_ChnBlockScanStrobe Restore status at block scan
Transfer (M/S/T/Q transfer)
(M4161)
M NN_ChnProgManTraverse Manual traverse of the axes active
(for lathes: Inspection operation)
(M4156)
M NN_ChnProgReturnContour Return to contour active
(after manual traverse or block scan)
(M4157)
January 2008 10 – 81
version
Channel – Touch probe
M NN_ChnTchProbeCycle Touch probe: Touch probe cycle active
(M4053)
M PP_ChnTchProbeMonitor Touch probe: Enabling the probing process
(M4055)
Channel – Feed rate
D NN_ChnProgFeedMinute Programmed feed per minute [mm/rev]
(D360)
D NN_ChnProgFeedRevolution Programmed feed per revolution [mm/min]
D NN_ChnProgFeedThread Programmed thread feed rate [mm/rev]
M NN_ChnProgMinuteActive Feed per minute active
M NN_ChnProgRevolution Feed rate per revolution active
Active
M NN_ChnProgThreadActive Thread feed rate is active
D NN_ChnContourFeed Current contouring feed rate [mm/min]
(D388)
D PP_ChnContourFeedMax Max. feed rate from PLC [mm/min]
(D596)
D NN_ChnFeedOverrideInput Feed-rate override set [%]
(W494)
D PP_ChnFeedOverride Feed-rate override entered by the PLC [%]
(W766)
D NN_ChnRapidFeedOverride Rapid traverse override set [%]
Input
(W496)
D PP_ChnRapidFeedOverride Rapid traverse override entered by the
PLC [%]
(W752)
D PP_ChnConfigOverride Configurable override (e.g. rapid traverse)
M PP_ChnFeedEnable Feed-rate enable for all axes
M PP_ChnWorkFeedEnable Rapid traverse enable for all axes
Channel – Status
M NN_ChnToolLifeExpired Tool life 1 expired
(M4543)
M PP_ChnEnableAxisKeyLatch Enabling latching of axis-direction key
M PP_ChnRapidTraverseKey Rapid-traverse key
(M4561)

PLC operands of the “Axis” group
version
Axis – Configuration
D NN_AxLogNumber Logical axis number (identical to axis
number of “axes of the machining channel”)
Axis – Drive
M NN_AxDriveReady Axis drive is ready
M PP_AxDriveOnRequest Switch axis drive on
(CM9161)
M NN_AxDriveOn Axis drive is on (and at least speed-
controlled)
(CM9162)
M PP_AxPosControlRequest Position-control the axis
(W1040)
M NN_AxPosControl Axis is position-looped
(W1024)
M PP_AxValueActToNominal Actual-to-nominal value transfer
M NN_AxCorrectingLagError Following error eliminated
M PP_AxClampModeRequest Prepare to open the position control loop
(W1038)
Axis – Control
M NN_AxReferenceAvailable Reference mark not yet traversed
(W1032)
M PP_AxReferenceEndPosition Reference end position
(W1054)
D PP_AxManualFeedMax Maximum manual axis feed rate [mm/rev]
M PP_AxFeedEnable Axis-specific feed rate enable
(W1060)
M NN_AxInMotion Axes in motion
(W1028)
M NN_AxInPosition Axes in position
(W1026)
M PP_AxTraversePos Manual traverse in positive direction
(W1046)
M PP_AxTraverseNeg Manual traverse in negative direction
(W1048)
M PP_AxHandwheelLocked Disable handwheel motion for specific axes
(W1062)
M PP_AxDeactivateMonitoring Deactivate monitoring functions
(W1042)
M NN_AxLubricationPulse Lubrication pulse: Value in
MP_lubricationDist exceeded
(W1056)
M PP_AxLubricationDistReset Reset the accumulated distance
(W1058)
January 2008 10 – 83
PLC Operands of the “Spindle” Group
version
Spindle – Configuration
D NN_SpiLogNumber Logical axis number of the spindle
Spindle – Drive
M NN_SpiDriveReady Spindle drive is ready
M PP_SpiDriveOnRequest Switch spindle drive on
(CM9161)
M NN_SpiDriveOn Spindle drive is on (and at least speed-
controlled)
(CM9162)
Spindle – Control
M NN_SpiReferenceAvailable Reference position found
(M4018)
M PP_SpiReferenceMarkSignal Trip dog
D PP_SpiSpeedMax Maximum speed of the spindle
(D604)
M PP_SpiEnable Spindle enabling
(M4008)
M NN_SpiInMotion Spindle in motion
(M4002)
M NN_SpiSpeedOK Spindle speed reached
(M4001)
M NN_SpiControl Spindle position-controlled
M NN_SpiControlInPos Spindle in position
(M4000)
M NN_SpiSyncSpeed Rotational speed synchronism active
M NN_SpiSyncAngle Angle synchronism active
M NN_SpiSyncReached Synchronous operation reached
D NN_SpiOverrideInput Speed override set [%]
(W492)
D PP_SpiOverride Speed override set by the PLC [%]
(W764)
M NN_SpiTapping Tapping active
(M4030)
M NN_SpiRigidTapping Tapping with spindle interpolated with
Z axis active
(M4031)

10.6 Specifications
10.6.1 PLC Inputs

Input signals of the switching inputs on the MC 320 and the PLD 16-8:
Voltage range MC 320 PLD 16-8

“1” signal: Ui 13 V to 30.2 V 13 V to 28.8 V
“0” signal: Ui -20 V to 3.2 V -3 V to 2.5 V
Current ranges MC 320 PLD 16-8

“1” signal: Ui 3.8 mA to 8.9 mA 2.5 mA to 5.8 mA
“0” signal: Ii when Ui = 3.2 V 1.0 mA 0.3 mA
Addresses of the switching inputs at:
Address Number Device

I0 to I31 31 + Control-is- PLC inputs directly on the MC 320, connector X42
ready signal
I64 to I127 64 PL 510 (PLD 16-8)
I128 to I152 25 Machine operating panel (MC 320, connector X 46)
I192 to I255 64 PL 510 (PLD 16-8)
I256 to I319 64 PL 510 (PLD 16-8)
I320 to I383 64 PL 510 (PLD 16-8)
Which PLC input is located on which pin of the connector?

--> See ”Connector Designations and Layouts” on page 14 – 133!
Note
The transmission of input states of handwheels and PLC input/output units (expansion cards)
is performed with HEIDENHAIN serial data transmission busses on the connectors X23
and X47.
On the X42 and X46 connectors, each input has its own wire.
January 2008 10 – 85
10.6.2 Analog Inputs
Note
The MC 320 does not have any analog inputs. If you need analog inputs or inputs for Pt 100
thermistors, the PL 510 PLC input/output unit can optionally be expanded with the PLA 4-4
analog module.
The PLA 4-4 PLC input/output unit (for PL 510) has analog inputs and inputs for Pt 100
thermistors.
Analog inputs (±10V)

PLA 4-4 4
(PL 510)
Voltage range: –10 V to +10 V

Input resistance: > 250 kΩ
Resolution (W480, W482, W484): 100 mV
Resolution (Module 9003, 9138): 4.9 mV (PLA 4-4)
Internal value range: –100 to +100, at a resolution of 100 mV
-1000 to +1000, at a resolution of 10 mV
–2040 to +2040, at a resolution of 4.9 mV
Which analog input is located on which pin of the connector?

10.6.3 Inputs for Pt 100 Thermistors

The PLA 4-4 (for PL 510) has inputs for Pt 100 thermistors.
Inputs for Pt 100

thermistors
PLA 4-4 4
(PL 510)
Constant current: 5 mA
Temperature range: 0 °C to 100 °C
Resolution (W486, W488, W490): 0.5 °C
Resolution (Module 9003, 9138): 0.03 °C (PLA 4-4)
Internal value range: 0 to 200, at a resolution of 0.5 °C
0 to 1000, at a resolution of 0.1 °C
0 to 3333, at a resolution of 0.03 °C
Which thermistor input is located on which pin of the connector?


10.6.4 PLC Outputs
Output signals The switching outputs are transistor outputs with current limitation.
and addresses
Please note:
Permissible load: Resistive load (ohmic load); inductive load (e.g. relay, contactor) only with
quenching diode parallel to inductance
MC 320: Short circuiting of one output is permissible.
No more than one output may be short-circuited at one time.
PLD 16-8: The outputs are short-circuit proof.
Output signals:
MC 320, PLD 16-8

Min. output voltage for “1” signal 3 V below supply voltage
Note
The switching outputs need a minimum load of 5 mA.

They conform to EN 61131-2.
DANGER
PLC outputs must neither be connected to a 24-V supply, nor to other PLC outputs with a
difference in potential. Otherwise, the voltage present at the PLC outputs is transmitted to
the power supply. As a result, the PLC outputs that can be switched off may nevertheless
be supplied with this voltage.
This could lead to damage or injury to property or persons!
Addresses:
Address Number Device

O0 to O30 31 PLC outputs directly on the MC 320,
connector X41
O0 to O7 8 Machine operating panel (MC 320, connector X46)
O32 to O62 31 First PLC input/output unit
O64 to O94 31 Second PLC input/output unit
O128 to O158 31 Third PLC input/output unit
O160 to O190 31 Fourth PLC input/output unit
The "control-is-ready" output at X41 can have the same load as a normal PLC output. If a higher
current is required for switching a relay, the "control-is-ready" outputs of the PLs can be used in
addition. A separate power supply for the PLs is necessary for this.
Note
The transmission of output states of handwheels and PLC input/output units (expansion
cards) is performed with HEIDENHAIN serial data transmission busses on the connectors
X23 and X47.
On the X41 and X46 connectors, each output has its own wire.
Which PLC output is located on which pin of the connector?

Supply See ”Power Supply for PLC Outputs” on page 15 – 164

voltage for
PLC outputs
January 2008 10 – 87
11 Memory Card and File Manager of the TNC 320
11.1 Introduction
The TNC 320 memory card contains the TNC data, the PLC data and the entire operating system
with the NC software.
Caution
Defects in the memory card may have the result that no functions can be called any more.
The CRF (compact flash removable) memory card is located in a slot at the bottom of the
MC 320 housing (X600).
CFR
Removal and insertion of the memory card

--> see “Exchanging the CFR Memory Card” on page 25 – 265.
Structure of the The CFR is divided into three partitions:

memory card
TNC:\ User-specific data
NC programs, tool tables, datum tables, etc. are stored here.

PLC:\ OEM-specific data
System files, PLC programs, machine parameters, help files, PLC dialogs,
PLC error tables, compensation value tables and OEM cycles, etc. are
stored here.
Enter the code number 807667 to access the PLC partition.
SYS:\ System-specific data
This partition contains the entire NC software (NC dialogs, HEIDENHAIN

cycles, etc.) and the HEIDENHAIN real-time operating system NC Kernel.
A special HEIDENHAIN password is required to open the SYS partition.
Caution
Alterations to the SYS partition can impair proper function of the control!
January 2008 11 – 89
Size of the
partitions
Partition Contents
SYS:\ System-specific data
PLC:\ OEM-specific data
TNC:\ User-specific data
Assignments to The control partitions are usually assigned to the following system variables:
system variables
Partition System variable
SYS:\ %SYS%
PLC:\ %OEM%
TNC:\ %USR%
11.2 Memory-Card Test
No communication If there is no communication with the CFR when the control is started, usually the following
with the CFR message is displayed:
DISK BOOT FAILURE, INSERT SYSTEM DISK AND PRESS ENTER
Check, whether the memory card is firmly in the slot, or check the memory card on a functioning
TNC 320 (if available).
At present no further tests are possible in the field!
Communication If the control still communicates with the memory card, some tests might be carried out in the
with the CFR field. --> Contact your HEIDENHAIN service agency for that matter.
Extensive tests can only be performed at a HEIDENHAIN repair agency!
Caution
Do not use your own memory-card test programs or repair programs!

Data recovery at HEIDENHAIN or a specialized company could thereby become more
difficult or even impossible.
11.3 Setting the System Time
If you want to set the system time of TNC 320 to the second contact the HEIDENHAIN
helpline.
In the configuration object CfgSystemTime / parameter offsetToUTC you can enter
the difference between local time and system time (input +/- 12 hours).
UTC (= Universal Time Coordinated) is used as system time.
Note
Changeover to winter / summer time is not automatic.

For this purpose offsetToUTC needs to be adjusted.
After the parameter offsetToUTC was edited, the control reboots automatically!

11.4 File Management in the TNC Partition
Calling the  Press the following key combination to call the TNC partition:
TNC partition
 Select the Programming mode of operation.
 Call Program Management.
The directory structure is displayed on the left.

The associated files are listed on the right.
Use the LEFT and RIGHT arrow keys to toggle between directory field and
files field.
With the +/- key or with ENTER you can open and close subdirectories.
Select subdirectories or files by pressing the UP and DOWN arrow keys.
The selected directory or file is displayed in the header.
January 2008 11 – 91
Overview of the File type File extension
most important
TNC file types NC program in HEIDENHAIN plain-language .H
NC program in ISO language .I
Tool table .T
Pocket table (tool changer) .TCH
Datum table .D
Touch probe table .TP
Note
If you cannot find certain files although the cursor is placed in the correct directory,
a file types filter may be active.
The filter setting is displayed above the file list, for example TNC:\*.H
To remove this filter use the soft keys SELECT TYPE --> SHOW ALL .
Which file type

is to be listed?
Use this key to switch between soft-key rows.
File information
File name Name consists of up to 25 characters plus file extension
Bytes File size in bytes
Status File properties:
E File selected in Programming mode of operation
S File selected in Test Run mode of operation
M File selected in a Program Run mode of operation
P Protected file that cannot be deleted or edited
Date Date on which file was last changed
Time Time at which file was last changed
Note
Refer to the TNC 320 User’s Manual for a detailed description of file management!

11.5 File Management in the PLC Partition
Calling the  Press the following key combination to call the PLC partition:
PLC partition
 After the code number has been entered, the PLC main menu is displayed.
 Call the program management.
The directory structure is displayed on the left.

The associated files are listed on the right.
Use the LEFT and RIGHT arrow keys to toggle between directory field and
files field.
With the +/- key or with ENTER you can open and close subdirectories.
Select subdirectories or files by pressing the UP and DOWN arrow keys.

The selected directory or file is displayed in the header.
January 2008 11 – 93
Overview of the File type File extension
most important
PLC file types ASCII files (text files, such as PLC dialogs and error messages) .A
Image files for PLC soft keys and help graphics .BMX
HEIDENHAIN cycles .CDC .CDF
Configuration files (machine parameters) .CFG
Compensation value assignments .CMA
Compensation value tables .COM
Help and dialog files .CSV
OEM cycles .CYC .DES .ELE
Definition files .DEF
PLC error table .PET
Compiled PLC programs .PLC
Oscilloscope trace file .SCO
Source files (source code) .SRC
Text file (e.g. help information and current values of configuration .TXT
objects and parameters)
Watch list file .WLT
ZIP files (e.g. backed-up machine parameters and log files) .ZIP
Note
If you cannot find certain files although the cursor is placed in the correct directory,
a file types filter may be active.
The filter setting is displayed above the file list, for example PLC:\*.DEF
With the soft keys SELECT TYPE --> DEFAULT you can select the predefined filters.
Press the DISPLAY FILTER soft key and enter *.* to view all PLC files.
Which file type

is to be listed?
Use this key to switch between soft-key rows.

File information
File name Name consists of up to 25 characters plus file extension
Bytes File size in bytes
Status File properties:
E File selected in Programming mode of operation
S File selected in Test Run mode of operation
M File selected in a Program Run mode of operation
P Protected file that cannot be deleted or edited
Date Date on which file was last changed
Time Time at which file was last changed
Note
Refer to the TNC 320 User’s Manual for a detailed description of file management!
January 2008 11 – 95
12 Data Backup
12.1 Introduction
Data backup When servicing it is often necessary or advisable to back up certain control data!
recommended
You should always back up the original machine parameters before you make any changes
to the settings of the machine. This can be done on the flash card of the TNC 320 without
having to transfer data to an external medium --> see “Backing up machine parameters” on page
28 – 299.
Moreover, all PLC data, i.e. the specific machine data determined by the manufacturer, are of
priority interest for service technicians.
Note
The machine data (PLC partition) for the machine tool can be obtained from the machine
manufacturer, or they are supplied with the machine.
Caution
If changes were made to the machine (NC software update, modifications, etc.) that result
in changes or adaptations of the machine data (machine parameters, PLC program, etc.),
a new backup for this machine must be created!
Available For data backup the following data interfaces are available on TNC 320:
data interfaces
Ethernet Connector X26
RS-232-C (V.24) Connector X27
USB Connectors X141 and X142
Note
The use of a USB stick is advisable for servicing.

This allows for very fast data transfer in both directions and backups of entire partitions
without much effort.
Note
If you want to profit from the additional functions of the data transfer software TNCremoNT
the use of the Ethernet interface is advisable.
The transfer rate of this interface is considerably higher than that of the RS-232 interface.
Depending on the Windows system of your laptop/PC, the proceedings for requesting and
setting the Ethernet configuration may be slightly different.
The following description is an example with Windows 2000.
Windows knowledge is required!
To access the network settings of your laptop/PC you require the appropriate access
rights (if required, ask your system administrator).
To access the network settings at the control the code number NET123 is required.
January 2008 12 – 97
Data transfer For data transfer and data backup the HEIDENHAIN data transfer software TNCremoNT
software as of version 2.6 is used in this description.
TNCremoNT
You can download the current version of TNCremoNT from the HEIDENHAIN website
(www.heidenhain.de/Services/...) and install it on your service laptop or stationary computer.
Note
Please use the current version of TNCremoNT.
Note
The TNCremoNT program includes detailed operating descriptions including a table of

contents in Menu/Help.
BINARY-to-ASCII In contrast to the other TNC controls TNC 320 does not feature BINARY-to-ASCII conversion
conversion for data backup!
The data on the TNC 320 memory card are in ASCII format!
USB stick A very simple way of backing up data is to copy them onto a USB stick.
Two USB interfaces are standard features of TNC 320. The memory stick is simply plugged in.
--> The control automatically detects a standard USB device.
In the program management of the control the data can now be backed up on the USB stick
(e.g. using the dual-window concept).

12.2 Connection Setup
12.2.1 Via USB
Requirements: A USB device (e.g. USB stick) with the following characteristics:
USB 1.1
FAT or VFAT formatted
Current consumption below 0.5 A (otherwise a separate power supply is required)
USB cable, max. 6 m (for longer cables amplifiers must be used)
Note
TNC 320 recognizes standard USB 1.1 sticks.

HEIDENHAIN cannot guarantee that all USB sticks available on the market work with
TNC 320!
Connecting the  Connect the USB stick to the interface specified by the machine manufacturer (in the console
USB stick or in the electrical cabinet) or directly to the MC 320.
The USB interfaces X141 and X142 are located on the lower left on the back side, behind the
Ethernet interface.
DANGER
Please bear in mind the danger of current and voltage when you open the console to
connect the USB stick.
 Switch to the Programming mode and press the PGMMGT key. -->
The USB device appears in the folder list.
Disconnecting the You are in the program management.

USB stick
 Switch the soft-key row until you see the MORE FUNCTIONS soft key.
 Press this soft key and then continue to switch the soft-key row, until the soft keys with the
USB-stick symbols appear.
 Press the soft key with the symbol "Remove USB stick".
--> The USB device disappears from the folder list.
 Remove the USB stick.
Caution
If you remove the USB stick without having pressed the "Remove USB stick" symbol before,
you may loose data on the stick!
January 2008 12 – 99
12.2.2 Via Ethernet
Requirements A laptop/PC with an Ethernet card

Either an Ethernet crossover cable for direct connection of laptop and control (peer-to-peer
connection) or a non-crossed Ethernet cable (patch cable) for connection via your local
network (intranet).
Note
Mark your cable as "crossed" or "non-crossed"!
DANGER
connect the data cables.
Connection via your Please ask your system administrator!

local network
Connection setup It is advisable to set up a direct connection between your service laptop and the control
at the customer's (peer-to-peer).
(service call)
 Ask your customer whether you may disconnect the control from his in-house network for
the duration of your work.
 Connect your laptop directly to the control by means of a crossed Ethernet cable.
 Now either adapt the IP address and the subnet mask of your laptop to the IP address
and subnet mask of the TNC 320, or vice versa.
If you want to adapt the settings of your laptop to those of the TNC:
 First determine IP address and subnet mask of our laptop:

Call the Programming mode of operation --> Press the PGMMGT key --> Press the NETWORK
soft key --> Press the NETWORK INFO soft key --> Read the IP address from the line eth0.
 Activate the properties of the TCP/IP protocol of the Ethernet card.
(For this purpose you may have to read the Windows Help or ask your system administrator.)
 Note down the original settings so that you can restore them later!
Note
To make the following changes to the settings of your Ethernet card, you require the
relevant permissions. Ask your system administrator.
 In the case of a peer-to-peer connection the IP address cannot be generated automatically

(DHCP = Dynamic Host Configuration Protocol)!
You require a fixed IP address! Specify this accordingly.
 Enter an IP address.
Note
We recommend using the IP address of the TNC 320 and increasing or decreasing the last
place by one.
Example:
Address of TNC 320 160.1.180.5
Address of laptop 160.1.180.6

 The subnet mask of your laptop must be identical with that of the control.
Enter this accordingly (other settings are of no significance here)!
 Confirm the settings (your laptop may reboot).
If you want to adapt the settings of your laptop to those of TNC 320:
 Determine IP address and subnet mask of your laptop:

In the prompt enter, e.g. the ipconfig command
(or you enter the winipcfg command, depending on the Windows version).
You can also find this information in My Computer\Control Panel\Network ...

 Enter the code number NET123 on the control and then call the program manager.
 Press the NETWORK soft key (switch soft-key row accordingly).
 Press the CONFIGURE NETWORK soft key (switch soft-key row accordingly).
January 2008 12 – 101

The following display appears:
Caution
Note down the original settings which you will have to restore later!
 In the case of a peer-to-peer connection the IP address cannot be generated automatically

(DHCP = Dynamic Host Configuration Protocol)!
You require a fixed IP address! If the control is set to DHCP, you must change this setting.
 Adapt the IP address of the control to the IP address of your laptop.
Note
We recommend using the IP address of the laptop and increasing or decreasing the last
place by one.
Example:
Address of laptop 160.1.11.227
Address of TNC 320 160.1.11.228 or 160.1.11.226
 Enter the same subnet mask as that of your laptop.

 Press the OK soft key twice.
 Now the control reboots, the new settings are active.

TNCremoNT  Start the HEIDENHAIN data transfer program TNCremoNT.
 Click this icon to open the configuration window (can also be opened via
Extras/Configuration ...).
 Now click on Connection and select Ethernet (TCP/IP).

 Subsequently, click on Settings and enter the IP address of the control.
Check the transfer mode. It should be set as follows:
 Confirm with Apply and OK.

 Click this icon. --> The connection is set up.
 The TNCremoNT screen is split and the control's hard disk is shown in the lower half of
the screen.
Note
If this does not work, please check the connecting cable and the settings.
You can also try, whether pinging works --> see next pages!
January 2008 12 – 103

Pinging If no TNCremoNT connection is established, check by pinging, whether the ...
Ethernet card in the laptop
Ethernet card in the control
Connection via Ethernet
... function properly.
"Ping-loopback test" on the laptop (test of the Ethernet card of the laptop):
 In the prompt enter the ping command followed a blank and the IP address of the Ethernet
card of the laptop.
 Confirm with ENTER. --> If the Ethernet card functions it will respond! If the Ethernet card
does not function, a timeout message etc. is displayed.
"Ping-loopback test" on the control (test of the Ethernet card of the control):
 Call the Programming mode of operation and press the PGMMGT key.
 Then press the soft keys NETWORK and PING.
 Enter the IP address of TNC 320.
 Press ENTER to confirm. --> If the Ethernet card functions, you will receive a positive response
(0% packet loss). If the Ethernet card does not function, a message is generated reporting the
loss of data packets.
Example of a "ping-loopback test“ at the control:
Pinging from the laptop to the control (test of the connection):

 In the prompt enter the ping command followed a blank and the IP address of the control.
 Press ENTER to confirm. --> If the connection works, the control will respond! If the
connection does not work, a timeout message etc. is displayed.

Example: Pinging from the laptop to the control:
Pinging from the control to the laptop (test of the connection):

 Call the Programming mode of operation and press the PGMMGT key.
 Then press the soft keys NETWORK and PING.
 Enter the IP address of the laptop.
 Press ENTER to confirm. --> If the Ethernet card functions, you will receive a positive response
(0% packet loss). If the Ethernet card does not function, a message is generated reporting the
loss of data packets.
Note
If the "pinging" does not work, you have to check again all settings and the hardware
(Ethernet cables, Ethernet cards).
Meaning of the
LEDs on the
Ethernet data LED Condition Meaning
interface X26 Green Blinking Interface active
Off Interface inactive
Yellow On 100 Mb net
Off 10 Mb net
Restoring the After you have finished data backup and separated the connection, do not forget to reactivate
original settings the original network settings of your laptop or of TNC 320.
 At the laptop enter the original settings and confirm with ENTER.
 At the control enter the original settings and confirm with ENTER.
Note
The control must be rebooted to activate these settings!
January 2008 12 – 105

12.2.3 Via serial interface RS 232/V.24
Requirements A laptop/PC with an RS 232 interface or a USB interface (for connection of a USB/RS 232
adapter)
A crossed serial data transfer cable (standard cable) for the connection of laptop and
D-sub connector on the electrical cabinet (HEIDENHAIN adapter block).
Possible configurations, also for direct connection of the laptop to TNC 320.
-->see “Cable Overview” on page 12 – 119.
DANGER
connect the data cables.
Note
Do not use self-manufactured cables (shielding problems, contact problems, short circuits,
etc.).
Mark your cable as "crossed" or "non-crossed".
Caution
Metallic isolation of the interface is required ("opto bridge")!

The RS 232 serial interface is not metallically isolated.
Therefore, you should use an "opto bridge".
This serial adapter connector ensures a metallic isolation via optocoupler and can thus
protect the serial interface against overvoltage, different load potentials and interference
voltages on the ground lines.
"Opto bridges" are available in specialized computer stores.
Please note: If the machine manufacturer has already mounted an opto bridge, a further
opto bridge will not function, as such components must be powered from both sides!
Baud rate for LSV-2 Select a baud rate for the LSV-2 protocol:
 Call the MP list.
 Open the path System/Network/Serial/CfgSerialPorts/baudRateLsv2.
 Open the selection window (Arrow Right key, GOTO key) and confirm the current baud rate
or select a higher baud rate. (Should this make problems you can revert to lower rates.)
Note
The TNC 320 recognizes automatically when the LSV-2 protocol is used (e.g., data transfer
with TNCremoNT).
TNCremoNT  Start the HEIDENHAIN data transfer program TNCremoNT.

 Click this icon to open the configuration window (can also be opened via
Extras/Configuration ...).
 Now click on Connection and select LSV-2 (serial connection).

 Then click on Settings and select the serial interface (e.g. COM1).
 Activate automatic detection of the data transfer rate on connection setup.
--> The baud rate you have set on TNC 320 is activated.
Note
If you use a USB/RS 232 adapter, automatic detection of the baud rate should not be active.
In this event set the transfer rate at the control and at the laptop.

Check the transfer mode. It should be set as follows:
 Confirm with Apply and OK.

 Click this icon. --> The connection is set up.
 The TNCremoNT screen is split and the control's hard disk is shown in the lower half of
the screen.
Note
If this does not work, please check the connecting cable and the settings.
January 2008 12 – 107

12.3 Reading In/Out Files and Directories
There are several possibilities of reading in and downloading files and directories:
Connection of a USB device; transfer using the dual-window concept in
the program management
Transfer using TNCremoNT
Transfer using TNCserver
Note
Information on setting up data interfaces and reading data (e.g. TNCserver operation) can be
found in the User's Manual of TNC 320.
Connection setup  Connect a USB stick --> see “Connection Setup” on page 12 – 99.
or
 Establish the connection between the control and the laptop using TNCremoNT
--> see “Connection Setup” on page 12 – 99.
Transferring data to  Switch to the Programming mode and press the PGMMGT key.
the USB stick
Note
Press the soft keys SHOW FILES and SHOW TREE to activate the respective view.
 Place the cursor on the USB0:\ directory

(or on the subdirectory to which you wish to transfer the data).
 Press the WINDOW soft key. --> The directory tree for example is now displayed on both
halves of the screen.
 Place the cursor in the right half on the directory, subdirectory or file you wish to transfer.

 Press the soft key COPY DIR. or COPY ABC -> XYZ.
The directory with its entire contents or the individual file is copied onto the USB stick.
 Press the soft key "Remove USB stick" before you remove the stick.
--> see “Disconnecting the USB stick” on page 12 – 99
Transferring data  Switch to the Programming mode and press the PGMMGT key.
from the USB stick
Note
Press the soft keys SHOW FILES and SHOW TREE to activate the respective view.
 Place the cursor on the USB0:\ directory

(or on the subdirectory from which you wish to take the data).
 Press the WINDOW SOFT KEY. --> The directory tree for example is now displayed on both
halves of the screen.
 Place the cursor in the right half on the directory or subdirectory to which you wish to transfer
the data.
 Return to the other side now.
January 2008 12 – 109

 Press the soft key COPY DIR. or COPY ABC -> XYZ.
The directory with its entire contents or the individual file is copied from the USB stick to
the control.
 Press the soft key "Remove USB stick" before you remove the stick. -->
see “Disconnecting the USB stick” on page 12 – 99

Reading out  In the upper half of the screen (laptop/PC contents) select the target directory.
data using --> Double-click the requested directory.
TNCremoNT --> The path information appears in the blue bar above.
 In the lower screen window (TNC contents), select the directory containing the file you wish
to read out.
In example PLC:\config
--> Double-click the requested directory.
--> The path information appears in the blue bar above.
Note
To change the partition, click one of the two buttons to the right of the blue bar with the path
information.
To change to the PLC partition, enter PLC: followed by the PLC code number.
January 2008 12 – 111

 Using the mouse, click the file you wish to read out.
 Press and hold the left mouse button and pull the file into the upper window.
 Release the mouse button. --> The file is being transferred.
Reading in  In the lower half of the screen (TNC 320 contents) select the target directory.
data using --> Double-click the requested directory.
TNCremoNT --> The path information appears in the blue bar above.
Note
information.
 In the upper screen window (laptop/PC contents), select the directory containing the file you
wish to upload onto TNC 320. In the example C:\Backup --> Double-click the requested
directory. --> The path information appears in the blue bar above.
 Using the mouse, click the file you wish to read in.
 Press and hold the left mouse button and pull the file into the lower window.
 Release the mouse button. --> The file is being transferred.

12.4 Data Backup on External Data Medium
During backup the data of the control's memory card are stored on an external data medium
(e.g. service laptop).
Note
The control should be in Power interrupted state while the backup is run.
Otherwise, files may be used by the system and therefore inaccessible.
Connection setup  Set up a connection to TNC 320 via TNCremoNT.

--> see “Connection Setup” on page 12 – 99
Selecting the  In the upper screen half (laptop contents), select the directory where you
partition you want to store the backup files. --> Double-click the requested directory.
--> The path information appears in the blue bar above.
You can also create a new folder with TNCremoNT.
For this purpose click File / Create folder ... or the respective icon.
Note
The folder where you save the backup should have an identifying name (e.g. the machine
number) so that it can clearly be assigned to the machine concerned!
Avoid long paths and file names (no more than 80 characters should be used).
 In the lower screen half (TNC contents), select the partition from which you want to back-up
data.
Note
information.
 Click the main directory of the selected partition (in the example PLC:).
It must be shown in the blue bar!
January 2008 12 – 113

Different  With Extras/Backup/Restore ... (or with the respective icon), call the backup menu.
backup types --> A new window appears.
 The backup type can be selected with the following icons …
 Scan directory
The files in the selected directory are scanned.
Files in subdirectories are ignored!
 Scan directory tree

The files in the selected directory and in all subdirectories are scanned.
 Scan system and machine files

All files in the PLC partition and several selected files in the SYS partition
(e.g. TIMES.SYS) are scanned.
 Scan all
All files in the TNC and PLC partitions and several selected files in the
SYS partition (e.g. TIMES.SYS) are scanned.
Note
Scanning in this context means creating a reference list for the directory tree.
A file with the extension *.LST is generated. This file serves to restore the original
directory tree at a later date.
Select the backup type according to the following criteria:
Backups for If you want to create a backup archive for your TNC or PLC data:
data archives
 Select Scan directory tree
 The backup should have an identifying name (for example the machine number, etc.)
Separate archives should be created for the TNC partition and for the PLC partition!
Backup for an If you intend to insert a new memory card (and still can backup data from the old card):
exchange of the
 Select Scan all ("full backup") or
memory card
 Scan system and machine files (if the TNC data have already been backed
up or the source files are stored on an external data medium)
The machine time (TIMES.SYS), the calibration data of the touch probes, etc. are copied and
transferred to the new memory card.
These backup types are not intended for an archive, since machine time, calibration data, etc.
continue to change.
Note
For these backup types the settings of date and time on control and laptop must match.
Otherwise the error message Wrong password! is displayed.

Starting a backup  Click Run/Backup (or the corresponding icon) to open the file window.
 Enter the name of the backup file (extension BCK) in the file name line.
 Start the data transfer with Save.
 When the backup is finished, the corresponding window is closed.

 Check on your laptop, whether there are two files with the extensions *.BCK and *.LST.
Note
The backup is only complete and can be restored at a later date, if both files are available:
*.BCK backup file with the original files in compressed format
*.LST reference list containing the directories and the files
January 2008 12 – 115

12.5 Extracting Files from the Backup File
General If you want to create a backup (e.g. of the PLC partition), all related files are stored in one
*.BCK file using a compression algorithm.
To view individual files you can extract them from the *.BCK file by means of TNCremoNT!
Extracting files  Start TNCremoNT.

 Go to the folder that contains the backup of the machine.
 Click the *.LST file --> the TNCbackup window is displayed.
 Sort the files listed there, e.g., by clicking the bar path.
(You can sort by file name, path, type and file size. Just click the corresponding bar.)
 Click Edit/Select all.

 Remove the blue check mark by clicking the corresponding icon (blue tick crossed out).
 Double-click to mark the files you want to extract. --> The blue check mark appears before the
file name.
 Click Run/Extract (or the corresponding icon).
 You can extract the selected files either directly or together with the corresponding directory
structure into your backup directory.
 Now the extracted files can be read, transferred individually etc.
Caution
After the extraction restore all marks in your *.LST file.

(Otherwise only the marked files of this backup will be restored.)

12.6 Restoring Data
When restoring the backup of a machine, the data (e.g., PLC data, TNC data, "full backup") are
restored from an external data medium (e.g. service laptop) to the control's memory card.
Caution
The machine must not operate while the data of the memory card are being restored.
The control should be in Power interrupted state.
Never press any key on your control while data transfer is running!
Note
If you work with Ethernet connection, please check or make the necessary settings.
--> see “Connection Setup” on page 12 – 99
Connection setup  Set up a connection to TNC 320 via TNCremoNT.

--> see “Connection Setup” on page 12 – 99.
Selecting the  In the upper screen half (laptop/PC contents), select the directory where you have stored the
backup file backup file.
In the example C:\Backup machine XYZ --> Double-click the requested directory. --> The path
information appears in the blue bar above.
Starting the  Double-click on the LST file to open it.

restore process  Start the data transfer with menu item Run/Restore or the corresponding icon.
January 2008 12 – 117

 For restoring PLC data you will be prompted the corresponding password.
 Confirm the following warning with OK:
 Confirm this message with No and continue data transfer:
 Restart the control after successfully restoring the machine backup (reboot).
Now the machine should operate as usual.
Note
If you receive the error message Wrong password when restoring data with TNCremoNT,
date and time of the control and the laptop probably do not correspond.
You may have to reset the system time on the control.
--> see “Setting the System Time” on page 11 – 90

12.7 Cable Overview
Please note:
Maximum cable length with Ethernet: 400 m (shielded), 100 m (unshielded)
Maximum cable length with RS-232-C/V.24: 20 meters
Note
Do not use self-manufactured cables (shielding problems, contact problems, short circuits,
etc.).
Mark your cable as "crossed" or "non-crossed".
Caution
The Ethernet interface is metallically isolated from the control electronics.

The RS 232 serial interface is not metallically isolated.
In the worst case this may result in sparking when you connect the serial data transfer cable
to your laptop and to the control. The reason could be the different potentials of the power
supply of both devices. HEIDENHAIN therefore recommends to use an "opto bridge". This
serial adapter connector ensures a metallic isolation via opto coupler and can thus protect
the serial interface against overvoltage, different load potentials and interference voltages
on the ground lines. "Opto bridges" are available in specialized computer stores.
Please note: If the machine manufacturer has already mounted an opto bridge, a further
opto bridge will not function, as such components must be powered from both sides!
12.7.1 Ethernet Interface RJ45 Connection

For direct connection of laptop and control ("peer-to-peer") you require a crossed Ethernet
cable ("crossover cable")!
Note
We recommend to mark the crossed Ethernet cable accordingly in order to avoid confusion.
If you establish the connection via your local network (intranet), you normally use a non-crossed
Ethernet cable (patch cable).
January 2008 12 – 119

12.7.2 RS-232-C / V.24
Note
The V.24 / RS-232-C has different pin layouts at TNC 320 (connector X27) and at the V.24
adapter block (D-sub connector on electrical cabinet).
Exception: The cable with the ID 366964-xx may be connected to the 9-pin adapter block or
directly to the control.
Note
The serial data interfaces are described in detail in the Service Manual 'Data Interfaces of
HEIDENHAIN Devices'.
Available for download from www.heidenhain.de/Services and Documentation/...
The Help menu of TNCremoNT also contains information on constellations and cables for
serial RS-232-C data transfer.
Overview:

Accessories The following accessories can be very helpful and are available in specialized computer stores:
D-sub adapter connector

25-pin
Metallically isolates the serial interface by means of integrated opto

couplers and thus protects from:
- Overvoltages
- Different load potentials by different main current circuits
- Interference voltages on ground lines
Please note: If the machine manufacturer has already mounted an

opto bridge, a further opto bridge will not function, as such
components must be powered from both sides!
D-sub adapter connector 25-pin
Adapts female to male
D-sub adapter connector 9-pin
Adapts female to male

25-pin
To test the data transfer lines
January 2008 12 – 121

25-pin
To cross the data transfer lines
Adapts 25-pin connector to 9-pin connector
Background:
The RS 232 adapter block on the electrical cabinet mostly has a
25-pin connector, the COM interface on the laptop mostly a 9-pin
connector.

13 Important Features of HEIDENHAIN Components
13.1 Hardware Identification

On every HEIDENHAIN product there is an ID label which indicates, e.g.
Unit designation
ID number
Serial number
Thus, each unit is uniquely identified.
ID label
(example)
Note
The most important information for the service is the unit designation and the ID!
In the following pictures the position of the ID labels on HEIDENHAIN components is marked
by arrows .
Control
MC 320
Compact contouring control with
integrated main computer, flat-panel
display and integrated operating keys.
MB 420 machine operating panel
(optional).
4 analog closed-loop axes
(EnDat, 1 VPP, 11 µA)
January 2008 13 – 123

Additionally required:
CFR Compactflash memory card
System Identification Key
SIK
Machine
operating panel
MB 420 Machine Operating Panel

Machine operating panel with snap-on
(switchable) keys.
Key assignment:
Emergency stop
Machine control voltage
NC start / NC stop
Direction keys for 5 axes
Rapid traverse
Coolant
Spindle start
Spindle stop
7 keys for machine functions
FN 1 to FN 5 (standard assignment)
Retract axis, tool change, unlock tool, menu
selection→, unlock door, rinse water jet, chip
removal (assignment for HEIDENHAIN basic
PLC program)

Handwheels
HR 410 Handwheel
Portable electronic handwheel with snap-on (switchable) keys.
Keys for selecting five axes
Keys for traverse direction
Keys for preset feeds
Actual-position-capture key
Three keys for machine functions
(definable via PLC)
Spindle right/left/stop
NC start/stop, spindle start;
for HEIDENHAIN basic PLC program
Two permissive buttons (24 V)
Emergency stop button (24 V)
Magnetic holding pads
The handwheel is available with or without detent.
HR 130 Handwheel
Panel-mounted handwheel
With ergonomic knob, radial
cable outlet
January 2008 13 – 125

HRA 110 Handwheel Adapter
For connecting up to three HR 150 handwheels to the TNC.
The axes and the subdivision factor are selected via rotary switch.
HRA 110
HR 150 cable outlet

radial
Handwheel selection switch

Touch Probe
Systems
TS 220 Touch Probe

Touch-trigger probe with cable connection for workpiece setup
and measurement during machining.
January 2008 13 – 127

TS 640, TS 440 Touch probe
Touch-trigger probe with infrared transmission,
for workpiece setup and measurement during machining.
TS 640
TS 440
SE 640 transceiver unit

SE 540 transceiver unit

Other Accessories
PL 510 PLC input/output unit

This is a modular I/O system for the expansion of PLC inputs
and outputs.
The PL 510 consists of the PLB 510 basic module and the
following components:
PLD 16-8 I/O module with 16 digital inputs and 8 digital outputs
PLA 4-4 analog module with 4 analog inputs for Pt 100
thermistors and four ±10 V analog inputs
Empty housing for partial assembly
The PL 510 can be mounted on a top hat rail (NS 35 EN 50022).
The PL 510 equipped (completely or partially) with PLD 16-8 is
compatible with PL 410 B/PL 405 B.
358 849-01 PLB 510 basic module
PLD 16-8 input/output module

PLA 4-4 analog module
Empty housing
January 2008 13 – 129

13.2 Display of System Information
General When you consult your machine manufacturer or HEIDENHAIN in the event of an error or a
malfunction of your machine, it is important that know which NC and PLC software is installed
on TNC 320.
Calling the display  Press MOD key
Note
You can display the system information in any mode of operation by pressing the
MOD key on your control!
Control model
NC software
340551 Program number of the NC software

02 Version of the NC software
SP4 Version of the service pack
No export license is required for the NC software of the control. --> TNC 320 is approved for
export to all countries!
HEIDENHAIN releases a new NC software type whenever it introduces extensive new
functions.

NC Kernel
NC Kernel is the operating system software of TNC 320.
PLC software
The machine manufacturer identifies his PLC software by means of a character string.
January 2008 13 – 131

14 Connector Designations and Layouts
14.1 Important Note
Caution
Do not engage or disengage any connecting elements while the unit is under power!
See ”Safety Precautions” on page 1 – 7!
14.2 MC 320
14.2.1 Designation and Position of Connectors
X1 to X4 Position encoder
X
X8 Nominal value output, analog
X44
X23 X100
X34 X12 TS touch trigger probe
X30
X27 X13 Reserved
X142 X26
X41 X23 Handwheel
X141
X1 X26 Ethernet data interface
X27 RS-232-C/V.24 data interface
X141, X142 USB interface
X46 X600 X2
X125 X8 X30 Reserved
X34 24 V for “control-is-ready”
X3
X601 output
X12 X41 PLC output
X42
X4 X42 PLC input
X121 X13 X44 24 V PLC supply voltage
X147 PLC expansion
X147
X46 Machine operating panel
X100 Power supply

X125 SIK (system Identification Key)
X X121 Reserved
X600 CFR CompactFlash memory card
X601 Reserved
B Signal ground
January 2008 14 – 133

14.2.2 Pin layouts on MC320:
X1 to X4: Pin layout:

Position encoder
1 VPP
MC 320 AK 309 783-xx Measuring system

AK 310 199-xx
Male Assignment Female Color Female Male Color
1 +5 V (UP) 1 Brown/Green 12 12 Brown/Green
2 0 V (UN) 2 White/Green 10 10 White/Green
3 A+ 3 Brown 5 5 Brown
4 A– 4 Green 6 6 Green
5 Do not assign 5
6 B+ 6 Gray 8 8 Gray
7 B– 7 Pink 1 1 Pink
8 Do not assign 8
9 +5 V (sensor) 9 Blue 2 2 Blue
10 R+ 10 Red 3 3 Red
11 0 V (sensor) 11 White 11 11 White
12 R– 12 Black 4 4 Black
13 0V 13
14 Do not assign 14 Violet 7 7 Violet
15 Do not assign 15
Hsg. External shield Hsg. External shield Hsg. Hsg. External shield
Note
The interface complies with the requirements of EN50178 for “low voltage electrical
separation”.

X1 to X4: Pin layout:
Position encoder
with EnDat
interface
MC 320 AK 332 115-xx VB 323 897-xx AK 313 791-xx

Male Assgmt. Female Color Female Male Color Fem. Male Color Fem.
Brown/ Brown/ Brown/
1 +5 V (UP) 1 Green 7 7 Green 7 7 Green 5b
White/ White/ White/
2 0 V (UN ) 2 Green 10 10 Green 10 10 Green 6a
Green/ Green/ Green/
3 A+ 3 Black 15 15 Black 15 15 Black 2a
Yellow/ Yellow/ Yellow/
4 A– 4 Black 16 16 Black 16 16 Black 2b
Line drop compensator 336 697-02, if required

5 Data 5 Gray 14 14 Gray 14 14 Gray 3b
Blue/ Blue/ Blue/
6 B+ 6 Black 12 12 Black 12 12 Black 1a
Red/ Red/ Red/
7 B– 7 Black 13 13 Black 13 13 Black 1b
8 Data 8 Pink 17 17 Pink 17 17 Pink 3a

+5 V
9 (sensor) 9 Blue 1 1 Blue 1 1 Blue 5a
10 Free 10 3 3 Red 3 3
0V
11 (sensor) 11 White 4 4 White 4 4 White 6b
12 Free 12 2 2 Black 2 2
Internal Internal Internal Internal
13 shield 13 shield 11 11 shield 11 11 shield
14 Clock 14 Violet 8 8 Violet 8 8 Violet 4a
15 Clock 15 Yellow 9 9 Yellow 9 9 Yellow 4b

External External External
Hsg. Housing Hsg. shield Hsg. shield Hsg. shield
Note
separation”.
January 2008 14 – 135

X8: Pin layout on MC 320 and connecting cables:
Analog output
1 to 6 MC 320 Connecting cables
D-sub Assignment D-sub Color
connctn. connctr.
(female) (male)
15-pin 15-pin
1 Analog output 1: ±10 V 1 Brown
2 Do not assign 2 Brown/Green
3 Analog output 2: ±10 V 3 Yellow
4 Analog output 5: ±10 V 4 Red/Blue
5 Analog output 3: ±10 V 5 Pink
6 Analog output 5: 0 V 6 Gray/Pink
7 Analog output 4: ±10 V 7 Red
8 Analog output 6: ±10 V 8 Violet
9 Analog output 1: 0 V 9 White
10 Do not assign 10 White/Gray
11 Analog output 2: 0 V 11 Green
12 Do not assign 12
13 Analog output 3: 0 V 13 Gray
14 Analog output 4: 0 V 14 Blue
15 Analog output 6: 0 V 15 Black
Housing External shield Housing External
shield
X12:
Connection of the
touch probe for
workpiece
measurement
Note
separation”.
Pin layout for TS 220:
MC 320 AK 274 543-xx TS 220

Female Assignment Male Color Pin Pin Color
1 0 V (internal shield) 1
2 Do not assign 2
3 Ready 3 Pink 4 4
4 Start 4
5 +15 V ± 10% (UP), max. 100 mA 5 Gray 3 3
6 +5 V ± 5% (UP), max. 100 mA 6 Brown/ 2 2 Brown
Green
7 Battery warning 7 Gray
8 0 V (UN) 8 White/Green 1 1 White
9 Trigger signal 9 Green 5 5 Green
10 Trigger signala 10 Yellow 6 6 Yellow
11 to 15 Do not assign 11 to 15
External
Hsg. External shield Hsg. shield Hsg.
a. Stylus at rest means logic level HIGH.

Pin layout for TS 440, TS 640 with SE 640:
MC 320 AK 310 197-xx SE 640 TS 440,

Female Assignment Male Color Female Male Color TS 640
1 0 V (internal shield) 1 White/ 7
Brown
2 Do not assign
3 Ready 3 Gray 5 5 Gray
4 Start 4 Yellow 3 3
5 +15 V ± 10% (UP), max. 100 mA 5 Brown 2 2 Brown
6 +5 V ± 5% (UP), max. 100 mA
7 Battery warning 7 Blue 6 6 Blue
8 0 V (UN) 8 White 1 1 White
9 Trigger signal
10 Trigger signala 10 Green 4 4 Green
11 to 15 Do not assign
External
Hsg. External shield Hsg. shield Hsg. Hsg.
Pin layout for TS 440, TS 640 with SE 540:
MC 320 AK 310 197-xx AK 517 375-xx SE 540

Female Assignment Male Color Female Male Color Female
1 0 V (internal shield) 1 White/ 7 7 Internal 7 TS 440,
Brown shield TS 640
2 Do not assign
3 Ready 3 Gray 5 5 Gray 5
4 Start 4 Yellow 3 3 Yellow 3
5 +15 V ± 10% (UP), 5 Brown 2 2 Brown 2
max. 100 mA
6 +5 V ± 5% (UP),
max. 100 mA
7 Battery warning 7 Blue 6 6 Blue 6
8 0 V (UN) 8 White 1 1 White 1
9 Trigger signal
10 Trigger signala 10 Green 4 4 Green 4
11 to 15 Do not assign
External External
Hsg. External shield Hsg. shield Hsg. Hsg. shield Hsg.
January 2008 14 – 137

X23: Pin layout:
Handwheel input
D-sub connection (female) 9-pin Assignment
1 CTS
2 0V
3 RTS
4 +12 V
5 Do not assign
6 DTR
7 TxD
8 RxD
9 DSR
Housing External shield
Note
separation”.

X26: Maximum data transfer rate:
Ethernet interface
For integration into the company network via NFS or SMB protocol:
RJ45 connection
10 or 100 Mbps
For LSV-2 protocol (in conjunction with TNCremoNT or RemoTools):
2 to 5 Mbps (depending on file type and network utilization)
Maximum cable length: 400 m (shielded), 100 m (unshielded)
RJ45 connection (female) 8-pin Assignment

1 TX+
2 TX–
3 REC+
4 Do not assign
5 Do not assign
6 REC –
7 Do not assign
8 Do not assign
Housing External shield
Face of the connector:
Note
separation“.
Meanings of the LEDs on the Ethernet data interface X26:
LED Condition Meaning

Green Blinking Interface active
Off Interface inactive
Yellow On 100 Mb net
Off 10 Mb net
For further information on the Ethernet interface and instructions on the configuration of the
interface, please see “Ethernet Interface RJ45 Connection” on page 12 – 119.
January 2008 14 – 139

X27: Pin layout:
RS-232-C/V.24 data
interface
Note
separation”.
25-pin adapter block:
MC 320 Connecting cable (VB) Adapter block Connecting cable (VB)

365 725-xx 310 085-01 274 545-xx
Male Assignment Female Color Female Male Female Male Color Female
1 Do not assign 1 1 1 1 1 White/ 1
Brown
2 RXD 2 Yellow 3 3 3 3 Yellow 2
3 TXD 3 Green 2 2 2 2 Green 3
4 DTR 4 Brown 20 20 20 20 Brown 8
5 Signal GND 5 Red 7 7 7 7 Red 7
6 DSR 6 Blue 6 6 6 6 6
7 RTS 7 Gray 4 4 4 4 Gray 5
8 CTS 8 Pink 5 5 5 5 Pink 4
9 Do not assign 9 8 Violet 20
Hsg. External shield Hsg. Extern Hsg. Hsg. Hsg. Hsg. Externa Hsg.
al l shield
shield
9-pin adapter block:
MC 320 Connecting cable (VB) Adapter block Connecting cable (VB)

355 484-xx 363 987-02 366 964-xx
Male Assignment Female Color Male Female Male Female Color Female
1 Do not assign 1 Red 1 1 1 1 Red 1
2 RXD 2 Yellow 2 2 2 2 Yellow 3
3 TXD 3 White 3 3 3 3 White 2
4 DTR 4 Brown 4 4 4 4 Brown 6
5 Signal GND 5 Black 5 5 5 5 Black 5
6 DSR 6 Violet 6 6 6 6 Violet 4
7 RTS 7 Gray 7 7 7 7 Gray 8
8 CTS 8 White/ 8 8 8 8 White/ 7
Green Green
9 Do not assign 9 Green 9 9 9 9 Green 9
Hsg. External shield Hsg. External Hsg. Hsg. Hsg. Hsg. External Hsg.
shield shield
X34: The control-is-ready signal output is powered by 24 Vdc provided by the inverter or the power
Power supply for supply unit of the machine. The voltage is connected with terminal X34.
"Control-is-ready"
Pin layout:
Connecting terminal X34 Assignment

1 +24 V
2 0V

X41:
PLC outputs
on MC 320 MC 320 Connecting cable (VB) ID 244 005-xx
ID 263 954-xx
D-sub Assignment D-sub
connctn. connctr.
(female) (male)
37-pin 37-pin
Supply via X44, pin 3; disconnectable with EMERGENCY STOP
1 O0a 1 Gray/Red
2 O1a 2 Brown/Black
3 O2 a 3 White/Black
4 O3a 4 Green/Black
5 O4a 5 Brown/Red
6 O5a 6 White/Red
7 O6a 7 White/Green
8 O7a 8 Red/Blue
9 O8 9 Yellow/Red
10 O9 10 Gray/Pink
11 O10 11 Black
12 O11 12 Pink/Brown
13 O12 13 Yellow/Blue
14 O13 14 Green/Red
15 O14 15 Yellow
16 O15 16 Red
Supply via X44, pin 2; disconnectable with EMERGENCY STOP
17 O16 17 Gray
18 O17 18 Blue
19 O18 19 Pink
20 O19 20 White/Gray
21 O20 21 Yellow/Gray
22 O21 22 Green/Red
23 O22 23 White/Pink
24 O23 24 Gray/Green
Supply via X44, pin 1; not disconnectable with EMERGENCY STOP
25 O24 25 Yellow/Brown
26 O25 26 Gray/Brown
27 O26 27 Yellow/Black
28 O27 28 White/Yellow
29 O28 29 Gray/Blue
30 O29 30 Pink/Blue
31 O30 31 Pink/Red
32, 33 Do not assign 32 Brown/Blue, Pink/Green
34 control-is-ready 34 Brown
signal
35, 36, 37 Do not assign 35 Yellow/Pink, Violet,
White
Housing External shield Housing External shield
a. Also via X46 (PLC inputs/outputs)
January 2008 14 – 141

X42: Pin layout:
PLC inputs
on MC 320
MC 320 Connecting cable ID 244 005-xx,

ID 263 954-xx
D-sub connctn. Assignment D-sub connctn.
(female) 37-pin (male) 37-pin
1 I0 1 Gray/Red
2 I1 2 Brown/Black
3 I2 3 White/Black
4 I3 Control-is-ready signal 4 Green/Black
acknowledgment
5 I4 5 Brown/Red
6 I5 6 White/Red
7 I6 7 White/Green
8 I7 8 Red/Blue
9 I8 9 Yellow/Red
10 I9 10 Gray/Pink
11 I10 11 Black
12 I11 12 Pink/Brown
13 I12 13 Yellow/Blue
14 I13 14 Green/Blue
15 I14 15 Yellow
16 I15 16 Red
17 I16 17 Gray
18 I17 18 Blue
19 I18 19 Pink
20 I19 20 White/Gray
21 I20 21 Yellow/Gray
22 I21 22 Green/Red
23 I22 23 White/Pink
24 I23 24 Gray/Green
25 I24 25 Yellow/Brown
26 I25 26 Gray/Brown
27 I26 27 Yellow/Black
28 I27 28 White/Yellow
29 I28 29 Gray/Blue
30 I29 30 Pink/Blue
31 I30 31 Pink/Red
32 I31 32 Brown/Blue
33 Do not assign 33 Pink/Green
34 Do not assign 34 Brown
35 0 V (PLC) test output; do not assign 35 Yellow/Pink
36 0 V (PLC) test output; do not assign 36 Violet
37 0 V (PLC) test output; do not assign 37 White
Housing External shield Housing External shield

X44: Pin layout on MC 320:
PLC supply voltage
Connection Assignment PLC Outputs
terminal
1 +24 V not disconnectable O24 to O30
with EMERGENCY STOP control-is-ready signal
2 +24 V disconnectable with O16 to O23
3 EMERGENCY STOP O0 to O15
4 0V
Note
If the +24-V power supply (not disconnectable with emergency stop) is missing at X44,
the error message Supply voltage missing at X44 appears.
X46: PLC inputs I128 to I152 and PLC outputs O0 to O7 are on connection X46 of the machine
Machine operating panel. The reference potential (PLC) for outputs O0 to O7 is connected to pins 34
operating panel and 35.
Pin layout on MC 320, connecting cables and machine operating panel:
Caution
PLC inputs I128 to I152 must be driven only with the power supply from pins 36 and 37,
since this power supply is internally protected (PLC power supply from X44 connection 2).
MC 320 Connecting cable ID 263 954-xx MB 420

D-sub Assignment D-sub D-sub D-sub Key
connctn. connctr. connctr. connctn.
(female) (male) (female) (male)
37-pin 37-pin 37-pin 37-pin
1 I128 1 Gray/Red 1 1 X–
2 I129 2 Brown/Black 2 2 Y–
3 I130 3 White/Black 3 3 Z–
4 I131 4 Green/Black 4 4 IV –
5 I132 5 Brown/Red 5 5 V–
6 I133 6 White/Red 6 6 X+
7 I134 7 White/Green 7 7 Y+
8 I135 8 Red/Blue 8 8 Z+
9 I136 9 Yellow/Red 9 9 IV +
10 I137 10 Gray/Pink 10 10 V+
11 I138 11 Black 11 11 Tool change
12 I139 12 Pink/Brown 12 12 Unlock tool
13 I140 13 Yellow/Blue 13 13 Menu
selection
14 I141 14 Green/Blue 14 14 Unlock door
15 I142 15 Yellow 15 15 Chip removal
16 I143 16 Red 16 16 Spindle on
17 I144 17 Gray 17 17 Spindle off
18 I145 18 Blue 18 18 Coolant
19 I146 19 Pink 19 19 NC start
January 2008 14 – 143

MC 320 Connecting cable ID 263 954-xx MB 420
D-sub Assignment D-sub D-sub D-sub Key
connctn. connctr. connctr. connctn.
(female) (male) (female) (male)
37-pin 37-pin 37-pin 37-pin
20 I147 20 White/Gray 20 20 NC stop
21 I148 21 Yellow/Gray 21 21 Rapid
traverse
22 I149 22 Green/Red 22 22 Retract axis
23 I150 23 White/Pink 23 23 Rinse water
jet
24 I151 24 Gray/Green 24 24 Via X3
25 I152 25 Yellow/Brown 25 25 Via X3
26 O0a 26 Gray/Brown 26 26 Via X4
27 O1a 26 Yellow/Black 27 27 Via X4
28 O2 a 28 White/Yellow 28 28 Via X4
29 O3a 29 Gray/Blue 29 29 Via X4
30 O4a 30 Pink/Blue 30 30 Via X4
31 O5a 31 Pink/Red 31 31 Via X4
32 O6a 32 Brown/Blue 32 32 Via X4
33 O7a 33 Pink/Green 33 33 Via X4
34, 35 0 V (PLC) 34, 35 Brown, Yellow/Pink 34, 35 34, 35
36, 37 +24 V (PLC) 36 Violet, white 36, 37 36,37
Housing Ext. shield Housing External shield Housing Housing
a. Also via X41 (PLC outputs on MC 320

X100:
Power supply
L Hot lead L1
N Neutral lead N
Ground lead (YL/GN)
X125: The system identification key is located in slot X125.

Slot for SIK
X141, X142 Pin layout:
USB connection (female) 4-pin Assignment

1 +5 V
2 USBP–
3 USBP+
4 GND
Note
If USB components that are connected to X141/X142 require more than 0.5A, a separate
power supply becomes necessary for these components. One possibility is the USB hub
from HEIDENHAIN (368 735-01).
USB hub The power supply for the USB hub must comply with EN 50 178, 5.88 requirements for “low
voltage electrical separation.”
Connections on the USB hub (368 735-01):
Connection designation Function

X1 24 V power supply
X32 5 V output
X140 USB input (to MC 320)
X141 USB output 1
X142 USB output 2
X143 USB output 3
X144 USB output 4
January 2008 14 – 145

X147: Pin layout:
PLC expansion on
MC 320
MC 320 Connecting cable ID 371 046-xx First PL 510

D-sub Assignment D-sub D-sub X1 Assignment
connctn. connctr. connctr. D-sub
(male) (female) (male) connctn.
26-pin 26-pin 26-pin (female)
26-pin
1 0V 1 Black 1 1 0V
2 0V 2 Violet 2 2 0V
3 0V 3 3 3 0V
4 Do not assign 4 4 4 Do not assign
5 Address 6 5 Yellow 5 5 Address 6
6 INTERRUPT 6 Blue 6 6 INTERRUPT
7 RESET 7 Red 7 7 RESET
8 WRITE 8 Gray 8 8 WRITE
EXTERN EXTERN
9 WRITE 9 Pink 9 9 WRITE
EXTERN EXTERN
10 Address 5 10 Green 10 10 Address 5
11 Address 3 11 White 11 11 Address 3
12 Address 1 12 Brown 12 12 Address 1
14 +5 V (output) 14 White/Blue 14 14
15 +5 V 15 Brown/Blue 15 15
(feedback)
16 PCB 16 White/Pink 16 16 PCB
identifier 2 identifier 2
17 PCB 17 Pink/Brown 17 17 PCB
identifier 1 identifier 1
18 Address 7 18 Brown/Green 18 18 Address 7
19 Serial IN 1 19 White/Gray 19 19 Serial IN
20 EM. STOP 20 Gray/Brown 20 20 EM. STOP
21 Serial OUT 21 White/Yellow 21 21 Serial OUT
22 Serial OUT 22 Yellow/Brown 22 22 Serial OUT
23 Address 4 23 White/Green 23 23 Address 4
24 Address 2 24 Gray/Pink 24 24 Address 2
25 Address 0 25 Red/Blue 25 25 Address 0
26 26 26 26
Housing External Housing External shield Housing Housing External
shield shield
X600: The memory card (compact flash removable) memory card is located in the slot X600.
Slot for CFR

14.3 Encoders
See ”X1 to X4: Position encoder 1 VPP” on page 14 – 134
Especially for machine retrofits, the use of adapters for encoder signal adjustment can be of
interest.
Encoder signals with 11 µAPP or TTL levels can be adapted to the 1 VPP interface with
HEIDENHAIN adapter connectors.
Adapters for encoder signals ID

TTL (HEIDENHAIN layout)/1 VPP 317 505-01
TTL (SIEMENS layout)/1 VPP 317 505-02
11 µAPP /1 VPP 313 119-01
Note
Please note:
The adapters adjust only the levels, not the signal shape.
The contamination signal of the square-wave encoder cannot be evaluated.
A square-wave signal can be subdivided no more than 4-fold.
January 2008 14 – 147

Adapter connector Pin layout of D-sub connector (female) and D-sub connector (male):
TTL (HEIDENHAIN)
/ 1 VPP D-sub connctr. Assignment D-sub Assignment
(female) connection
15-pin (male) 15-pin
1 +5 V (UP) 1 +5 V (UP)
2 0 V (UN) 2 0 V (UN)
3 A+ 3 Ua1
4 A– 4 –Ua1
5 0V 5 0V
6 B+ 6 Ua2
7 B– 7 –Ua2
8 0V 8 0V
9 +5 V 9 +5 V
10 R+ 10 Ua0
11 0V 11 0V
12 R– 12 –Ua0
13 0V 13 0V
14 –UaS 14 –UaS
15 Not assigned 15 Not assigned
TTL (SIEMENS)
/ 1 VPP D-sub connctr. Assignment D-sub Assignment
(female) connection
2 0V 2 0V
3 A+ 3 Ua1
4 A– 4 –Ua1
6 B+ 6 Ua2
7 B– 7 –Ua2
10 R+ 10 Not assigned
12 R– 12 Ua0
13 Not assigned 13 –Ua0

11 µAPP / 1 VPP
D-sub connctr. Assignment D-sub Assignment
(female) connection
1 +5 V (UP) 1 +5 V (UP)
2 0 V (UN) 2 0 V (UN)
3 A+ 3 0°+
4 A– 4 0°–
5 0V 5 0V
6 B+ 6 90°+
7 B– 7 90°–
8 0V 8 0V
9 +5 V 9 +5 V
10 R+ 10 R+
11 0V 11 0V
12 R– 12 R–
13 0V 13 0V
14.4 Touch Probe Systems
Touch probe See ”X12: Connection of the touch probe for workpiece measurement” on page 14 – 136.
systems for
workpiece
measurement
January 2008 14 – 149

14.5 Handwheels
X23: See ”X23: Handwheel input” on page 14 – 138

Handwheel input
14.5.1 HR 410 Portable Handwheel

The HR 410 is a portable electronic handwheel.
Pin layout Pin layout for the various extension cables, adapter cables, connecting cables, and the
handwheel:
Connecting cable Connecting cable Connecting cable HR 4xx

ID 281 429-xx ID 296 466-xx
D-sub D-sub D-sub Cplg. on Cnnctr. (male) Cnnctr. Connector
connector connctr. connector mntg. (5+7)-pin (female) (male)
(male) (female) (male) base (5+7)- (5+7)-pin
9-pin 9-pin 9-pin (female) pin
(5+7)-
pin
Housing Shield Housing Housing Shield Housing Housing Shield Housing Housing Shield
2 White 2 2 White E E White E E
4 Brow 4 4 Brown D D Brown D D
n
6 Yello 6 6 Yellow B B Yellow B B
w
7 Gray 7 7 Gray A A Gray A A
8 Green 8 8 Green C C Green C C
6 6 BK 6 6
7 7 RD/BL 7 7
5 5 Red 5 5
4 4 Blue 4 4
2 2 WH/ 2 2
GN
3 3 BN/ 3 3
GN
1 1 GY/PK 1 1
WH/ 3 Contacts 1 + 2
BN
WH/ 2 Contact 2 (left) permissive button
YL
WH/ 1 Contact 1 (right)
GN
WH/ 1 Contact 1
BL
WH/ 2 Contact 1 EMERGENCY STOP
RD
YL/BK 3 Contact 2
WH/ 4 Contact 2
BK

The adapter includes plug-in terminal strips for the contacts of the EMERGENCY STOP button
and permissive button (max. load 24 V–, 1.2 A).
The plug-in terminal strips are supplied together with the adapter cable. If you have an
immediate need for these terminal strips, they can be ordered in advance.
See the “Additional components” table below.
Internal wiring of the contacts for the EMERGENCY STOP and permissive buttons:
permissive button 1 permissive button 2 ermergency stop
contact 1
contact 2
cable adapter
contact 2
contact 1
contact 1
contact 2
contact 1+2
contact 2
contact 1
Additional components ID
Dummy plug for EMERGENCY STOP circuit 271 958-03
Connecting cables
Spiral cable 312 879-01
Normal cable 296 467-xx
Metal armor tubing 296 687-xx
Plug-in terminal strips for advance ordering

3-pin terminal block 266 364-06
4-pin terminal block 266 364-12
14.5.2 HR 130 Panel-Mounted Handwheel

Standard cable length for the HR 130 is 1 meter.
Pin layout for extension cable and handwheel:
Connecting cable ID 281 429-xx HR 130 ID 254 040-xx

D-sub connctr. D-sub connctr. D-sub connctr.
(male) 9-pin (female) 9-pin (male) 9-pin
Housing Shield Housing Housing Shield
2 White 2 2 White
4 Brown 4 4 Brown
6 Yellow 6 6 Yellow
8 Green 8 8 Green
7 Gray 7
January 2008 14 – 151

14.6 PLC Input/Output Units
14.6.1 Designation and Position of Connectors
PL 510 PLB 510 Basic Module
PLD 16-8 input/output module PLA 4-4 analog module

14.6.2 PL 510 Pin Layout
X1: PLC expansion See ”X147: PLC expansion on MC 320” on page 14 – 146
on MC 320
X2: PL 510 Pin layout on PLB 510 basic module

PLC expansion
on PL 510
PL 510 Connecting cable ID 371 046-xx PL 510 on PL 510

D-sub Assignment D-sub D-sub X1 Assignment
connctn. connctr. connctr. D-sub
(male) (female) (male) connctn.
26-pin 26-pin 26-pin (female)
26-pin
1 0V 1 Black 1 1 0V
2 0V 2 Violet 2 2 0V
3 0V 3 3 3 0V
5 Address 6 5 Yellow 5 5 Address 6
6 INTERRUPT 6 Blue 6 6 INTERRUPT
7 RESET 7 Red 7 7 RESET
8 WRITE 8 Gray 8 8 WRITE
EXTERN EXTERN
9 WRITE 9 Pink 9 9 WRITE
EXTERN EXTERN
10 Address 5 10 Green 10 10 Address 5
11 Address 3 11 White 11 11 Address 3
12 Address 1 12 Brown 12 12 Address 1
14 +5 V (output) 14 White/Blue 14 14
15 +5 V 15 Brown/Blue 15 15
(feedback)
16 PCB identifier 16 White/Pink 16 16 PCB identifier
2 2
17 PCB identifier 17 Pink/Brown 17 17 PCB identifier
1 1
18 Address 7 18 Brown/Green 18 18 Address 7
19 Serial IN 1 19 White/Gray 19 19 Serial IN
20 EM. STOP 20 Gray/Brown 20 20 EM. STOP
21 Serial OUT 21 White/Yellow 21 21 Serial OUT
22 Serial OUT 22 Yellow/Brown 22 22 Serial OUT
23 Address 4 23 White/Green 23 23 Address 4
24 Address 2 24 Gray/Pink 24 24 Address 2
25 Address 0 25 Red/Blue 25 25 Address 0
26 26 26 26
Housing External Housing External shield Housing Housing External
shield shield
X3: Supply Pin layout on PLB 510 basic module

voltage for
logic circuit Terminal Assignment
1 +24 Vdc (20.4 V to 28.8 V)
2 +0 V
January 2008 14 – 153

X4 to X5: Pin layout on the PLD 16-8 input/output module:
PLC inputs
on PL 510
Note
The 0-V terminals of X4 and X5 of the PLD 16-8 are connected internally. These connections
are used for connecting the potential of the electronics and for operating the LEDs. Since
only a low current is required (max. 50 mA), it is sufficient to establish only one 0-V
connection (preferably at X4).
X4
Assignment Pin
1 2 3 4 5 6 7 8 9 10
First Socket 1 0V 0V I64 I65 I66 I67 I68 I69 I70 I71
PL 510 Socket 2 0V 0V I80 I81 I82 I83 I84 I85 I86 I87
Socket 3 0V 0V I96 I97 I98 I99 I100 I101 I102 I103
Second Socket 1 0V 0V I192 I193 I194 I195 I196 I197 I198 I199
Third Socket 1 0V 0V I256 I257 I258 I259 I260 I261 I262 I263
Fourth Socket 1 0V 0V I320 I321 I322 I323 I324 I325 I326 I327
X5
Assignment Pin
1 2 3 4 5 6 7 8 9 10
First Socket 1 0V 0V I72 I73 I74 I75 I76 I77 I78 I79
Second Socket 1 0V 0V I200 I201 I202 I203 I204 I205 I206 I207
Third Socket 1 0V 0V I264 I265 I266 I267 I268 I269 I270 I271
Fourth Socket 1 0V 0V I328 I329 I330 I331 I332 I333 I334 I335

X6: Pin layout on the PLD 16-8 input/output module:
PLC outputs
on PL 510
X6
Assignment Pin
1 2 3 4 5 6 7 8 9 10
a b
First Socket 1 O32 O33 O34 O35 O36 O37 O38 O39 +24 V +24 Vc
PL 510 Socket 2 O40 O41 O42 O43 O44 O45 O46 O47 a
+24 V b
+24 Vc
Socket 3 O48 O49 O50 O51 O52 O53 O54 O55a +24 Vb +24 Vc
Socket 4 O56 O57 O58 O59 O60 O61 O62 - +24 Vb +24 Vc
Second Socket 1 O64 O65 O66 O67 O68 O69 O70 O71a +24 Vb +24 Vc
PL 510 Socket 2 O72 O73 O74 O75 O76 O77 O78 O79 a
+24 Vb +24 Vc
Third Socket 1 O128 O129 O130 O131 O132 O133 O134 O135a +24 Vb +24 Vc
PL 510 Socket 2 O136 O137 O138 O139 O140 O141 O142 O143a +24 Vb +24 Vc
Fourth Socket 1 O160 O161 O162 O163 O164 O165 O166 O167a +24 Vb +24 Vc
PL 510 Socket 2 O168 O169 O170 O171 O172 O173 O174 O175a +24 Vb +24 Vc
a. The function of this terminal can be set with a sliding switch
on the rear side of the PLD 16-8 I/O modules:
Setting 1: Control-is-ready signal
Setting 2: PLC output
b. Group 1 (terminals 1 to 4)
c. Group 2 (terminals 5 to 8)
Note
If you use only the outputs at X6 for a PLD 16-8 I/O unit (and no inputs), the 0-V connection
for supplying the electronics and for operating the LEDs must be established at X4 or X5.
Note
The iTNC 530 cyclically monitors the PLC outputs of the PL 510 for a short-circuit.
X6: Pin layout at X6 (power supply for PLC outputs):

Power supply for
thePLC outputs on Terminal Assignment
PLD 16-8 input/
9 +24 Vdc (20.4 V to 28.8 V) for group 1 (O1 … O4)
output module
January 2008 14 – 155

X15 to X18:
Analog input on
PLA 4-4analog Connecting Assignment
module terminals
1 -10 V to +10 V
2 0 V (reference potential)
3 Shield
Note
The interfaces comply with the requirements of EN50178 for “low voltage electrical
separation”.
X19 to X22:
Connection for Pt
100 on the PLA 4-4 Connecting Assignment
analog module terminals
1 I+ Constant current for PT 100
2 U+ Measuring input for PT 100
3 U– Measuring input for PT 100
4 I– Constant current for PT 100
5 Shield
Note
The interfaces comply with the requirements of EN50178 for “low voltage electrical
separation”.
Connecting the Characteristics of the connecting cable:

analog voltage
Shielding
2 conductors with 0.14 mm²
Maximum length: 50 m
Connection of the  Configure the thermistor connection as a "four-conductor circuit":

Pt 100 thermistors
I
1
I
Messeingang U+ 1
2
Measuring input
Messeingang U 2
3
Measuring input
I 3
4
I 4
5
5
Pt100 Verbindungskabel kundenseitig
Pt100 4 x 0.14 mm2 abgeschirmt,
Customer's cable
4 x 0.14max
mm30 m
2 screened,
max 30 m

14.7 Machine Operating Panel
14.7.1 Designation and Position of Connectors on MB 420
14.7.2 Pin Layouts on MB 420
X1: See ”X46: Machine operating panel” on page 14 – 143

Connection to MC
X2: The NC start key and the NC stop key are connected with the MB 420 via X2.
Connection of
NC start and
NC stop key
X3: Pin Assignment

PLCinputs
1 I151
2 I152
3 +24 V
X4:
PLC outputs
Pin Assignment
1 O0
2 O1
3 O2
4 O3
5 O4
6 O5
7 O6
8 O7
9 0V
January 2008 14 – 157

15 Power Supply
15.1 Power Supply for MC 320
The power is supplied to MC 320 via the connector X100.

Supply voltage: 85 - 264 V~
Power-line frequency: 47 - 440 Hz
Power consumption: 60 W
Pin layout:

L Hot lead L1
N Neutral lead N
Ground lead (YL/GN)
Note
If USB components that are connected to X141/X142 require more than 0.5 A, a separate
power supply becomes necessary for these components. One possibility is the USB hub
from HEIDENHAIN.
Note
For cable lengths > 10 m between MC 320 and encoders with EnDat interfaces (EnDat 2.1)
a line drop compensator is required (efficiency = 75 %).
MC 320 powers the connected devices, such as linear encoders, touch probes, transmitter-
receiver units, handwheels, USB devices.
Exceptions:
The PLC outputs are powered with 24 V machine voltage.
Infra-red touch probes have a battery.
Note
MC 320 features "polyfuses". These are electronic fuses that separate defective peripheral
devices from the low voltages in the control in the event of an error.
If a defective peripheral device draws too much current, it is "separated" from the control.
In most events a corresponding error message is displayed.
A short-circuit of the touch-probe or handwheel interface may still generate a black screen.
January 2008 15 – 159

15.2 Power Supply for Control-Is-Ready Signal
X34: The Control-Is-Ready output is powered with 24 V machine voltage via terminal X34.
Power supply for
"Control-Is-Ready"
signal output

1 +24 V
2 0V
Error If 24 Vdc are missing at X34 when the machine is switched on:
The EMERGENCY STOP chain is interrupted.
--> The machine cannot be switched on!
If the 24 Vdc at X34 fall off during machine operation:

The EMERGENCY STOP chain is interrupted.
--> The control reports External EMERGENCY STOP.
Note
For this purpose the Control-Is-Ready signal output must be integrated correctly into the
EMERGENCY STOP chain.
--> see “Basic Circuit Diagrams” on page 2 – 16, see “EMERGENCY STOP test” on page 1
– 1!

15.3 Buffer Battery
General If the machine is switched off, the power for the RAM is supplied by the buffer battery.
The rated voltage is 3 V.
The typical service life of the buffer battery is three to five years.
For safeguarding the RAM data, an additional capacitor (Gold cap) was integrated onto the PCB
of MC 320. This capacitor stores the RAM content for approx. one day without battery.
Message The following message can only be generated as of the NC software version 340551-03:
Caution
If the voltage of the buffer battery falls below 2.6 V, the error message
Replace buffer battery is generated.
The error message is activated every 30 minutes.
Replace the buffer battery at the next opportunity!
Checking the Before you replace the buffer battery, the charge status of the Gold cap should be checked:
charge status of
 Enter the code number 654321 to call the on-line monitor.
the "Gold cap"
 Press the LOGIN PLC soft key.
 Now press the AD VALUES soft key.
 In the Value column you can read the value for the goldCap -->
The voltage must be >= 3000 mV!
Note
The capacitor (Gold cap) is only being charged when the control is switched on. If the Gold
cap is not sufficiently charged, please wait a few seconds.
If the voltage of the Gold cap does not reach 3000 mV or more, the MC 320 must be
replaced.
Replacing the To exchange the buffer battery, proceed as follows:

buffer battery
 Switch off the machine.
 Open the console.
DANGER
Housing parts need to be removed to replace the buffer battery.

The device must not be under power; observe the safety precautions.
---> see “Safety Precautions” on page 1 – 7
January 2008 15 – 161

 Screw off the rear cover plate.
Note
Replacing the buffer battery may be easier, if you dismount the entire MC 320 from the
console. In this event, label all cables before you disconnect them.
 Remove the cover plate.
Caution
Take ESD-preventive measures, see “ESD protection” on page 25 – 263, and work with
great care!
 Remove the old buffer battery.
DANGER
Do not touch the switch-mode power supply at the top left.

High voltages and residual charges may be present in the switch-mode power supply,
even when the machine is switched off or MC 320 dismounted!

 Insert the new buffer battery.
Due to the non-symmetric shape of the battery there is only one possibility of inserting.
Battery type: 1 lithium battery, type CR 2450N (Renata), ID 315878-01
 Screw the cover plate back on and remount the MC 320 in the console, if required.
Note
If the battery was exchanged although the Gold cap was not loaded sufficiently, the battery-
buffered ranges of the RAM may be deleted. The non-volatile PLC markers and words
belong to this range. This may mean that several components of the machine must be set
again (tool changer, swivel head, etc.) --> Ask the machine manufacturer!
In the BIOS settings, date and time are lost. Set these values again. --> see “Setting the
System Time” on page 11 – 90.
January 2008 15 – 163

15.4 Power Supply for PLC Outputs
15.4.1 General
The integral PLC of TNC 320 as well as the PLC expansion cards PL 410B/PL 405B/PL 510
are powered by the 24 Vdc control voltage of the machine (in accordance with VDE 0551).
The control voltage must be smoothed with a capacitance of 150 µF/A rated, at least however
with 1000 µF/A. At a current load of 15 A, for example, this corresponds to a capacity of 2250 µF.
EN 61 131-2:1994 permits:
5% alternating voltage component is permissible
Minimum absolute value: 20.4 Vdc
Maximum absolute value: 28.8 Vdc
Power If half of the outputs are on at the same time, the following values apply for power consumption:
consumption
MC 320: 115 W
PL 410 B: approx. 460 W
PL 405 B: approx. 235 W
PL 510: approx. 385 W
Rated operating MC 320: 0.150 A

current per output PL 410 B: 2 A (with max. current consumption of 20 A)
PL 405 B: 2 A (with max. current consumption of 20 A)
PLD 16-8: 2A
Simultaneity:
2 outputs with 2 A each
4 outputs with 1 A each
8 outputs with 0.5 A each
Total current:
Out0 to Out7: ≤ 4 A

15.4.2 Supply Voltage for PLC Outputs on MC 320
X44:
PLC supply voltage
Pin layout on MC 320:
Connection Assignment PLC Outputs

terminal
1 +24 V not disconnectable O24 to O30
with EMERGENCY STOP
2 +24 V disconnectable with O16 to O23
3 EMERGENCY STOP O0 to O15
4 0V
Error If the 24-V power supply (not disconnectable with emergency stop) is missing at X44, the error
message Processor check error! Relay ext. DC voltage missing appears.
The corresponding PLC outputs do not function. Depending on the PLC program of the machine
manufacturer, corresponding PLC error messages are displayed.
Note
Checking the PLC outputs --> see “The TABLE Function” on page 10 – 63.
January 2008 15 – 165

Troubleshooting
X44
Checking X44
Switch on the main switch of the machine.
Measure 24 V supply voltages at connector X44.
No
24 V voltages available? Repair defect in electrical
Contacts o.k.? cabinet etc.
Yes
Switch off the main switch of the machine.
Remove, check or measure the fine-wire fuses.

(Seen from the rear they are located above X44).
Fine-wire fuses o.k.? Replace fine-wire fuses.
No
Yes
MC 320 probably defective (PLC board, etc.)
Fine wire fuses
Caution
Use only original replacement fuses.

15.4.3 Supply Voltage for PLC Outputs on the PL 4xx B
Connection
X9 to X14: Pin layout on the PL 410 B:

Power supply
Pin Assignment PL 1 PL 2 PL 3 PL 4
X9 0V
X10 +24 Vdc logic power supply and for control-is-ready signala
X11 +24 Vdc O32 – O64 – O128 – O16O –
power supply O39 O71 O135 O167
for outputsa
X12 +24 Vdc O40 – O72 – O136 – O168 –
for outputsa
X13 +24 Vdc O48 – O80 – O144 – O176 –
for outputsa
X14 +24 Vdc O56 – O88 – O152 – O184 –
for outputsa
a. 20.4 V to 28.8 V
Pin layout on the PL 405B:
Pin Assignment PL 1 PL 2 PL 3 PL 4
X9 0V
X10 +24 Vdc logic power supply and for control-is-ready signala
X13 +24 Vdc O48 – O80 – O144 – O176 –
for outputsa
X14 +24 Vdc O56 – O88 – O152 – O184 –
for outputsa
a. 20.4 V to 28.8 V
January 2008 15 – 167

X23: The PL 410B input/output unit is also available with additional analog inputs and inputs for
Supply Pt 100 thermistors. The power supply must comply with EN 50 178, 5.88 requirements for
voltage for ”low voltage electrical separation.”
the analog inputs
on PL 410 B Terminal Assignment
1 +24 Vdc as per EN 50 178, 5.88
2 +0 V
Functional check Ensure that:

The green LED near the bus connectors X1/X2 is on.
If this is not the case:

Measure whether the 24 V supply voltage is available at X9/X10.
Note
If LED is not shining, despite available power supply, the PL board is probably defective.
Measure all other power supply connections.
Note
On older PLC expansion boards PL 4xx B, you still find fine-wire fuses (glass fuses) on the
board. These may be replaced, if necessary:
On newer PL 4xx B, the glass fuse has been replaced by an SMD fuse.
The SMD fuse is firmly soldered to the board. Contact your HEIDENHAIN service agency.

15.4.4 Supply Voltage for PLC Outputs on PL 510
Note
TNC 320 cyclically monitors the supply voltage and short circuits of the PLC outputs of a
PL 510.
Connection
PLB 510 basic Pin layout for X3 (power supply for logic circuit):
module
Terminal Assignment
1 +24 Vdc (20.4 V to 28.8 V)
2 +0 V
PLD 16-8 input/ Pin layout at X6 (power supply for PLC outputs):
output module
Terminal Assignment
January 2008 15 – 169

Error The corresponding PLC outputs do not function. Depending on the PLC program of the machine
manufacturer, PLC error messages are displayed.
Note
Checking the PLC outputs --> see “The TABLE Function” on page 10 – 63.
Functional check Ensure that:

The green LEDs on X6 pin 9 and pin 10 of the PLD16-8 input/output modules are shining.
The green LED POWER ON on the PLB 510 basic module is shining.
If this is not the case:

Measure whether the 24 V supply voltages are available as indicated above.
Note
If the LEDs are not shining, despite available power supply, the PLB 510 basic module or
the corresponding PLD 16-8 input/output module is probably defective.

16 Encoder Interface
16.1 Position Encoders
16.1.1 Introduction
Position encoders are also referred to as linear encoders.
They report positions and movements of the machine to the control.
TNC 320 operates with incremental and absolute encoders.
Encoders with one reference mark or distance-coded reference marks and with EnDat interface
are permissible.
Linear encoders (e.g. LF, LC, LS, LB) are often referred to as scales .
Circular position encoders are referred to as angle encoders (e.g. RCN, RON, ROD, ERP,
ERA).
MC 320 features the following position encoder inputs:
X1 to X4
X5 with optional encoder input board
Scales for linear axes or angle encoders for rotary axes/spindle may be connected here.
Note
devices from the low voltages in the control in the event of an error. This is also true for the
encoders!
If a defective encoder draws too much current, it is "separated" from the control.
Corresponding error messages are displayed.
January 2008 16 – 171

16.1.2 Configuration Data
The configuration data (machine parameters) for encoder monitoring are stored in the path
Axes/ParameterSets/Key for parameter set/CfgEncoderMonitor/...
Parameter Criterion Error Message

checkAbsolutPos Absolute position with Position encoder
distance-coded <axis>: defective
reference marks
checkSignalLevel Amplitude of encoder Position encoder
signals <axis>: amplitude too
low
checkFrequency Edge separation of Position encoder
encoder signals <axis>: frequency too
high
DANGER
The monitoring functions for the position encoders must always be active!
Safe machine operation is not ensured without these monitoring functions.
Exception: checkAbsolutPos is only active for position encoders with distance-coded
reference marks.
The configuration data (machine parameters) for encoder connection are stored in the path
Axes/ParameterSets/Key for parameter set/CfgAxisHardware/...
The position encoder type (not distance-coded, distance-coded, EnDat) is specified in the
machine parameter posEncoderType.
The allocation of the position encoder inputs (X1 ... X4) to the axes and spindles is specified
in the machine parameter posEncoderInput.
The signal type 1Vpp or 11µApp is defined in the machine parameter posEncoderSignal.
For other signal types (TTL, etc.) adapters must be used.
--> see “Encoders” on page 14 – 147
16.1.3 Possible Causes of Errors

Contamination of the position encoder
Damage to the position encoder
Scanning head misaligned (parallelism, distance, etc.)
Roller bearing in scanning head defective
Cable damaged
Signal error caused by high frequency, strong magnetic fields, etc.
Penetration of humidity
Short circuit in cable or scanning head
Light unit defective (LED, incandescent lamp)
Strong machine vibrations
Interface on the control defective
Caution
The amplitude of the reference marks is not monitored!

For example, if a reference mark cannot be evaluated due to contamination, with distance-
coded encoders a corresponding error message (e.g., Reference marks: Incorrect
spacing) is generated. With encoders with one reference mark, an error message is not
generated immediately. The reference run does not function properly any more, and the axis
may hit the limit switch.

16.1.4 Error Codes for Encoders with EnDat Interface
In the event of an error, the error message EnDat defective <error code> <axis> will appear.
The error code is shown in hexadecimal notation. Error codes may also appear combined,
in which case they add themselves together.
There are two possible types of errors:
The encoder reports an error.
Access to the encoder via the EnDat interface is faulty.
Codes for errors reported by the encoder:
Error code Meaning

0x00000001 Light source defective
0x00000002 Signal amplitude too low
0x00000004 Incorrect position value
0x00000008 Overvoltage
0x00000010 Undervoltage
0x00000020 Overcurrent
0x00000040 Replace battery
0x00000080 reserved
0x00000100 reserved
0x00000200 reserved
0x00000400 reserved
0x00000800 reserved
0x00001000 reserved
0x00002000 reserved
0x00004000 reserved
0x00008000 reserved
Error codes if the access to the encoder via the EnDat interface is faulty:
Error code Meaning

0x80010000 Delete the alarm bit
0x80020000 Read the alarm status
0x80040000 Read the number of pulses
0x80080000 Read the number of signal periods
0x80100000 Read the number of differentiable revolutions
0x80200000 Read the measuring steps
0x80400000 Read the serial number
0x80800000 Read the type of encoder
0x81000000 Read the position value
0x82000000 reserved
0x84000000 reserved
0x88000000 Read the checksum
0x90000000 Alarm bit remains set
0xA0000000 Timeout while waiting for data signal “high”
0xC0000000 Timeout while waiting for data signal “low”
0x80000000 Error during access to EnDat interface
January 2008 16 – 173

16.1.5 Troubleshooting
To find out whether the connected encoder or the control interface is defective, you can operate
the encoder with another interface of the control. Use the interface of a working axis for this
purpose.
Example: For fault diagnosis, proceed as follows:

Error in
X axis
Assumed
configuration Axes/ParameterSets/PX/CfgAxisHardware/posEncoderInput X01 (X axis at input X1)
Axes/ParameterSets/PY/CfgAxisHardware/posEncoderInput X02 (Y axis at input X2)
Axes/ParameterSets/PZ/CfgAxisHardware/posEncoderInput X03 (Z axis at input X3)
Block diagram
X axis
Original assignment: MC 320
... / pos Encoder Input: X 01
X1
X axis
Assignment for exchange:

Y axis
Assignment for exchange:
Y axis
Original assignment: X2
Note
Always exchange both, the cable and the interface assignment via machine parameter!

Flowchart
Interchanging the position encoders
Interchange position-encoder cables for

the axes concerned at the MC 320
(in example: connectors X1 and X2).
Do not confirm the Power interrupted message

but immediately call the configuration editor and
interchange the input values for
posEncoderInput of the axes concerned
(in the example: X01 und X02).
Switch on the machine.
Does the error No

move to the other axis
(in the example
from X to Y)?
Yes
The defect is located in the

The defect is probably located in the position
position encoder / scanning head /
encoder input of the control.
position-encoder cable.
January 2008 16 – 175

16.1.6 Corrective Action
If you have found that the interface on the control is defective:
Replace the control --> see “Exchanging MC 320” on page 25 – 264.
If you have found that the encoder/scanning head/cable is defective:

Exchange the encoder or the encoder component or perform corrective action
(e.g. clean scale).
Note
To exchange encoder components, use the included mounting aids (spacers, mounting
brackets, test gauges, etc.) as well as the mounting and exchange instructions.
If available, use special HEIDENHAIN equipment (PWM 9, PWT, PWM 8, IK 215) for
adjustment and signal assessment. --> see “Inspection and Testing Equipment” on page 27
– 283
In a special encoder training course you can learn about corrective action (e.g. cleaning of
scales) and how this equipment is used.
The following tolerances apply by default …
For 1 Vpp encoders: 0.6 ... 1.2 Vpp
For 11 µApp encoders: 7 ... 16 µApp
The exact tolerances of the encoders can be found in the HEIDENHAIN brochures that are
available for download from the HEIDENHAIN website. --> www.heidenhain.de
Note
The scanning head of an EnDat linear encoder is programmed to match the scale
(datum shift, etc.)
For this reason EnDat linear encoders in the field must be replaced together with the
scanning head!
If you have found that the angle encoder is defective:

Replace the encoder.

16.1.7 Resetting the Machine Datum
As the machine datum (machine reference) refers to the scale datum, it may be necessary to
reset it after removing and mounting of scales, scale tapes or angle encoders.
Note
On simple 3-axis machines, it is often not required to reset the machine datum. It is
sufficient to the check the software limit switches and to reset them, if necessary.
If you have any questions, please contact your machine tool builder!
Setting the machine datum is absolutely essential on most machine tools with tool
changers, tilting axes, etc..
Contact the machine tool builder for the correct proceeding.
Note
The OEM may have defined the machine datum beyond the range accessible by the
machine axes, i.e. it cannot be approached.
In such a case the OEM will specify a fixed point (reference hole or stud, etc.) in the
machine's work envelope with an offset to the machine datum (e.g. 500 mm).
Preparation  Always try to mount the encoder as exactly as possible to its original position!
 Reference the axis concerned.
 In Manual Operation set the display to POSITION + STATUS.
 Press the STATUS POS.DISP. soft key.
 Set the position display to REF ACTL on one side and to REF NOML on the other side.
 With the machine parameter displayPace you can set the position display to a high resolution.
 Compare the position displays.
If the difference is too large, the drive concerned should be readjusted --> see “Adjusting the
Electrical Offset” on page 19 – 206.
It may also be required to inspect the mechanics of the machine. --> If necessary, ask the
machine manufacturer!
If a 3-D touch probe  Set the position display to ACTL.

is used  Probe the reference point (or the reference stud, etc.) defined by the machine manufacturer
with the 3-D touch probe.
Note
You may have to expand the traverse range (software limit switches)!
The software limit switches are defined in the machine parameters swLimitSwitchPos and
swLimitSwitchNeg (possibly the operator has limited the traverse range even further).
 Set the reference point to the measured value.

 Traverse to the reference point in the Positioning with Manual Data Input mode.
 Set the position display to REF NOML. --> Now you can see the current nominal position of
the axis referenced to the machine datum.
 Write down the REF value (e.g. 500.012 mm).
 If required, subtract the offset to the machine datum defined by the machine manufacturer
(e.g. 50 mm).
 Invert the result (e.g. -0.012 mm).
 Add this value to the value in the machine parameter refPosition for the axis concerned and
enter the result.
 Check, whether the reset machine datum is correct (e.g., with M91)!
 If required, reset the traverse range its original values.
January 2008 16 – 177

If a dial indicator  Set the position display to REF ACTL. --> Now you can see the current actual position of the
is used axis referenced to the machine datum.
 Use the dial indicator to position the axis to the reference point of the machine defined by the
machine manufacturer. --> Ask the machine manufacturer!
Note
You may have to expand the traverse range (software limit switches)!
The software limit switches are defined in the machine parameters swLimitSwitchPos and
swLimitSwitchNeg (possibly the operator has limited the traverse range even further).
 Write down the REF value (e.g. 500.012 mm).

 If required, subtract the offset to the machine datum defined by the machine manufacturer
(e.g. 500 mm).
 Invert the result (e.g. -0.012 mm).
 Add this value to the value in the machine parameter refPosition for the axis concerned and
enter the result.
 Check, whether the reset machine datum is correct (e.g., with M91)!
 If required, reset the traverse range its the original values.
Further information --> see “Reference Run” on page 17 – 183

16.1.8 Resetting the Spindle Orientation
If you have replaced an angle or motor encoder used for oriented spindle stop (e.g. for tool
change), you must now readjust the spindle preset.
DANGER
Contact the machine manufacturer and observe the machine manufacturers's safety
precautions (setup mode, etc.)!
 Set the machine parameter refPosition to zero.

 Start the spindle orientation with rotating spindle.
 Observe the position that is established.
 Stop spindle orientation (M5); the spindle must be free to rotate.
DANGER
Press EMERGENCY STOP.

It must be ensured that the spindle cannot be switched on!
 If required, activate the display of the spindle position with active M5 in the machine
parameter spindleDisplay.
 Return to the Manual operating mode.
 Switch the display to REF ACTL. --> Now you can read the deviation of the reference mark
from the desired position.
 Rotate the spindle to correct position (use e.g. dial indicator, touch probe, orientation point,
etc.) --> Ask the machine manufacturer!
 Subtract the displayed value from 360° and enter the result in the machine parameter
refPosition (spindle preset).
 Check, whether spindle orientation is correct!
Caution
If the spindle position is measured indirectly (gear, etc.), the machine parameter
refPosition exists several times (in the respective parameter sets).
In the configuration editor check in the table, whether there are several parameter sets for
the spindle.--> see “Machine Parameters” on page 28 – 295
If so, set the correct positions!
Further information --> see “Reference Run” on page 17 – 183
January 2008 16 – 179

16.1.9 Investigating Position Encoders
For rapid troubleshooting on a machine tool, find the defective encoder (as described in this
section) and replace it.
If you intend to subject the faulty encoder to further investigations, you normally require special
testing equipment.
Note
The HEIDENHAIN testing equipment described below can also be used for preventive
maintenance.
If you find out, for example, that the specifications (e.g. the signal amplitude) of an encoder
are very close to the tolerance limits, you can replace this encoder as a preventive measure,
in order to guard against machine standstill at a later date!
HEIDENHAIN Incremental encoders are checked with the PWM 9 Phase Angle Measuring Unit.
testing equipment --> see “PWM 9 Encoder Diagnostic Set” on page 27 – 289
The absolute tracks of EnDat encoders can be inspected with the IK 215 interface card.
--> see “IK 215 Adjusting and Testing Package” on page 27 – 292
The incremental signals of EnDat 2.1 encoders are checked with the PWM 9 Phase Angle
Measuring Unit.
--> see “PWM 9 Encoder Diagnostic Set” on page 27 – 289
PWM 9 To be able to judge the electrical function of an encoder, it must be measured with a phase
angle measuring unit (PWM), an oscilloscope and possibly an impedance tester.
--> see Operating Instructions, PWM 9 Encoder Diagnostics Kit
Adapters Various adapters have been developed to permit PWM measurement of the different encoder
signals (11 µApp, 1 Vpp, TTL). You will find a connection diagram of the adapters with
ID numbers in the PWM 9 operating manual.
Internal For technical reasons encoder signals cannot be recorded by the internal oscilloscope of
oscilloscope TNC 320.

16.2 Speed Encoders
The speed encoders for analog axes and spindles are mounted to or inside the motors.
Speed encoders are also referred to as tachometers (DC motors) or as motor encoders
(AC motors).
Contact the manufacturer of the analog servo amplifier regarding inspection, troubleshooting
and speed encoder settings.
January 2008 16 – 181

17 Reference Run
17.1 Definition
The position value (the coordinates) of an axis position is defined with respect to a freely
selectable datum. When the axes are moved, the ACTUAL position is calculated incrementally.
If there is an interruption in power, the reference between the axis position and the position
value is lost.
Reference marks HEIDENHAIN linear encoders (except EnDat) are designed with one or more reference marks.
The reference marks identify an axis position at a known distance from the machine datum.
The position of the freely selectable datum is defined with respect to the machine datum.
The datum and the actual position can be reproduced as soon as the reference marks are
traversed.
+Z REF value REF value

–44.985 0
Workpiece
datum 10 20 30 40
0 +X
Workpiece
Machine table
Position encoder
Reference mark
Machine datum
Machine The machine datum is determined by the machine manufacturer.

datum It is required for:
Defining the limits of traverse (software limit switches)
Moving to machine-referenced positions (such as tool change positions)
Setting the workpiece datum
Distance between For distance-coded reference marks, the machine datum is defined with respect to the scale
the scale reference reference point, which is at the first reference mark after the beginning of the measuring length.
point and the
 The machine parameter refPosition contains the distance between the scale reference point
machine datum
and the machine datum.
Note
After an encoder was removed and remounted you may have to reset the machine
parameter refPosition!
See ”Resetting the Machine Datum” on page 16 – 177
Spindle preset An appropriate angle encoder or even the motor encoder can be used for oriented spindle stop.
 The machine parameter refPosition contains the deviation from the desired position.
Note
After you have replaced the angle encoder for the spindle, you must reset the machine
parameter refPosition!
See ”Resetting the Spindle Orientation” on page 16 – 179
January 2008 17 – 183

17.2 Traversing the Reference Marks
If no EnDat encoders are used, the reference marks need to be retraversed after every power
interruption.
Note
Ask the machine operator about the referencing procedure at the machine concerned.
After the reference marks have been traversed:

The software limit switches are activated.
The most recently saved datum and machine datum are reproduced.
PLC positioning and positioning with M91 and M92 become possible.
The counter is set to zero for axes in an open loop.
Automatic  Press the NC STARTkey.

reference run --> The reference marks are traversed automatically.
(The sequence of axes and how often the NC START key must be pressed was determined
by the machine manufacturer.)
Manual
tool retraction
DANGER
When servicing, the machine may be in a position where the sequence for the automatic
referencing of axes could result in a collision and thus may cause damage to the machine
or even personal injury (e.g., error message with reboot).
First, the axes must be retracted carefully!
If necessary, ask the machine operator.
 Select a low feed rate.

 Press the axis direction keys successively.
 After having retracted all axes press the NC STARTkey.
--> The automatic reference run is started.
Soft key PASS If no or not all reference marks were traversed after the machine was switched on (e.g., due to
OVER REFERENCE a previous change to another operating mode), the reference mark traverse must be activated
MARK again with the soft key PASS OVER REFERENCE MARK.
 Choose the manual mode of operation for this purpose.
 Press the PASS OVER REFERENCE MARK soft key.
--> The message Pass over reference mark is displayed at the top of the screen.
 Start the reference run with NC-START.
Encoders with Position encoders with EnDat interface can be connected to MC 320. With these encoders
EnDat interface reference mark traverse is not required. The position value is only read when the control is
switched on. It cannot be read again.
Note
If the use of multiturn encoders with EnDat interfaces results in overflows, the
corresponding information is stored temporarily. If the control is exchanged, these
temporary data must be transferred, or the machine parameter refPosition re-adjusted
(see “Exchanging MC 320” on page 25 – 264).

17.3 Possible Causes of Errors
Here the same causes of error apply as for the encoders.
--> see “Possible Causes of Errors” on page 16 – 172
Especially for referencing, causes of error may be:

Defective trip dog (reference end position)
Magnet in scale housing shifted (wrong or no reference mark is evaluated)
Paint wiped off or removed otherwise from reference marks (previously inactive reference
marks are evaluated)
Trip dogs are too close to the reference mark signal (during reference run via the motor
encoder, the "neighboring" reference position is evaluated)
17.4 Deselecting Referencing of Axes

For axis examinations it is possible to deselect referencing:
 In the machine parameter enter refType: None for the axis concerned.
January 2008 17 – 185

18 Checking the Enables on TNC 320
18.1 General
For an operating axis (axis in control loop) ...
No "Axis clamped" symbol is shown.
The "NC START" (control-in-operation) symbol is displayed.
The feed rate display must not be highlighted.
The position display changes when the axis moves.
(When operating with velocity feedforward and display of servo lag, the change
is only minimal.)
In order to work with axes or spindles the appropriate enables are required.
If one or several enables are missing, an error message is output or the axes and/or the spindles
cannot be operated.
The following conditions must be fulfilled to drive axes and spindles:
I3 set
(X42/4, Control-is-ready signal acknowledgement)
Drives ready for operation

(The analog servo drives must report that they are ready or must be ready for operation.)
Note
Many analog servo drives provide a "ready" signal that can be evaluated by the PLC of
TNC 320. Normally, the drive is only enabled, after the servo drives have reported that they
are ready. --> Observe LEDs and LCD displays of the drives!
A number of servo drives do not provide a "ready" signal. In this event the drive enable must
be set without actually knowing the status of the drives. If an axis or spindle cannot be
operated, as the drive is not ready, an error message (e.g. Servo lag) is generated.
January 2008 18 – 187

Marker PP_AxDriveOnRequest set
(With this marker the PLC switches on the axis drive.)
Note
In the PLC mode the status of axes and spindles can be read in API DATA / AXIS
or SPINDLE.
The respective PLC operands are explained in chapter "18.2 Examination".

18.2 Examination
18.2.1 Checking the EMERGENCY STOP chain

On MC 320 the EMERGENCY STOP chain starts at the "control-is-ready" output (X41/pin 34)
and ends at the "control-is-ready acknowledgment" input I3 (X42/pin 4).
If the message EMERGENCY STOP test or External relay dc voltage missing does not
disappear after you press the Control ON key, carry out fault diagnosis as follows:
“Control is Ready“ check
Switch on the control as far as possible.
Check in the
PLC TABLE whether I3 is set
or check the
status of the indicator _NE1_p in OLM
The control records the

Yes acknowledgment. The message
Acknowledgment present
Emergency stop test or
(green indicator or
Relay external DC voltage missing
I3 = 1)?
should disappear. If it does not,
please call HEIDENHAIN!
No
Yes The PLC does not detect the

+ 24 V present at input
high level. Probably the input I3
Acknowledgment: Control is Ready
on the MC is defective.
(X42/PIN4)?
-> Replace the MC!
No
Yes
EMERGENCY STOP chain
(EMERG. STOP button, axis limit Remove the interruption.
switches, etc.) interrupted?
No
Yes
+24 V present at output There is still an interruption which
Control is Ready needs to be removed. (Use the circuit
(X41/PIN34)? diagram of the machine.)
No
Yes
Supply voltage present for The Control is Ready output of the
output Control is Ready (connector MC is probably defective.
X34/PIN1 = 24V, PIN2 = 0V)? -> Replace the MC!
No
Find the reason and correct the error.

(Make use of the circuit diagram of the machine.)
January 2008 18 – 189

Page from OLM Enter code number 654321 --> Login Ipo --> HW --> Next --> HW Ports I
(see “Diagnosis with the Online Monitor (OLM)” on page 8 – 41)
Excerpt from the Here you can see the terminals that can be measured.
basic circuit (In most of the cases the PLC inputs and outputs are connected to a strip in the electrical
diagram cabinet.)

Note
If the Control-is-ready output on the MC is defective, you can use the Control-is-ready
output of a PLC expansion board as a makeshift:
PL 405 B or PL 410 B: X8 / pin16
PL 510, input/output module PLD 16-8: X6 / terminal 8
(The function of this terminal can be set with a sliding switch on the rear side of
the I/O module concerned; setting 1 = "Control is ready";
see “X6: PLC outputs on PL 510” on page 14 – 155)
Sliding switch
on I/O module
January 2008 18 – 191

Error message If the error message Emergency Stop Defective appears when the machine is switched on,
EMERGENCY STOP carry out fault diagnosis as follows:
defective
Error message EMERGENCY STOP defective
Switch off the main switch of the machine;

confirm the Power interrupted message;
do not press the Control ON switch yet!
Measure the voltage on I3

(X42/Pin4).
Yes Find the reason (e.g., a relay no

Is the input I3
longer opens) and correct the
(X42/Pin4) permanently
error (make use of the circuit
at high level?
diagram of the machine).
No
Shut down the control and switch off the machine.
Disconnect and secure the original wires.

Insert a bridge between X41/Pin34 and X42/Pin4
(output and input of Control is ready).
Disconnect the connectors for the drive enable from

the analog servo amplifier.
Ensure that the drives cannot be switched on!
Switch on the machine and confirm the

Power interrrupt message.
Yes
Does the error message
EMERGENCY STOP defective MC is defective.
reappear?
No
The fall time of mechanical switching equipment

(relays, safety contactors, etc.) is too long or the
switching equipment that is triggered by the output
X41/Pin34 is defective.
Make use of the circuit diagram of the machine!

Bridge inserted
Acknowledgment: Control is Ready

Control is Ready
I3
Note
The function of the Control-is-ready output of a PLD 16-8 I/O module can also be tested
with this method.
Note
Procedure for the EMERGENCY STOP tests --> see “Annex: Monitoring Functions” on page
1 – 1!
January 2008 18 – 193

18.2.2 Checking the Readiness of the Analog Servo Drives
Find out whether the analog servos for the axis and spindle drives are switched on and ready
for operation!
Note
Information on this is available e.g. in the operating manual of the servo drive manufacturer.

18.2.3 Checking PLC Operands of the "Axis" Group
To obtain the display below...
 Enter the PLC code number. --> see “Calling the PLC mode” on page 10 – 55
 Press the soft keys API DATA / AXIS.
Display
Note
For the correct interpretation of the axis status, support from the machine manufacturer
may be helpful or often even necessary.
Description
Markers Description
Axis – Configuration
D NN_AxLogNumber Logical axis number (identical to the axis
number from axisList)
Axis – Drive
M NN_AxDriveReady Axis drive is ready
M PP_AxDriveOnRequest Switch axis drive on
(CM9161)
M NN_AxDriveOn Axis drive is on (and at least speed-
controlled)
(CM9162)
M PP_AxPosControlRequest Position-control the axis
(W1040)
M NN_AxPosControl Axis is position-looped
(W1024)
M PP_AxValueActToNominal Actual-to-nominal value transfer
M NN_AxCorrectingLagError Following error eliminated
January 2008 18 – 195

Markers Description
M PP_AxClampModeRequest Prepare to open the position control loop
(W1038)
Axis – Control
M NN_AxReferenceAvailable Reference mark not yet traversed
(W1032)
M PP_AxReferenceEndPosition Reference end position
(W1054)
D PP_AxManualFeedMax Maximum manual axis feed rate [mm/rev]
M PP_AxFeedEnable Axis-specific feed rate enable
(W1060)
M NN_AxInMotion Axes in motion
(W1028)
M NN_AxInPosition Axes in position
(W1026)
M PP_AxTraversePos Manual traverse in positive direction
(W1046)
M PP_AxTraverseNeg Manual traverse in negative direction
(W1048)
M PP_AxHandwheelLocked Disable handwheel motion for specific axes
(W1062)
M PP_AxDeactivateMonitoring Deactivate monitoring functions
(W1042)
M NN_AxLubricationPulse Lubrication pulse: Value in lubricationDist
exceeded
(W1056)
M PP_AxLubricationDistReset Reset the accumulated distance
(W1058)

18.2.4 Checking PLC Operands of the "Spindles" Group
To obtain the display below...
 Enter the PLC code number. --> see “Calling the PLC mode” on page 10 – 55
 Press the soft keys API DATA / SPINDLE.
Display
Note
For the correct interpretation of this display, support from the machine manufacturer may
be helpful or often even necessary.
Description
Markers Description
Spindle – Configuration
D NN_SpiLogNumber Logical axis number of the spindle
Spindle – Drive
M NN_SpiDriveReady Spindle drive is ready
M PP_SpiDriveOnRequest Switch spindle drive on
(CM9161)
M NN_SpiDriveOn Spindle drive is on (and at least speed-
controlled)
(CM9162)
Spindle – Control
M NN_SpiReferenceAvailable Reference position found
(M4018)
M PP_SpiReferenceMarkSignal Trip dog
D PP_SpiSpeedMax Maximum speed of the spindle
(D604)
January 2008 18 – 197

Markers Description
M PP_SpiEnable Spindle enabling
(M4008)
M NN_SpiInMotion Spindle in motion
(M4002)
M NN_SpiSpeedOK Spindle speed reached
(M4001)
M NN_SpiControl Spindle position-controlled
M NN_SpiControlInPos Spindle in position
(M4000)
M NN_SpiSyncSpeed Rotational speed synchronism active
M NN_SpiSyncAngle Angle synchronism active
M NN_SpiSyncReached Synchronous operation reached
D NN_SpiOverrideInput Speed override set [%]
(W492)
D PP_SpiOverride Speed override set by the PLC [%]
(W764)
M NN_SpiTapping Tapping active
(M4030)
M NN_SpiRigidTapping Tapping with spindle interpolated with Z axis
active
(M4031)

19 Interface to the Analog Drives
19.1 Introduction
Analog servo amplifiers are also referred to as analog servos.
They are available as dc and ac versions.
For analog drives dc motors and three-phase ac motors are used.
The analog servo amplifiers are controlled via ±10 V interfaces.
The position controller is located in the MC, speed and current controller in the servo amplifier.
The HEIDENHAIN control supplies the nominal speed value. This is why the ±10 V interface is
also referred to as nominal speed command interface.
The connector X8 is the analog speed command output of MC 320.
On this D-Sub connector there are several analog channels.
19.2 Configuration Data

The configuration data (machine parameters) for the connection of the analog axes or
spindles are stored in the path Axes/ParameterSets/Key for ParameterSet/CfgAxisAnalog/...
The allocation of the speed command outputs (channel on X8) to the axes and spindles is
specified in the machine parameter analogOutput.
19.3 Specifications
Load capacitance: RL ≥ 5 kΩ, I ≤2 mA

CL ≤ 2 nF
Short-circuit stability: One output short-circuit proof at a time
Voltage range: Uamax = +10 V ± 100 mV
Uamin = -10 V ± 100 mV
Resolution: 16 bit = 65536 steps

Smallest step:

Nominal speed command interface of MC defective (X8)
Cables defective
Servo amplifier defective
Motor (carbon brushes, tachometer brushes, winding, etc.) defective
Poor shielding and grounding
Mechanical defects
Errors in the NC or PLC software
Wear and tear of mechanical parts
Aging of the machine
There is a large variety of possible error causes.
Profound knowledge of the machine and the interaction of the components is very helpful
especially for this type of errors.
When an error message is displayed, press the HELP key. You will obtain information on
possible error causes and tips for corrective action.
Note
Owing to the complexity of error conditions of the drives, we recommend to consult the
machine operator and the machine manufacturer.
January 2008 19 – 199

19.5 Troubleshooting
19.5.1 Observing the Analog Voltage
Example:  First find out, whether the enabling conditions (e.g., door contacts, permissive buttons, etc.)
X axis does for the axis movements are given.
not move For the axes to be traversed ...
No "Axis clamped" symbol must be shown for the axis concerned.
The feed rate display (F ...) must not be highlighted.
The "NC START" (control-in-operation) symbol must be displayed.
If necessary, ask the machine operator!
 Press one of the axis direction keys.

 Find out, whether the control outputs an analog voltage between 0 V up to ±10 V maximum.
This voltage can be ...
Observed with the integrated oscilloscope.
Measured at the connecting terminals of the servo amplifier.
Measured directly at the MC by means of the HEIDENHAIN test adapter.
Danger
As a reference potential for measuring the analog voltage only use the 0 V of the channel to
be measured (connector X8 on MC 320).
If you measure e.g. against the housing, the axis to be inspected could start to move
unintendedly!
Settings for the

integrated
oscilloscope
See ”Integrated Oscilloscope” on page 9 – 45.

Display of the
integrated
oscilloscope
Danger
For inspecting the analog axes (as described in the flowchart on the next page) the
monitoring tolerances are increased.
You may have to increase the monitoring values in small steps until a reasonable analysis
of the analog voltage can be made.
Do not forget to restore the original values after completion of the tests!
January 2008 19 – 201

Flowchart
Analog axis does not move
Switch off the machine and connect a multimeter to the

terminal strip of the servo amplifier of the axis to be checked.
(Use the circuit diagram of the machine.)
Do not confirm the Power interrupted message but call the

config editor and increase the tolerances for movement, standstill
and following-error monitoring in the axis to be checked (note
down the original values and restore them later):
movementTreshold : 0 (= switched off)

checkPosStandstill : 30 [mm]
servoLagMin1 : 30 [mm]
servoLagMax1 : 30 [mm]
servoLagMin2 : 30 [mm]
servoLagMax2 : 30 [mm]
Increase the values, if necessary.

Caution: Danger from increased monitoring tolerances!
Switch on the machine and set the position display to LAG.
Turn the feed-rate potentiometer to zero and start reference run

for the defective axis (e.g. with axis direction button).
Slowly turn up the feed-rate potentiometer and observe the

display of the multimeter.
Yes The MC operates correctly;

Does the multimeter read a the defect is probably due
voltage in the range of +/-10 V? to the analog servo amplifier
and its cables, to the motor, etc.
No
Switch off the machine and disconnect the analog servo amplifier
from the speed command cable. Repeat the above procedure with
the servo amplifier disconnected.
Yes
Does the multimeter read a
voltage in the range of +/-10 V?
No
MC or nominal speed cable defective.

Note
If the control operates properly, a nominal speed command voltage can be read with the
above routine until the monitoring values (movement, following error, etc.) are reached. The
nominal speed voltage 0 V is output together with the respective error messages.
Measuring If available, you can connect the test adapter between connector X8 of MC 320 and the nominal
setup with speed command cable. Connect a multimeter to the corresponding banana jacks of the test
test adapter adapter.
Assignment for the analog channels --> see “X8: Analog output 1 to 6” on page 14 – 136
MC 320
Servo
amplifier X8
ANALOG
Test adapter
Id.Nr. 375830-01
. . .V
Multimeter
19.5.2 Using a Battery Box

If you have a "battery box" (not a HEIDENHAIN product), you can check whether the analog
servo amplifier can be operated with it.
This battery box replaces the control and provides the analog servo amplifier with a nominal
speed value of ±10 V.
The servo amplifier must be enabled for this purpose. --> If necessary, ask the machine
manufacturer!
January 2008 19 – 203

19.5.3 Switching the Analog Channels
To find out whether the connected drive or the control interface is defective, you can connect
the drive to another analog channel of the control.
Example: For fault diagnosis, proceed as follows:

Error in
X axis
Assumed
configuration Axes/ParameterSets/PX/CfgAxisAnalog/analog Output 1 X8, X axis at channel 1
Axes/ParameterSets/PY/CfgAxisAnalog/analog Output 2 X8, Y axis at channel 2
Axes/ParameterSets/PZ/CfgAxisAnalog/analog Output 3 X8, Z axis at channel 3
Block diagram
Note
Always exchange both, the cable and the interface assignment by means of machine
parameter!

Flowchart
Interchanging the analog outputs
Open the electrical cabinet where the interface

cable for the analog axes is connected to the
terminal strip.
Interchange the cables to the analog

servo amplifiers at the terminal row
for the analog channels.
Do not confirm the Power interrupted message

but immediately call the configuration editor
and interchange the input values of
analogOutput of the axes concerned.
Switch on the machine.
Move the axes.
Does the error No

move to the other axis?
(in the example
from X to Y)?
Yes
The defect is probably located

The defect is probably located at the analog
in the drive system (power
interface X8 of the MC 320.
stage, motors, cable, etc.).
January 2008 19 – 205

19.6 Adjusting the Electrical Offset
General An offset adjustment is required or recommendable, if ...

The axis drifts.
The servo lag of the axis at standstill is impermissibly high.
You have exchanged the MC.
You have exchanged the servo amplifier.
You have exchanged the motor.
You have replaced the motor brushes.
You have replaced cables or electrical lines at the machine.
Offset adjustment Analog servo amplifiers are not HEIDENHAIN products.

at servo amplifier Follow the instructions of the servo manufacturer (operating instructions, etc.)!
Below you will find two proposals.
Proposal 1:
 Press EMERGENCY STOP and switch the machine on.
Note
Copy the original entry values before you edit any machine parameters!
 Set the offset compensation to zero.

--> Enter the value 0 [V] for the axis concerned in the machine parameter analogOffset.
 Set the machine parameter feedForwardFactor to 1 (100% velocity feedforward).
 If required, select a high resolution in the machine parameter displayPace.
 Call the integrated oscilloscope. --> see “Integrated Oscilloscope” on page 9 – 45
 In the oscilloscope make the following settings for the axis concerned:

 Start recording.
 Unlock the EMERGENCY STOP button and and switch the machine on.
--> The axes to be adjusted must be in the control loop (if necessary, ask the machine
manufacturer).
 Stop the recording and adjust the s diff signal by means of the soft key "Vertical resolution
with zero line".
 Restart the recording and adjust the offset at the servo amplifier until the s diff signal is as
close as possible to the zero line (target value ±3 - 5 m).
 Now change to Manual Operation and switch the position display to LAG.
 From the servo lag display you can see, whether the selected axis has reached a very
small value (target value ±3 - 5 µm).
 Reset the original values in machine parameters and in the position display
 Carry out offset fine adjustment with the code number 75368.
--> see “Offset fine adjustment via code number” on page 19 – 209
January 2008 19 – 207

Proposal 2:
 Switch off the main switch of machine.
 Disconnect the nominal speed cable from the control.
 Bring the nominal value of the axis to be adjusted to zero potential (short-circuit the
±10 V line with the 0 V line of the axis concerned).
Note
You can also produce a D-Sub connector for the analog nominal speed command interface
X8. In this connector there is a bridge between ± 10 V and 0 V for each channel.
(see “X8: Analog output 1 to 6” on page 14 – 136)
Connect this connector to the nominal speed cable that you have disconnected from the
control (X8).
Advantage of this method: The nominal speed cable is included in the offset adjustment of
the servo amplifier.
 Switch on the main switch of the machine.

 Do not acknowledge the Power interrupted message, but call the machine parameter list
immediately.
Note
 Set the machine parameter axisMode for all axes and spindles to Display.
--> No output of nominal value; axes and spindles are simply displayed.
 Switch on the machine completely.
 Check the controller enabling on the servo amplifier and establish it, if required.
(If necessary, ask the machine manufacturer)!
 Select Manual operation, set the display to ACTL value and set the axis to zero.
 Adjust the servo amplifier to standstill as close as possible. The axis movement can be seen
on the actual value display and possibly on a pulley.
 Restore the original condition (cabling, parameters).
 Carry out offset fine adjustment with the code number 75368.
--> see “Offset fine adjustment via code number” on page 19 – 209

Offset fine The following conditions must be fulfilled:
adjustment via
Before you carry out offset fine adjustment via code number, you must first adjust the offset
code number
at the servo amplifier!
Note
With the offset fine adjustment via code number the control can compensate ±1 V!
This corresponds to 10% of the ±10 V interface!!
If the offset adjustment at the servo amplifier is highly insufficient, this can thus no longer
be compensated with adjustment via code number.
The machine parameter noOffsetAdjust must be set to FALSE for the axes concerned.
The axes to be compensated must be in the position control loop.
The spindles to be compensated should be oriented for this purpose (e.g. M19).
 Enter the code number.
 Confirm.
The following dialog box is displayed:
TNC 320 displays the offset values determined for the analog axes.
 Press the OK soft key to confirm the values.
--> The values are written to the analogOffset machine parameters automatically.
Note
Offset adjusting via code number compensates the current offset values of the entire
control loop. Later changes in offset are not compensated.
January 2008 19 – 209

19.7 Speed Adjustment at Servo Amplifier
General You should adjust the speed at the servo amplifier, if ...
You have exchanged the servo amplifier or the motor.
You have replaced the motor brushes.
The servo lag is impermissibly high at constant traverse.
Milled circles are not round.
You have updated the mechanics of the axis.
(E.g., guideway, bearing, belt, coupling, ball screw, etc.)
The aim of speed adjustment is to achieve that the output nominal speed value is equal
to the really measured actual speed value (Vnom = Vact).
Execution Analog servo amplifiers are not HEIDENHAIN products.

Follow the instructions of the servo manufacturer (operating instructions, etc.)!
Below you find a proposal:

 Press EMERGENCY STOP and switch the machine on.
Note
 Set the machine parameter feedForwardFactor to 0 (following error).

For this purpose you may have to increase the tolerances for following-error monitoring
(servoLagMin and servoLagMax).
 For the axis to be adjusted write the test program below.
(If possible select a larger traverse range than the 'X + 100' stated in the example.)
Danger
Enter this test program together with the machine operator. Please be careful to prevent
a collision (retract Z axis first, etc.)!
0 BEGIN PGM Tachometer_adjustment X MM

1 LBL 1
2 L X+ 0 F MAX
3 L X+ 100 F MAX
4 CALL LBL 1 REP 100
5 END PGM Tachometer_adjustment X MM
 Call the integrated oscilloscope. --> see “Integrated Oscilloscope” on page 9 – 45

 In the oscilloscope make the following settings for the axis concerned:

 Start recording.
 Set the feed rate potentiometer to zero.
 Run the program in the Program Run, Full Sequence operating mode and turn the feed rate
potentiometer slowly to 100 %.
 Stop the recording and adjust the signals such that you get approximately this image:
January 2008 19 – 211

 Use the formulas below to determine the value to which you must set the s diff signal in the
oscilloscope ( = LAG display).
Note
The kv factor for operation with following error is defined in the machine parameter
kvFactor.
For the displayed traversing speed the machine parameter kvFactor2 may be active. The
limit velocity as of which the kvFactor2 takes effect, is entered in the machine parameter
kvSpeedLimit. Contact your machine manufacturer.
Example:
Description Machine parameter Value

Rapid traverse maxFeed 12000 [mm/min]
kv factor kvFactor 40 [mm/mm*s]
Note
You can read the exact signal values on the bottom left of the oscilloscope screen next
to CU1:
Use the arrow keys to select the channel to be read.
In this example, the following error ideally is 5 mm at 9 V analog voltage and an actual speed
of 12000 mm/min (the same as the nominal speed)!
 Reset the machine parameters to their original values.

19.8 Switching the Position Display for Service Purposes
Call  Press the following key combination to switch the position display:
 Select a machine operating mode (Manual Operation, Program Run/Full
Sequence, etc.).
 Press GOTO to open a list box.
Description of Possible position displays:

the settings
NOML Nominal position
ACTL. Actual position
REF ACTL Actual position referenced to the machine datum
REF NOML Nominal position referenced to the machine datum
LAG Following error
DIST. Distance to go
 Using the arrow keys, select the desired position display.
 Press ENT to activate the position display.
 Press the END soft key to close the window.
January 2008 19 – 213

20 Flat-Panel Display
20.1 Introduction
The 15.1" TFT flat-panel display is a component of MC 320; it is integrated in the housing of
the MC.
Power supply and control of display signals are effected inside the MC housing.
The soft keys on the screen are controlled via the horizontal and the vertical soft-key row.

Defective screen
Faulty power supply of the screen
No display signals from the graphic card
Defective device (primarily touch probe and handwheel) or cable that is connected to the
control and impairs it
Defective screen soft keys
Caution
handwheel (12 V) or in the 15 V power supply of the touch probe (not the 5 V supply)
--> The screen goes blank!
January 2008 20 – 215

20.3 Troubleshooting
Screen The soft key rows are connected to the keyboard PCB with ribbon cables.
soft keys
Troubleshooting --> see “Checking the Switches” on page 23 – 247.
Monitor If the machine is switched on but the screen remains black, proceed as follows:
Machine is switched on but

screen remains black
Measure the power supply on the

MC 320 (connector X100).
Is a 85 – 264 V No
alternating current Establish power supply.
available?
Yes
Connect your service laptop with the MC 320 and start

the HEIDENHAIN PC software TNCremoNT.
Establish the connection and click one of the

camera symbols in the menu bar.
Is the display No Is the graphics board of the

information now available MC 320 defective?
on the laptop? Exchange the control.
Yes
The graphics board of the MC 320 is probably in order.
Shut down the control and switch off the machine.
Label all cables and disconnect all connectors from

the MC 320 (exception: power supply X100)
Also remove the USB devices and data cables.
Press the EMERGENCY STOP and

switch on the machine again.
No The monitor or the

Is an image displayed now? control is defective!
Exchange the control.
Yes
The control is impaired by a defective unit or cable such

that the monitor cannot be operated properly.

Note
If you can see the display information with TNCremoNT, it is still not 100% sure that all areas
of the graphics card are in good order!
If the function of the display is adversely affected by defective devices, the reason is
mostly the touch probe or the handwheel:
 Check, whether these devices have got wet or damaged.
 Check the cables for damage.
 Check the touch probe and the handwheel (including the cables) for short-circuits.
If you cannot find any defect, you can successively connect all connectors, USB devices, data
interfaces, etc. (the machine must always be switched off) and observe, when the error occurs
again (in this case the black screen). Subsequently, search the error of the connected device
including its cable.
20.4 Corrective Action

It is not possible to replace a defective monitor in the field!
Exchange the MC 320. --> see “Exchanging MC 320” on page 25 – 264
January 2008 20 – 217

21 Operating Keys and Potentiometers
21.1 Introduction
The keyboard and the potentiometers are components of MC 320 integrated in the MC housing.
The screen soft keys are on separate boards (horizontal and vertical soft keys) that are connected
to the keyboard PCB via ribbon cables.
The key signals are transmitted to the controls by means of a matrix with every cross point of
an SL (ScanLine) being assigned to a certain key via an RL (ReturnLine).
The OEM can disable machine operation by keys as long as the handwheel is active.

Heavy contamination --> Key gets stuck
Chips jammed --> Key gets stuck
Pressure contact defective --> Key no longer reports actuation
Note
Defective keys either do not contact any more or are in continuous contact.
Liquid penetrated
Ribbon cable defective
Connector of ribbon cable defective
Soft-key row or keyboard PCB defective
Potentiometer wiper worn
January 2008 21 – 219

21.3 Checking the Keys
This inspection comprises the hard keys on the key field and the horizontal and vertical soft
keys around the monitor. The soft key rows are connected to the keyboard PCB with ribbon
cables.
Correct  Make sure that the key really functions in the selected operating mode.
operation? --> Consult the machine operator or the user's manual!
Visual inspection  Perform visual inspection first!

Is the key heavily contaminated (grease, dust, oil, etc.)?
Are there any jammed chips?
The key may thus get stuck.
In such events carefully clean the keyboard. --> see “Exchanging Keyboard Components” on
page 25 – 271
DANGER
When liquid cleaning agents have been used, the electrical devices must dry completely
before they may be operated again.
Does the control To make sure whether the signal is received, observe the key code in the PLC double word
receive the NP_GenKeyCode when you press the keys:
key signal?
 Press EMERGENCY STOP.
 Reboot the control.
 Do not acknowledge the Power interrupted message.
 Call the PLC table for the words (see “The TABLE Function” on page 10 – 63).
 Press the key to be examined and check, if the display changes to the key code valid now or
the key reacts accordingly!
Principle of the The keys are evaluated via a matrix. Every key is located at a cross point of SL (= scan line) and
key matrix RL (= return line).
--> see “Key Matrix of MC 320” on page 21 – 228

Flowchart Is a line (cable, board) or the key element defective?
Inspection of the keys
Use the key matrix to find a key that is

selected by the same RL line as the
defective key (and which functions in
the selected operating mode).
Press this key.
No
Any reaction?
Yes
Use the key matrix to find a key that is

selected by the same SL line as the The line to the matrix is interrupted.
defective key (and which functions in Check the ribbon cable (measure the
the selected operating mode). cable, try replacement, etc.)
and the connectors.
Is the keyboard PCB defective?
Press this key.
No
Any reaction?
Yes
The matrix lines (ribbon cable,

keyboard PCB) are in order.
The contact of the key is
probably defective.
January 2008 21 – 221

Measuring setup The following setup allows for a precise statement about the state of the connected keypad.
with test adapter For this purpose the MC 320 must be dismounted and the front panel removed. Moreover,
special equipment is required.
--> see “Test Adapter” on page 27 – 284
Note
If no test adapter is available, you can measure directly at the contacts of the ribbon cable
X1 on the keyboard PCB.
However, this is very cumbersome, since you must contact the right pins precisely while
pressing the key to be inspected!

 Remove the MC 320 from the console (take care that all connected cables are labeled).
 Unfasten the rear screws of the front panel.
 Separate the front panel from the housing. The 50-pin ribbon cable connector must be
disconnected for this purpose.
Caution
Handle the glass in the front panel and the monitor in the housing with great care.
Pay attention not to damage, scratch or contaminate the glass panel or the monitor.
In particular, when you dismount or remount the front panel, the monitor might
be scratched by the spacer bolts on the front panel!
Place the components etc. on a soft and clean surface.
 With the ribbon adapter cable connect the test adapter to the connector X1 on the keyboard
PCB.
 Connect the measuring lines of a multimeter to the banana jacks of the test adapter.
Use the corresponding key matrix with the pin layout.
--> see “Key Matrix of MC 320” on page 21 – 228
 Set the multimeter to "alarm" (acoustic signal) or to ohm measurement.
 Press the key to be examined.
If the key functions, the multimeter will "ring". If you use ohm measurement, the measured
resistance is approx. 1 ohm (consider the resistance of the measuring lines).

MC
Test adapter
Id.Nr. 375830-01
... W
Multimeter
Note
Restriction for Return Line 2:

The alarm method cannot be used to test the cross points of the scan lines (SL) and the
return line 2 (RL 2). There are logical gates between RL 2 and the related keys. These gates
serve for keyboard identification.
Direct ohm measurement is thus not possible here.
January 2008 21 – 223

21.4 Checking the Potentiometers
Displayed The values of the feed-rate potentiometer (0 ... 150 %) are displayed on the screen.
potentiometer The display of the spindle speed depends on the position of the spindle potentiometer.
values
 Turn the potentiometers and observe, whether the display changes accordingly.
Note
The minimum and the maximum permissible spindle speed is defined by the OEM.
This means that the speed does not necessarily have to cover the entire range between
0 and 150 %.
Note
The positions of the potentiometers may also be displayed in the small PLC window.
--> Ask the machine operator!
Potentiometer You can use the PLC TABLE to find out, whether the control receives the potentiometer signal.
values
The potentiometer setting is displayed in the following PLC operands:
in API DATA
NN_SpiOverrideInput (= S override)
NN_ChnFeedOverrideInput (= F override)
Proceed as follows:
 Switch the machine on and confirm the Power interrupted message.
 Call the API DATA function (see “The API DATA Function” on page 10 – 58).
 Press the SPINDLE soft key.
 Switch to decimal display.
 With the cursor select the PLC operand NN_SpiOverrideInput.
 Turn the spindle potentiometer.

 Check whether the display can be changed from the minimum to the maximum value.
Note
The minimum and maximum values are defined in the machine parameter CfgPlcOverrideS.
These values are multiplied by the factor 100 for display in the PLC.
 Press the CHANNEL soft key.

 With the cursor select the PLC operand NN_ChnFeedOverrideInput.
 Turn the feed-rate potentiometer.
 Check whether the display can be changed from 0 to 15000.
Potentiometer With the integrated oscilloscope you can record the states of PLC operands as well.
values in the The advantage of this method is that possible interruptions of the potentiometer wipers can be
oscilloscope detected more easily than in the API DATA display.
Proceed as follows:
 Switch the machine on and confirm the Power interrupted message.
 Call the WATCH LIST (see “The WATCH LIST Function” on page 10 – 60).
 Press the SYMBOL LIST soft key.
 Place the cursor on NN_ChnFeedOverrideInput and press INSERT. Proceed accordingly with
the PLC operand NN_SpiOverrideInput.
The following window will appear:
 Take a note of the absolute addresses in the ADDR column.

 Now call the integrated oscilloscope. --> see “Integrated Oscilloscope” on page 9 – 45
January 2008 21 – 225

 Enter the double words in the selection window.
 Start recording and turn the potentiometers.

 Stop recording and adjust the signals.
 Restart recording. --> Now you can examine the wiper areas of the potentiometers.

Note
These minimum and maximum values for the spindle potentiometer are defined in the
machine parameter CfgPlcOverrideS. The values are multiplied by the factor 100 for display
in the oscilloscope.
The values for the feed-rate potentiometer are between 0 and 15000.
Measure For this purpose the MC 320 must be dismounted and the front panel removed.
potentiometer
values directly
 Remove the MC 320 from the console (take care that all connected cables are labeled).
 Separate the front panel from the housing. The 50-pin ribbon cable connector must be
disconnected for this purpose.
Caution
In particular, when you dismount or remount the front panel, the monitor might be
scratched by the spacer bolts on the front panel!
 Remove the front panel.

 Disconnect the ribbon-cable connector of the potentiometer.
 Using a multimeter, check the resistances of the potentiometer.
Pin 1 is normally distinguished by a red line of the ribbon cable.
Measurement between Resistance value

the pins
1-3 approx. 10 k
1-2 approx. 0 ... 10 k
January 2008 21 – 227

21.5 Key Matrix of MC 320
Keyboard PCB
Keya PGM
ERR CALC MOD HELP
X1 pinb MGT
1a RL0 X X
2a RL1 X X X
3a RL2 X X
4a RL3 X
5a RL4 X X
6a RL5 X X
7a RL6 X
8a RL7 X
9a RL8
10a RL9
1b SL0 X
2b SL1
3b SL2 X
4b SL3
5b SL4 X X X X
6b SL5
7b SL6 X X X X X
8b SL7 X X X
a. Key
b. Ribbon cable connector X1 on keyboard PCB

Key APPR CHF L CR RND CT CC C
X1 pin DEP FK
1a RL0
2a RL1
3a RL2
4a RL3
5a RL4 X
6a RL5 X
7a RL6 X X
8a RL7 X X
9a RL8 X X X X
10a RL9
1b SL0 X
2b SL1 X
3b SL2 X X X
4b SL3 X X X X X
5b SL4
6b SL5
7b SL6
8b SL7
Key TOUCH CYCL CYCL LBL LBL TOOL TOOL PGM

STOP
X1 pin PROBE DEF CALL SET CALL DEF CALL CALL
1a RL0
2a RL1
3a RL2
4a RL3 X
5a RL4 X X X
6a RL5 X X
7a RL6 X X
8a RL7 X X
9a RL8
10a RL9
1b SL0 X X X X X
2b SL1 X X X X
3b SL2 X
4b SL3
5b SL4
6b SL5
7b SL6
8b SL7
January 2008 21 – 229

Key GOTO
X1 pin
1a RL0
2a RL1
3a RL2
4a RL3
5a RL4
6a RL5 X X
7a RL6 X
8a RL7 X X
9a RL8
10a RL9 X X X
1b SL0 X
2b SL1 X
3b SL2 X
4b SL3
5b SL4
6b SL5 X X X
7b SL6 X X
8b SL7
Key
X1 pin X 7 8 9 Y 4 5 6 Z 1 2 3
1a RL0 X X X
2a RL1 X X X
3a RL2 X X X
4a RL3 X X X
5a RL4
6a RL5
7a RL6
8a RL7
9a RL8
10a RL9
1b SL0
2b SL1
3b SL2 X X X X
4b SL3 X X X X
5b SL4 X X X X
6b SL5
7b SL6
8b SL7

Key
0 -/ Q CE DEL
P I
X1 pin +
1a RL0 X
2a RL1 X
3a RL2 X X X
4a RL3 X X X
5a RL4 X X
6a RL5
7a RL6 X
8a RL7
9a RL8 X
10a RL9
1b SL0 X
2b SL1 X X X X
3b SL2
4b SL3
5b SL4 X
6b SL5 X X X
7b SL6 X
8b SL7 X X
Key NO END
X1 pin ENT ENT
1a RL0 X X
2a RL1 X
3a RL2
4a RL3
5a RL4
6a RL5
7a RL6
8a RL7
9a RL8
10a RL9
1b SL0 X
2b SL1
3b SL2
4b SL3
5b SL4
6b SL5 X X
7b SL6
8b SL7
January 2008 21 – 231

Soft-key rows
on VDU
13a 14a 15a 16a 1b 2b 3b 4b 5b X1 pina
RL12 RL13 RL14 RL15 SL0 SL1 SL2 SL3 SL4 Keyb
X X
X X
X X
X X
X X
X X
X X
a. Ribbon cable connector X1 on keyboard PCB

b. Key
MF = Vertical soft key (from top to bottom)
Keya
SK1 SK2 SK3 SK4 SK5 SK6 SK7 SK8
X1 pinb
13a RL12 X X X
14a RL13 X X X
15a RL14 X X X
16a RL15 X X X
1b SL0 X X
2b SL1 X X X X
3b SL2 X X X X
4b SL3 X X
a. Key
b. Ribbon cable connector X1 on keyboard PCB
SK = Horizontal soft key (from left to right)
Note
Keys that were pressed are entered into the keystroke log.
The SK1 key is entered as HorzSoftkey1, the SK2 key as HorzSoftkey2, ..., the SK8 key
as HorzSoftkey8.
The horizontal soft keys are numbered serially from left to right.
The MF1 key is entered as VertSoftkey1, the MF2 key as VertSoftkey2, and so on.
The vertical soft keys are numbered serially from top to bottom.

Keys If a key no longer makes contact:
Defective pushbuttons are not replaced individually!

Reason: If individual pushuttons make bad contact or fail, other keys will also reach the end of
their service life soon.
Therefore, only complete boards including the pushbuttons are replaced.
-->see “Exchanging Keyboard Components” on page 25 – 271
If a key permanently makes contact:
If required, remove chips and clean the keyboard!

 Remove the MC 320 from the console (take care that all connected cables are labeled before
you disconnect any).
 Separate the front panel from the housing. (The 50-pin ribbon cable connector must be
disconnected for this purpose.)
Caution
 Disassemble the keyboard.

 Clean the components with a standard cleaning agent and a piece of cloth.
 Dry (or let dry) the components.
 Reassemble the keyboard.
DANGER
When liquid cleaning agents have been used, the electrical units must dry completely before
they may be operated again.
Potentiometers Replace the defective potentiometer.

--> see “Replacing the Potentiometers” on page 25 – 268
January 2008 21 – 233

22 Machine Operating Panel
22.1 Introduction
Machines with up to four axes may feature the HEIDENHAIN machine operating panel MB 420.
It is normally mounted below the TNC.
The machine operating panel is connected to the connector X46 of MC 320.
The keys and buttons of MB 420 are transmitted to the control as PLC inputs.
Moreover, MB 420 is provided with 8 PLC outputs (which serve, for example, to control the
lamps of the buttons).
If a machine operating panel from the machine tool builder is used, please refer to the
corresponding circuit diagram from which you can see the wiring of the keys.
Caution
HEIDENHAIN recommends to check the function of the EMERGENCY STOP switch on the
machine operating panel or operating tableau in regular intervals!

Heavy contamination --> Key gets stuck
Chips jammed --> Key gets stuck
Pressure contact defective --> Key no longer reports actuation
Note
Liquid has penetrated

Defective cable between MB and control
Connector defective
Interface on the control defective
Board defective
Buttons defective
Note
If the NC STOP signal (low-active) between MB and control is interrupted, the machine
cannot be traversed any more. The same problem is caused, if the NC STOP key gets stuck.
EMERGENCY STOP button defective
January 2008 22 – 235

22.3 Checking the Power Supply
The MB 420 is powered with 0 V at X1/PIN 34, 35 and with 24 V PLC voltage on X1/PIN 36, 37.
Check, whether the power supply is in order!
Measuring setup
with test adapter
MC 320
MB
X 46
Test adapter
Id.Nr. 375830-01
. . .V
Multimeter
Procedure:
 Connect the test adapter between the MC connector X46 and the MB 420 connecting cable.
 Switch the machine back on again.
 Check the supply voltage at the pins concerned with a multimeter.
Note
machine operating panel!
If a defective machine operating panel draws too much current, is "separated" from the
control. Error messages may be displayed.

22.4 Checking the Keys
Correct  Make sure that the key really functions in the selected operating mode.
operation? --> Consult the machine operator or the user's manual!
Visual inspection  Perform visual inspection first!

Is the key heavily contaminated (grease, dust, oil, etc.)?
Are there any jammed chips?
The key may thus get stuck.
In such events carefully clean the machine operating panel.
--> see “Exchanging Components of the Machine Operating Panel” on page 25 – 275
DANGER
Does the control The keys and buttons of MB 420 are assigned to the following PLC inputs:
receive the
key signal?
I
I I I I I I I 146
136 135 134 137 138 143 145
I I I I I I I
128 148 133 149 139 144 150
I I I I I I I I
129 130 131 132 140 141 142 147
Two further inputs (I151 and I152) may be wired via terminal block X3:
Terminal X3 Assignment
1 I151
2 I152
3 +24 V
The inputs are connected to the control (MC, connector X46) via the connecting line X1.
Connectors and pin layouts on MB 420 --> see “Machine Operating Panel” on page 14 – 157.
The function of the MB keys can be checked via the PLC input table:
 Switch on the machine.
 Call the table with the PLC inputs. --> see “The TABLE Function” on page 10 – 63.
 Press the keys.
January 2008 22 – 237

 The inputs must change to 1!
Exception: I147 = NC STOP --> Changes to 0 when actuated (broken wire interlock!)
Note
Measure the input voltages, e.g. at terminal X3 of MB 420 or via test adapter at
connector X1. --> see “Test Adapter” on page 27 – 284.
The logical states in the PLC TABLE must be in agreement with the voltage level of the
respective inputs!
22.5 Checking the Outputs

MB 420 features 8 PLC outputs (which serve, for example, to control the lamps of the buttons).
These outputs are located on the connecting line X1 and on the terminal block X4:
Terminal X4 Assignment
1 O0
2 O1
3 O2
4 O3
5 O4
6 O5
7 O6
8 O7
9 0V
The function of the outputs can be checked via the PLC output table:
 Call the PLC output table. --> see “The TABLE Function” on page 10 – 63
 Establish the conditions for setting the output concerned (keystroke, function call, etc.).
If necessary, use the User's Manual or the circuit diagram of the machine or consult the
machine manufacturer.
 The outputs must change condition!
You can now find out, e.g., whether a lamp is defective or is not controlled correctly.
Note
Measure the output voltages, e.g. at terminal X4 of MB 420 or via test adapter at
connector X1. --> see “Test Adapter” on page 27 – 284.
The logical states in the PLC TABLE must be in agreement with the voltage level of the
respective outputs!

Pushbuttons If a key no longer makes contact:
Defective buttons are not replaced individually!

Reason: If individual buttons make bad contact or fail, other buttons will also reach the end of
their service life soon.
Therefore, only complete boards including the pushbuttons are replaced.
--> see “Exchanging Components of the Machine Operating Panel” on page 25 – 275

 Remove the MB 420 from the console (take care that all connected cables are labeled before
you disconnect any).
 Dismount the board.
 Clean the components with a standard cleaning agent and a piece of cloth.
 Dry (or let dry) the components.
 Reassemble the keyboard.
DANGER
Other Replace defective components, such as the cable between MB and control, the board, the
components buttons NC START, NC STOP and EMERGENCY STOP with original components!
Control If you have found that the MB interface on the control is defective (connector X46) --> Replace
the control.
--> see “Exchanging MC 320” on page 25 – 264
January 2008 22 – 239

23 Handwheel
23.1 Introduction
The following handwheels can be connected to TNC 320:

One HR 410 portable handwheel
One HR 130 panel-mounted handwheel
Three HR 150 panel-mounted handwheels via HRA 110 handwheel adapter
(as of NC software 340551-03)
Shock or vibrations can cause a slight motion at the handwheel and produce an unintentional axis
movement. The threshold sensitivity of the handwheel encoder is specified in the config object
CfgHandwheel / machine parameter sensitivity.
Portable handwheels with EMERGENCY STOP button are connected to the control via an
adapter. The circuits for EMERGENCY STOP circuit and for the permissive keys are located
in the cable adapter ID 296466-xx.
Pin layouts and wiring (e.g., EMERGENCY STOP key and permissive key on handwheel adapter)
--> see “Handwheels” on page 14 – 150
Operation of the electronic handwheels --> See TNC 320 User's Manual.
Caution
HEIDENHAIN recommends to check the function of the EMERGENCY STOP button on

the handwheel in regular intervals!
January 2008 23 – 241

The portable handwheel was dropped down and damaged.
Heavy contamination --> Key gets stuck.
Chips jammed --> Key gets stuck.
Pressure contact defective --> Key no longer reports actuation.
Note
Board defective
EMERGENCY STOP button defective
Handwheel encoder defective
Liquid has penetrated
Handwheel cable defective
Error in cable adapter --> Continuous EMERGENCY STOP or permissive keys non-functional
Short circuit in cable or handwheel
Shock or vibrations --> Unintended traverse movements
Handwheel interface on MC defective
Caution
handwheel (12 V). --> The screen goes blank!

23.3 Error Diagnosis at HR 410 Portable Handwheel
Functional check Switch the control display to "Nominal value" and observe, whether the display changes while
you turn the HR.
Check, whether the EMERGENCY STOP button and all other keys function properly.
Note
If available, connect an identical handwheel and test its function.
Visual inspection Perform a visual inspection of handwheel, EMERGENCY STOP button, keys, cable, contacts,
etc.
Examine the device for damage: Are keys heavily contaminated! Are there any jammed chips?
Have liquids entered, etc.?
Voltage Connect the test adapter between connector X23 of the MC and the handwheel and measure
supply OK? the +12 V voltage (see “Test Adapter” on page 27 – 284).
MC
X 23
Test adapter
ID 375830-01
Note
handwheel!
If a defective handwheel draws too much current, is "separated" from the control.
However, in this case the screen may go blank!
January 2008 23 – 243

Checking the Keys With the PLC diagnostic function TABLE or with the integrated oscilloscope you can check the
function of the handwheel keys by means of the corresponding PLC inputs:
 Call the table with the PLC inputs or start the integrated oscilloscope.
--> see “PLC Diagnostics” on page 10 – 55, see “Integrated Oscilloscope” on page 9 – 45
 Press the handwheel keys.
 Check whether the corresponding inputs change to 1.
In the config object CfgHandwheel / machine parameter initValues[0] is defined, whether the
handwheel keys are evaluated by the NC or the PLC.
Evaluation of the keys by the NC. --> initValues[0] =0
X IV
Y V
Actual
position
Z capture
Low Medium High

feed rate feed rate feed rate
– +
O109 O110 O111
I173 I174 I175
All keys are evaluated by the NC, except the function keys A, B and C!

Evaluation of the keys by the PLC. --> initValues[0] = 1
Note
Ask the machine manufacturer, whether you may change the value in the machine
parameter initValues[0] for testing. The PLC program may prevent this.
O96 O97
I160 I161
O98 O99
I162 I163
O100 O103
I164 I167
O104 O105 O106

I168 I169 I170
I171 I172
O109 O110 O111

I173 I174 I175
All keys are evaluated by the PLC!
January 2008 23 – 245

23.4 Deselecting the HR 410 Portable Handwheel
You have found out that an HR 410 is defective and must be exchanged or repaired.
The customer can deselect the handwheel to be able to continue work without it.
 Unscrew the handwheel from the handwheel adapter at the console.
 Screw the dummy plug onto the handwheel adapter.
Note
The dummy plug bridges the handwheel in the EMERGENCY STOP chain.
If no dummy plug is available, use wire to bridge the EMERGENCY STOP contacts of the
handwheel in the EMERGENCY STOP chain.

 Do not acknowledge the Power interrupted message, but call the config editor immediately.
 In the machine parameter System/CfgHandwheel/type select NONE and save the setting.
 Switch on the machine and perform functional testing.
DANGER
If you have bridged the handwheel contacts in the EMERGENCY STOP chain, you must
remove the bridge when you reconnect the handwheel to operate it.
You must absolutely check, whether the EMERGENCY STOP button on the
handwheel functions properly!
Dummy plug The dummy plug for the handwheel adapter can be purchased from the machine manufacturer
or from HEIDENHAIN (ID 271958-03).

23.5 Error Diagnosis at Panel-Mounted Handwheels
HR 150 with As of NC software 340551-03!

HRA 110
With the HRA 110 handwheel adapter you can connect two or three HR 150 panel-mounted
handwheels to TNC 320.
The first and second handwheels are assigned to the X and Y axes. The third handwheel can be
assigned either through a selection switch (option) or via config object.
HR 150 HRA 110
X31 24 V
X1 S2 Achswahl (Option)
AXIS SELECTION (OPTIONAL)
S1 Unterteilungsfaktorwahl (Option)
X2
INTERPOLATION FACTOR (OPTIONAL)
X3 X23 X23 (LE)
Id.-Nr. 270 909..
max. 20 m max. 50 m
An additional switch enables you to select, for example, the interpolation factor for the
handwheel. The current position of the selection switch is evaluated by the PLC.
23.5.1 Checking the Switches

The function of the selection switches can be checked via the PLC table for the inputs:
 Call the table with the PLC inputs. --> see “The TABLE Function” on page 10 – 63
 Turn the selection switches.
 Use the tables on the next page to check, whether the respective inputs change to 0.
January 2008 23 – 247

Assignment of the The tables below list the assignments of switch positions of S1 and S2 to the PLC inputs
switch positions to I160 to I175.
the PLC inputs
The two switches work with a 0 V logic circuit.
Example:
If switch S1 is set to position 3, input I162 is logically 0; all other inputs
are logically 1.
Selection switch 1: Selection switch for choosing the interpolation factor
Switch position PLC input

1 (at the left stop) I160
2 I161
3 I162
4 I163
5 I164
6 I165
7 I166
8 (at the right stop) I167
Selection switch 2: Axis selection switch
Switch position PLC input

1 (at the left stop) I168
2 I169
3 I170
4 I171
5 I172
6 I173
7 I174
8 (at the right stop) I175

Keys If a key no longer makes contact:

Return the handwheel for repair!
Individual keys, boards and other handwheel components are not exchanged in the field!

 Screw off the handwheel.
 Clean it with a standard cleaning agent and a piece of cloth.
 Dry the handwheel.
DANGER
Caution
Handwheels must not be disassembled in the field!
Cables and Replace defective parts only by original HEIDENHAIN components!

handwheel
adapters
EMERGENCY If the EMERGENCY STOP button is defective, replace the entire handwheel!
STOP button
Control If you have found that the HR interface on the MC 320 control is defective (connector X23),
replace the control. --> see “Exchanging MC 320” on page 25 – 264
January 2008 23 – 249

24 Touch Probe
24.1 Introduction
Touch probes serve to:
Align workpieces
Set reference points
Measure workpieces
A TNC 320 can be equipped with different touch probes:
Touch probe with signal transmission via cable (e.g. TS 220)

These touch probes are inserted manually into the spindle by the machine operator.
Touch probe with infrared transmission of the trigger signal (e.g., TS 640, TS 440)
These touch probes are designed for use on machines with automatic tool changer.
The infrared transmission is established between the touch probe and the transmitter/receiver
unit.
It is tolerant to noise and can even be reflected.
The probes are battery-operated.
The TS 640 is equipped with an integrated cleaning blower.
January 2008 24 – 251

Various styli can be inserted into the touch probes. These feature a rated break point!
By means of touch probe cycles ...

Datums can be set in manual and automatic mode.
Workpiece misalignment can be compensated manually and automatically.
Workpieces can be measured automatically.
Touch probe systems can be calibrated.
Pin layout --> see “Touch Probe Systems” on page 14 – 149.
You will find further information on touch probes in …

The TNC 320 User's Manual
The corresponding mounting instructions
The brochure 3-D Touch Probes for Machine Tools
These documents can be downloaded from the HEIDENHAIN website (www.heidenhain.de).

If you cannot find the requested document, ask the machine manufacturer or your HEIDENHAIN
service agency!
Note
touch probes!
If a defective touch probe draws too much current, is "separated" from the control.
Corresponding error messages are displayed.

Collision (stylus, probe or transmitter/receiver unit damaged, etc.)
Humidity
Touch probe cable defective
Short circuit in the cable, in the transmitter/receiver unit or in the touch probe
Cable to transmitter/receiver unit defective
Battery dead --> A corresponding error message is generated when a touch probe is started.
Contamination of probe and/or transmitter/receiver unit --> No infrared connection
Obstacle in infrared connection or strong shadowing of transmitter or receiver
Contact on infrared touch probe not closed or defective
Several touch probes may be within the receiving range of one SE; the infrared signals cannot
be allocated any more; faulty operation
Interface to touch probe or transmitter/receiver unit on MC defective
Caution
The video signal is switched off, if there is a short-circuit in the 15 V power supply of a touch
probe (not the 5 V supply). --> The screen goes blank!
January 2008 24 – 253

24.3 Checking TS 220, TS 440 and TS 640
Negative influence If there is suspicion that a damaged touch probe (or a touch probe into which humidity has
on control? penetrated) impairs the function of the control, disconnect the probe and observe the reaction.
Visual inspection Check, whether the stylus is broken or the touch probe or the cable are damaged, etc.
Functional test
DANGER
Contact the machine manufacturer and observe the machine manufacturers's safety
precautions (setup mode, etc.)!
The machine is on, the touch probe to be examined is in the spindle and no error message
related to the battery is generated.
 Call the on-line monitor. --> see “Diagnosis with the Online Monitor (OLM)” on page 8 – 41
 Successively press the soft keys LOGIN IPO / HW / NEXT / HW-PORTS II.
The following display appears:
Note
Please note that the signals for 3-D readiness and 3-D signal are low-active (broken wire
interlock)!
 Check the 3-D ready display. If the touch probe is ready for operation, the signal is red.
 Check the 3-D warng display. If no warning is pending, the signal is red.
 Deflect the stylus by hand.
 Check the LEDs on the touch probe (see “Checking the LEDs of TS 220” on page 24 – 255)
or at the transmitter/receiver unit (see “Checking the LEDs of TS 440 and TS 640” on page 24
– 256).
 At the same time, check the display of the 3-D signal in the OLM. When the stylus is
deflected, the signal changes to red!

Note
You can also connect the test adapter between the MC (X12) and the cable of the touch
probe and measure the voltages and signals. --> see “Test Adapter” on page 27 – 284!
Ready signal (X12/pin3) +15 V --> Touch probe ready
Negated trigger signal (X12/pin10) +5 V --> Touch probe ready, stylus at rest
Negated trigger signal (X12/pin10) 0 V --> Touch probe ready, stylus deflected
0 V (UN) are on pin 8 --> see “X12: Connection of the touch probe for workpiece
measurement” on page 14 – 136
Checking the Red LEDs on the TS 220 indicate that the stylus is deflected:
LEDs of TS 220
January 2008 24 – 255

TS 220
Note
If available, you can also connect an identical touch probe to test the functionality!
Checking the By means of two multicolor LEDs, a visual status check of SE 440, SE 640 and EA 632
LEDs of TS 440 transmitter/receiver units is possible:
and TS 640

LED with "flash" or "radio" symbol LED with "probe" symbol
Color Meaning Color Meaning
Green Infrared connection Green Touch probe ready, stylus at rest
in order
Orange Infrared connection Orange Touch probe ready, stylus
still acceptable deflected
Red Infrared connection Red Battery capacity of probe approx.
interrupted 10%; exchange probe battery
Off Touch probe not ready
On SE 540, there is a LED with the following meaning:
Color Meaning
Red (blinking) Touch probe ready, but no infrared connection
available
Green Infrared connection available
Orange Stylus already in contact
Off Touch probe not ready
Note
A detailed description of the visual status check, of the beam direction, of battery
exchange, stylus exchange, centering, specifications, etc. can be found in the mounting
instructions of the touch probe!
TS 640 with
SE 640
Note
If available, you can also connect an identical touch probe to test the functionality!
January 2008 24 – 257

TS 440 with
SE 540
Measuring the If available, you can connect the test adapter between MC 320 (X12) and the cable of the touch
voltages and probe to measure the voltages and signals. --> see “Test Adapter” on page 27 – 284!
signals with the
test adapter Voltage / signal Pin Voltage Meaning
+ 15 V X12/Pin5 + 15 V Power supply
+5V X12/Pin6 +5V Power supply
Ready signal X12/Pin3 +15 V Probe is ready
Negated trigger X12/Pin10 +5 V Probe is ready, stylus at rest
signal 0V Probe is ready, stylus deflected
The 0 V reference potential (UN) is on pin 8. --> see “X12: Connection of the touch probe for
workpiece measurement” on page 14 – 136

Exchange of If required, replace the battery, the broken stylus, the defective cable, etc.
components
Note
A detailed description of the visual status check, of the beam direction, of battery
exchange, stylus exchange, centering, specifications, etc. can be found in the mounting
instructions of the touch probe!
Cleaning Use standard cleaning agents to clean transmitter/receiver units.
Recalibration After a collision, check the accuracy of the touch probe. Consult the machine operator, the
machine manufacturer or your HEIDENHAIN service agency!
Note
A detailed description of the visual status check, of the beam direction, of battery exchange,
stylus exchange, centering, specifications, etc. can be found in the mounting instructions
of the touch probe!
Returning the Return defective touch probes and those that impair the function of the control for examination.
touch probe
Returning the If the touch probe interface of MC 320 is defective, replace the entire control.
control --> see “Exchanging MC 320” on page 25 – 264
January 2008 24 – 259

25 Exchange of HEIDENHAIN Components
25.1 Important Information
DANGER
Observe the safety precautions to avoid injury or damage to persons or machines.

--> see “Safety Precautions” on page 1 – 7.
Caution
Use only original HEIDENHAIN components!
Which components MC 320

may be exchanged (Main computer, control)
in the field? CFR
(Memory card, compact flash removable)
SIK
(System identification key)
Fuses
Buffer battery in MC 320
Potentiometers
Battery in touch probe
Stylus
HEIDENHAIN peripherals
(e.g., encoders, handwheels, touch probes, machine operating panels, etc.)
Cables and accessories
What could be Components of the keyboard

exchanged in
addition? Components of the machine operating panel
More extensive replacing activities are described later in this chapter.

Simple exchanges are not described or can be found in the respective chapters of this manual.
Update of An NC software update is performed by the machine manufacturer or in coordination with

NC software him.
As per special prescriptions of the OEM, the PLC program, the machine configuration or the
data in the PLC partition may also be updated.
DANGER
The HEIDENHAIN NC software for TNC 320 must be released by the OEM!
January 2008 25 – 261

Goods subject to As TNC 320 does not feature more than 4 axes interpolating with each other, no export license
export license is required, neither for the NC software, nor for CFR and SIK.
However, high-accuracy and high-resolution encoders may require an export license.
Therefore, always use original devices as replacements!
Contact your OEM, if you suspect conflicts!
Replacement units For replacement units and spare parts, ask your machine manufacturer!
and spare parts The same is true for NC software!
Please observe:
Always use original HEIDENHAIN components as replacements!
Replacement CFRs or new CFRs are normally equipped with the most recent NC software.
If you wish to keep the previously installed - older - NC software version, please contact your
OEM.
He can restore this version.
Please send the defective unit in its original packaging to your machine manufacturer or your
HEIDENHAIN agency.
Information on If possible, write the assumed error or circumstances that caused the failure of the device on
possible errors a piece of paper, which you attach to the device.
Note
Replacement controls arrive with a form that you should fill in to provide information on the
error of the defective control.
Repair Many HEIDENHAIN devices are not repaired on site but are exchanged or replaced.
These devices are exclusively repaired by HEIDENHAIN specialists. The devices are also
updated to the latest state-of-the-art and subjected to tests.
ID numbers When placing a service order, always indicate the ID number of the HEIDENHAIN device
concerned.
SIK
The SIK (= System Identification Key) ...

Is located in a slot on the side of the MC 320 housing (X125).
Stores enabled control loops and software options (e.g, cylindrical surface interpolation, etc.)
Comprises the NC software license (export version).
Is inserted in the replacement control, if the control needs to be exchanged.
--> Thus, all enabled options are still available!

After you have entered the code word SIK, the SIK number and the enabled options are
displayed on the screen. You also find it on the SIK housing or on a sticker below the ID label
of MC 320.
ESD protection
Caution
When you exchange HEIDENHAIN components, you might come into contact with
electronic components.
These ESD-sensitive components may also come into contact with a statically charged
object (tool, tool table, packaging, etc.)
Therefore observe the ESD protective measures, when you exchange the buffer battery
and all devices with accessible electronic components or contacts!
Equipotential bonding conductor with

protective resistance
R=1MΩ
Grounding connection
(e.g. protective earth conductor socket)
MOS not required if protection mat is placed
protection mat on machine table
Bracelet
January 2008 25 – 263

25.2 Exchanging MC 320
Preparing the If still possible …

machine
 Move the machine to home position (axes, tool changer, etc.)
Ask the machine operator!
Removing the  Switch off the main switch of the machine and take precautions that is cannot be switched
defective MC 320 B on. --> see “Safety Precautions” on page 1 – 7!
 Label and remove all connectors from the MC.
 Screw off the ground lead.
 Dismount the MC from the console.
 Remove the flash card (connector X600).
--> see “Exchanging the CFR Memory Card” on page 25 – 265
 Remove the SIK (connector X125).
Mounting the new  Insert the flash card into the new MC 320 and lock it.
MC 320 --> see “Exchanging the CFR Memory Card” on page 25 – 265
 Insert the SIK into the new MC 320.
 Mount the MC 320 in the console.
 Screw on the ground lead.
 If required, remove the protective caps from the MC connectors.
 Re-connect and attach all lines and cables.
Caution
Do not forget the grounding screw!

Do not confuse any of the connectors!
 Switch on the main switch of the machine.
Restoring the  Check the electrical offset and readjust it, if necessary.
original state of the --> see “Adjusting the Electrical Offset” on page 19 – 206
machine  Check date and time and reset it, if necessary.
--> see “Setting the System Time” on page 11 – 90
Check the machine functions.

If necessary, you may ...
Recalibrate the touch probes.
Initialize the tool changer again.
Information can be provided by your OEM!
Return shipment  Replacement controls arrive with a form which you should use to provide information on the
error of the defective control.
Please fill in this form and attach it to the housing of the MC 320.
 Use the original packaging of the new MC 320 to package the defective MC 320.
 Return the defective MC 320 to the machine manufacturer or to your HEIDENHAIN service
agency.

25.3 Exchanging the CFR Memory Card
Caution
For this reason a CFR may only be exchanged in consultation with the machine
manufacturer.
CFRs that you receive in exchange and new CFRs are already partitioned and formatted.
The NC software is installed and a basic configuration set.
CFRs are normally equipped with the most recent NC software.
This NC software must be released by the machine manufacturer!
Moreover, you require support by the machine manufacturer, if you must adapt the saved
data of your previous NC software version to the new NC software version (update rules).
If the machine manufacturer has not released the latest NC software, or if you wish to keep
the NC software version that was installed on your defective CFR, this version must be
installed. For this purpose you also require support from the machine manufacturer.
Preparing the If still possible:

machine
 Move the machine to home position (axes, tool changer, etc.)
Ask the machine operator!
If possible … Data backup

It must be assumed that you can no longer create a data backup of the defective CFR.
If this is still possible:
 Back up all control data on the CFR. Select the icon Scan all.
--> see “Data Backup on External Data Medium” on page 12 – 113
Removing the  Switch off the main switch of the machine and take precautions that is cannot be switched
defective CFR on. --> see “Safety Precautions” on page 1 – 7!
 Pull the support bracket of the CFR towards you to loosen the locking mechanism.
January 2008 25 – 265

 Remove the CRF downward.
Installing the  Insert and lock the new CFR.

new CFR  Switch on the machine.
 The control should now start up without any problem.
It will then activate the simulation mode:
Defining the NC  Check the currently active NC software version. --> see “Display of System Information” on
software version page 13 – 130
If you require a different software version, it must be loaded now. --> Please contact your
machine manufacturer!
Setting the data  Either make the settings for Ethernet transmission on the control. --> see “Via Ethernet” on
interface page 12 – 100
 Or define the settings for the RS 232 interface. --> see “Via serial interface RS 232/V.24” on
page 12 – 106

Restoring the data As you could probably not save any data from the defective CFR, you must use available
archives (PLC data, TNC data) to restore the data on the new flash card.
Note
If required, you can obtain PLC and machine data from the machine manufacturer.
 Load the backup on the new CFR. --> see “Restoring Data” on page 12 – 117
Updating the The data of the old NC software version may have to be adapted to the new NC software version
machine (update rules). -- > Ask the machine manufacturer!
configuration data
Restoring the On machines with analog axes an offset fine adjustment with the HEIDENHAIN code number
default should be performed after the control was replaced.
settings of the -> see “Adjusting the Electrical Offset” on page 19 – 206
machine
Check the machine functions.
Depending on the machine features you have to ...
Recalibrate the touch probes.
Initialize the tool changer again.
Contact the machine manufacturer for information!
Check the reference points (preset table --> ask the machine operator).
Check date and time and reset it, if necessary.
--> see “Setting the System Time” on page 11 – 90.
Creating a machine If changes were made to the machine or control (e.g., new machine parameters added),
backup you should create a backup of the current machine data.
--> see “Data Backup on External Data Medium” on page 12 – 113!
Return shipment  Attach a note with the error description to the CFR.
 Use the original packaging of the new CFR to package the defective CFR.
 Return the defective CFR to the machine manufacturer or to your HEIDENHAIN service
agency.
January 2008 25 – 267

25.4 Replacing the Buffer Battery
See ”Buffer Battery” on page 15 – 161.
25.5 Replacing the Potentiometers
DANGER
Housing parts need to be removed to replace the potentiometers.

great care!

 Label and disconnect all cables connected to MC 320.
 Dismount the MC 320 from the console.
 Screw off the rear part of the housing.

 Lift the housing a little from below and carefully disconnect the ribbon cable of the keyboard
PCB.
Caution
If you open the housing at too much of an angle, there is the risk that you bend the upper
spacer bolts.
Caution
Place the components on a clean surface.
 Carefully pull the housing straight up.
January 2008 25 – 269

 Disconnect the potentiometer cable.
 Dismount the defective potentiometer. For this purpose, first remove the cover with a small
screwdriver or a knife.
 Mount the new potentiometer such that the range of 0 to 150 % can be covered.
Note
The potentiometer assembly is delivered with mounting instructions.
 Carefully remount the components. (Do not forget to connect the ribbon cable for the
keyboard!)

25.6 Exchanging Keyboard Components
DANGER
Housing parts need to be removed to replace keyboard components.

great care!

 Label and disconnect all cables connected to MC 320.
 Dismount the MC 320 from the console.
 Screw off the rear part of the housing.
January 2008 25 – 271

 Lift the housing a little from below and carefully disconnect the ribbon cable of the keyboard
PCB.
Caution
If you open the housing at too much of an angle, there is the risk that you bend the upper
spacer bolts.
Caution
Place the components on a clean surface.
 Carefully pull the housing straight up.

 Disconnect the ribbon cables.
 Mark the spacer bolts (e.g. with a felt-tip pen or a sticker) before you unscrew them.
January 2008 25 – 273

 Unscrew the nuts and spacer bolts.
 Replace defective keyboard component(s), such as board, rubber mat, spacer plate.
Note

Reason: If individual pushbuttons make bad contact or fail, other keys will also reach the end
of their service life soon.
Read the ID number of the board concerned and order the board.
 Carefully remount the components:

Screw in the spacer bolts at the right places and do not forget to connect the ribbon cable for
the keyboard!

25.7 Exchanging Components of the Machine Operating Panel
 Dismount the MB from the console.
 Now you can replace, for example, lamps and key elements.
DANGER
You must absolutely check, whether the EMERGENCY STOP button functions properly!
 If you intend to replace keyboard components, we recommend that you dismount the MB 420
entirely. Please label the key elements and cables before doing so!
January 2008 25 – 275

 Replace defective keyboard component(s), such as board, rubber mat, spacer plate.
Note

Reason: If individual pushbuttons make bad contact or fail, other keys will also reach the end
of their service life soon.
Read the ID number of the board concerned and order the board.
 Carefully remount the components.
DANGER
You must absolutely check, whether the EMERGENCY STOP button functions properly!

25.8 Exchanging Other HEIDENHAIN Components
Many HEIDENHAIN products (encoders, scanning heads, etc.) are supplied with mounting
aids (metal forks, spacer plates, etc.)
Mounting Instructions and Mounting Information are also included in delivery.
The HEIDENHAIN inspection device PWM 9 or PWT is a good aid for adjusting scanning
heads.
--> see “PWM 9 Encoder Diagnostic Set” on page 27 – 289
When analog servo amplifiers and motors including the cables are replaced, the analog servo
amplifiers may have to be readjusted.--> Ask the manufacturer.
--> see “Adjusting the Electrical Offset” on page 19 – 206
--> see “Speed Adjustment at Servo Amplifier” on page 19 – 210
When exchanging mechanical components, readjustment of the control loops of axes and
spindle may be necessary. --> Contact the machine manufacturer!
Exchange cables only for original cables! Do not exceed any maximum lengths!
If required, ensure proper shielding and grounding of cables and components.
If possible, use the original packaging from HEIDENHAIN.
Note
If you have any questions, contact the machine manufacturer or a HEIDENHAIN service
agency.
January 2008 25 – 277

26 Loading of Service Packs
26.1 Introduction
Errors in the current HEIDENHAIN NC software are corrected by means of service packs.
Service packs are loaded in addition to the NC software.
The service pack must match the released NC software version.
The latest service pack version includes all changes of the predecessor versions, i.e., only the
service pack with the highest version number must be loaded.
As per special prescriptions of the OEM, the PLC program, the machine configuration or the
data in the PLC partition may also be updated when a service pack is loaded.
Caution
Normally a service pack is loaded by the machine manufacturer or should be done at his
initiative and after prior consultation.
End users may receive the service packs from the machine manufacturer.
Machine manufacturers who have access rights to the protected section of the HEIDENHAIN
website (member area), can download the service pack from the HEIDENHAIN website after
having entered user name and password.
Display on If you press the MOD key while the machine is on, you can see whether a service pack is active.
the screen In this case you find the letters SP followed by the version number (e.g., 340551 01 SP3) behind
the ID number of the NC software.
Note
If a service pack has already been installed, it will not be possible to install a service pack
with a lower version number. This will be checked during the installation of a service pack
and a message will be displayed if an error is found.
January 2008 26 – 279

26.2 Preparations and Execution
Downloading the If you have access rights to the protected section of the HEIDENHAIN website (member area),
new service pack you can download the latest service packs.
For this purpose proceed as follows:
 Go to www.heidenhain.de on the Internet.
 Click on Services and Documentation/Member Area/FileBase.
 Enter your user name and your password.
 Click on NC Milling TNC320.
 Click on Software.
 Select the appropriate service pack with the highest version number for the NC software on
your machine (e.g., 34055102 - TNC320 service pack 3).
 Download the service pack onto a USB stick or onto your service laptop/PC.
Note
The USB stick must ...

Be USB 1.1 compatible.
Have at least 512 MB memory capacity.
Be FAT or VFAT formatted.
 Decompress the ZIP file (e.g., 34055102sp3.zip) to the USB stick or to a folder on the laptop.
A folder with the number of the NC software (e.g., 34055102) is created. This folder contains
a subdirectory (e.g., 340551_002_SP3) with the file setup.zip.
 Copy or move the setup.zip file to the root directory of the USB stick.
Note
End users may receive the service packs from the machine manufacturer.
This means that the OEM decides whether the end user can or should load the service pack
himself.
Preparing the  Move the machine to home position (axes, tool changer, etc.)
machine Ask the machine operator!
Note
HEIDENHAIN recommends backing up the control data, (e.g. with TNCremoNT) before
loading the service pack.
Loading the  Shut down the control and switch off the machine.
service pack  Connect the prepared USB stick to the USB interface provided by the machine manufacturer
(in most cases at the console or at the electrical cabinet) or directly to X141 or X142 of
MC 320. X141 and X142 are at the lower rear of the housing.
 Switch on the machine and, as soon as the blue screen appears , press DEL until the booting
procedure is interrupted and the following message is displayed:
Welcome to HeROS 4.X!

Username:
 Enter 049866931 as user name. (If a USB keyboard is connected to the control, you can also
enter update as an alternative.)

 Press the ENT key or the RETURN key on the external USB keyboard.
The following window appears:
 Select the Update menu item and confirm your entry with the ENT key.
 Select Source: USB stick. Confirm your selection with the ENT key.
 The control then starts the boot updater. A new window opens, which displays the contents
of the update packet:
 Select 1 and confirm your selection with the ENT key.

 The control automatically loads the service pack.
 When the service pack has been successfully loaded, the control generates the message:
Remove the USB stick and then press ENT or Return!
 Remove the stick and press the ENT key.
January 2008 26 – 281

 TNC 320 reboots; the service pack is loaded now.
 Check, for example in the code number window, whether the new version of the service pack
is active.
 Finally, check the machine functions!

27 Inspection and Testing Equipment
27.1 Important Notes
Caution
The following inspection, measuring and testing equipment is only intended for a test run
on machines!
DANGER
Observe the safety precautions in chapter 1 of this manual.

--> see “Safety Precautions” on page 1 – 7
Caution
When using the test adapter or the universal measuring adapter, encoder cables, for
example, are no longer continuously shielded.
When using grounded measuring equipment (e.g., oscilloscope with power connection),
always the socket of the machine's electrical cabinet should be used for power supply.
Compensating currents caused by different earth potentials can thus be avoided!
For measuring voltages, the contact should first be established with 0 V and only then the
contact with the voltage to be measured!
Caution
Always observe the operating instructions of the corresponding units PWM 9,

PWT 10/17/18 and IK 215!
January 2008 27 – 283

27.2 Test Adapter
The test adapter ...
Currently has the ID 375830-01.
Is the successor of the "Universal measuring adapter" (see “Universal Measuring Adapter” on
page 27 – 288) and is fully compatible.
Can be connected to all D-Sub and ribbon-cable connectors of HEIDENHAIN devices.
Requires adapter cables.
Has numbered banana jacks to which, e.g., a multimeter can be connected.
Permits signal and voltage measurement during the operation of HEIDENHAIN devices.
Has 5 prepared banana plugs with eyes to be clipped on the measuring lines. These banana
plugs are located at the upper right; if required, they can be plugged into the numbered banana
jacks.

Adapter cable to Each ribbon cable and D-sub connector requires its own adapter cable.
the test adapter
Connecting cable,
ribbon type
50, 40, 34-pin
ID 375833-01
Connecting cable,
ribbon type
26, 20, 16-pin
ID 375833-02
A new and an old version of the D-sub adapter cables are available.
The older version has disadvantages:
The oval-head screws on the D-sub connector reduce the insertion depth.
An adapter connector can/must be used.
More space is required as the adapter connector has a lateral cable outlet and the original
connector must be connected directly to the adapter connector.
D-sub adapter cable

9-pin
ID 255481-01
New version
D-sub adapter cable

9-pin
ID 255481-01
Older version
January 2008 27 – 285

D-sub adapter cable
15-pin
ID 255482-01
New version
D-sub adapter cable

15-pin
ID 255482-01
Older version
D-sub adapter cable

25-pin
ID 255483-01
New version

D-sub adapter cable
25-pin
ID 255483-01
Older version
D-sub adapter cable

37-pin
ID 255484-01
New version
D-sub adapter cable

37-pin
ID 255484-01
Older version
January 2008 27 – 287

27.3 Universal Measuring Adapter
The universal measuring adapter …
Currently has the ID 255480-01.
Is the predecessor of the test adapter.
Cannot be connected to a ribbon-cable connector!
Otherwise functions the same as the test adapter.
The required D-Sub adapter cables are listed in the test adapter section
(see “Test Adapter” on page 27 – 284).

27.4 PWM 9 Encoder Diagnostic Set
General The PWM 9 set currently has the ID 512134-01.

The PWM 9 phase angle measuring unit is a universal testing device for inspecting and adjusting
HEIDENHAIN incremental linear and angle encoders.
PWM 9 is the successor of PWM 8.
PWM 9 combines the functionalities of PWM 8 and PWT (phase angle measuring unit).
The graphic bar display in the PWT MODE facilitates the quantitative and qualitative assessment
of the analog incremental signals and the reference signal. The integrated adjusting aid (PWT
MODE) for exposed encoders is of help for mounting scanning heads.
In the PWM-MODE you can measure on-to-off ratio, phase angle, encoder current consumption
and encoder voltage and configure the settings relevant for PWM 9.
There are different expansion modules available for checking the different encoder signals.
The values can be read on an LCD monitor. Five soft keys provide ease of operation.
Three BNC sockets (A/B/C) are available for checking the encoder output signals on an
oscilloscope (recommended by HEIDENHAIN).
PWM 9 can be connected in series between the encoder and the subsequent electronics.
The axis functions of the machine axes are not influenced.
For inspecting and adjusting HEIDENHAIN measuring systems "at the workplace" PWM 9 can
also be used without subsequent electronics.
January 2008 27 – 289

Available functions The PWM 9 functions consist of the PWT MODE and the PWM MODE.
The most important functions of the PWM MODE:

Display of phase angle and on-to-off ratio
Display of scanning frequency
Measurement of signal amplitude, current consumption and supply voltage of the measuring
system
Display of internal UNIVERSAL COUNTER and of encoder signal periods (pulse count)
Display of reference signal, fault-detection signal and counting direction
Output of amplified scanning signals (interface board: 11 µApp, 1 Vpp) or of the original
scanning signals (TTL, HTL interface board) via 3 BNC sockets (e.g. to an oscilloscope)
The most important functions of the PWT MODE:

Graphic bar display of
Signal amplitude
Signal quality
Width of reference signal
Position of reference signal
Check-Ref function
Adjusting aid for mounting scanning heads of exposed encoders
Checking distance-coded reference marks
Note
Each PWM 9 is delivered with detailed operating instructions.

These operating instructions are available on the Internet in German and in other languages.
They can be downloaded from www.heidenhain.de/Services and Documentation/...
During our training courses on encoders or special PWM 9 trainings the PWM 9 is
explained in detail.
We recommend that you participate in a HEIDENHAIN service training course so that
you can use the PWM 9 correctly and effectively.
Contact HEIDENHAIN Traunreut or your regional agency.

27.5 PWT 10/17/18 Mounting Aid
General The PWT 10/17/18 phase angle testing unit is a mounting aid for scanning heads. The different
signal parameters are combined in one display.
For a detailed assessment of the signal quality, an inspection with PWM 9 is recommended.
Three different PWT versions are available:
PWT 10 encoder diagnostic set for 11 µApp scanning heads, ID 325411-xx
PWT 17 encoder diagnostic set for TTL scanning heads, ID 325412-xx
PWT 18 encoder diagnostic set for 1 Vpp scanning heads, ID 325413-xx
Available functions With PWT it is possible to display the …

Signal amplitude
Signal quality
Position of the reference mark
Width of the reference mark
Note
Each PWT is delivered with operating instructions.

These operating instructions are available on the Internet in German and in other languages.
They can be downloaded from www.heidenhain.de/Services and Documentation/...
A detailed explanation of the PWT is part of our training courses on measuring systems.
January 2008 27 – 291

27.6 IK 215 Adjusting and Testing Package
Current ID number 547858-01.
The IK 215 is an adapter card for PCs for inspecting and testing absolute HEIDENHAIN encoders
with EnDat or SSI interface. Parameters can be read and written via the EnDat interface.
This card serves for example, to program a datum shift in the scanning head of the scale,
i.e. to adapt the position value read by the head to the scale.
Note
Each IK 215 Adjusting and Testing Package is delivered with detailed operating
instructions.
These instructions are also available on the Internet in German and English. They can be
downloaded from www.heidenhain.de/Services and Documentation/...
A detailed explanation of the IK 215 Adjusting and Testing Package is part of our training
courses on measuring systems.
We recommend that you participate in a HEIDENHAIN service training course so that you
can use the IK 215 Adjusting and Testing Package correctly and effectively.
Contact HEIDENHAIN Traunreut or your regional agency.

27.7 Battery Box
The battery box - a device that steplessly outputs a +/- 10 V dc voltage - serves to traverse analog
servos.
This can be very helpful for error diagnosis at analog drives.
Note
HEIDENHAIN does not offer such devices.

You may receive information from the manufacturer of the analog servos!
January 2008 27 – 293

28 Machine Parameters
28.1 Explanation
A contouring control must have access to specific data (e.g., traverse distances, acceleration)
before it can execute its programmed instructions. You define these data in what are known as
machine parameters.
The parameter values are entered in the configuration editor.
The configuration editor contains config objects in a tree structure. The name of a config object
starts with Cfg ....
These config objects contain machine parameters in which, for example, the properties of an
analog axis are defined.
Example:
Properties of an
analog axis in the
configuration editor
The machine settings are saved in parameter files with the extension *.cfg on the three
partitions of the control: TNC:\ , PLC:\ and SYS:\.
Assignments to The control partitions are usually assigned to the following system variables:
system variables
Partition System variable
SYS:\ %SYS%
PLC:\ %OEM%
TNC:\ %USR%
Caution
You should only make changes to the parameter files by using the configuration editor.
Do not edit *.cfg files directly!
January 2008 28 – 295

Classification of the Each config object has a name that gives information about the associated machine parameters.
config objects The parameters are differentiated into system-specific, channel-specific and axis-specific types.
Many objects have “key names” for unique identification.
The following applies:
System data (parameters that are valid for the entire system) only occur once.
The configuration editor does not require a key name for these config objects, nor is one
entered. These objects are identified with an “empty” key in the *.cfg files.
Config objects that apply to axes occur more than once.

A unique key name is assigned to each axis. All objects that apply to a certain axis must be
identified with this key.
Example: The key name “X axis” for all objects that belong to the X axis;
The key name “Spindle” for all objects that belong to the spindle.
Config objects that apply to channels occur more than once.

A unique key name is assigned to each channel. All objects that apply to a certain channel must
be identified with this key.
Example: The key name “Channel1” for all objects that belong to channel 1.

28.2 The Configuration Editor
Important Notes For service purposes, the service technician must not only look up values set in the configuration
editor, but he must also be able to edit them, if required. The configuration editor is protected
against unauthorized editing with a code number.
Please note:
DANGER
Machine parameters may only be changed after consultation with the machine
manufacturer.
Only edit machine parameters while the control is in "power interrupted" status or if
EMERGENCY STOP is pressed.
Machine parameters that concern the control loops may only be edited when
EMERGENCY STOP is pressed!
Note
It is advisable to back up the configuration data (parameter files) before making any
changes in the configuration editor.
It is advisable to create a backup of the machine data on an external data medium, if you
intend to make comprehensive changes to the machine settings.
Subgroups of It is also possible to call subgroups of the original MP list.

the MP List After pressing the USER PARAMETERS soft key, the user parameters released by the machine
manufacturer are available to the operator.
The code number 123 must be entered to make available those parameters that have been
defined by HEIDENHAIN or by the OEM.
PLC options The PLC program from the machine manufacturer can read machine parameters and
overwrite them!
When the PLC overwrites machine parameters, the values are changed in the process memory.
The values of the original MP list (basic data) do not change!
Other configuration files can be selected by PLC (provided that such files exist on the memory
card).
MP subfiles (subgroups of the original MP file, sometimes with different values) can also be
activated by PLC. The MP subfile content is loaded into the process memory. All MP values that
are not in this file remain unchanged.
Note
So it is possible that the values in the original MP list (basic data) are not valid at any rate.
You may have edited values in the MP list for test purposes which, however, are
overwritten by the PLC when special machine functions are run!
If necessary, ask the machine manufacturer which values are active in which special mode
of the machine.
January 2008 28 – 297

Calling the Call the main menu (see figure below) of the configuration editor as described below:
configuration editor
 Enter the code number 95148 or press the CONFIG EDIT soft key.
Note
When you call the configuration editor for the first time the basic data are displayed.

Backing up It is advisable to save the original settings before you make any changes to machine parameters
machine for servicing (troubleshooting, testing, etc.)
parameters
 For this purpose press the DATA BACKUP soft key in the main menu of the configuration
editor.
 The following window appears:
 Press the OK soft key. --> A new window appears in which the name of a ZIP file is suggested,
e.g. BKUP2007-09-07_.ZIP.
You may change this file name, if required.
 Press OK again to confirm the entries. Then press OK a third time to save the ZIP file in the
path PLC:\service\ ...
January 2008 28 – 299

Searching machine  Press the CONFIG DATA soft key. --> The tree structure of the config objects is displayed.
parameters
 Press the FIND soft key. --> A window is displayed in which you can enter the search string.
The current word or a part of the object or machine parameter name may be entered as the
search string. No distinction is made between upper and lower case letters.
 Press the GOTO key. --> The Text input window is displayed, where you can enter letters via
the numerical keys (like when writing an SMS).
Note
If you want to enter longer search strings, it is advisable to connect a USB keyboard. The
USB interface of MC 320 features the "hot-plug capability." This means that you can connect
the USB keyboard while the control is operating. It is ready for operation immediately and can
be disconnected at any time.
 Now select, whether you want to search in forward or in backward direction. --> Place the
cursor on Search forward and press the GOTO key.
 Press the SEARCH soft key repeatedly until you have found the match you require.
Positioning the Within the tree, place the cursor on the requested config object or machine parameter.
cursor Either use the ...
the search function
or
the arrow keys.
To open a branch:
 Press the + key, the ENT key or the ARROW RIGHT key.
To close a branch:
 Press the – key, the ENT key or the ARROW LEFT key.

Icons in the The icon at the beginning of each line in the parameter tree shows additional information about
object tree this line.
The icons have the following meanings:
Branch exists but is closed
Branch is open
Empty object, cannot be opened
Initialized machine parameter
Uninitialized (optional) machine parameter
Can be read but not edited
Cannot be read or edited
Copying, The cursor is on the requested config object or machine parameter.

commenting and
 Press the HELP key. --> On the right half of the screen information on the config object or
editing parameter machine parameter is displayed.
values
Note
If the help text does not fit on one page (1/2 is then displayed at the upper right, for example),
press the HELP PAGE soft key to scroll to the second page.
Additional information, such as the unit of measure, the initial value, or a selection list, is also
displayed.
To exit the help text, press the HELP key again.
 Successively press the soft keys MORE FUNCTIONS / COMMENT / CREATE COPY.
--> A copy of the original value is made.
January 2008 28 – 301

 Now enter a comment (name, date of last change, etc.) and press the OK soft key.
You can clear faulty inputs from left to right with the CE key.
If a USB keyboard is connected, you can also use the backspace key to delete from right to
left.
Note
Machine parameters with copied values and/or comments are displayed on the right side of
the tree and are identified with an . The subordinate config object also contains an .
 Press ENT or ARROW RIGHT. --> A selection window opens.

 Press the GOTO key. --> A selection list or the text input field opens.
 You can edit the parameter this way!
Note
Units of measure can be defined for numeric machine parameters. The unit of measure
assigned to this parameter is displayed. Enter a value appropriate to this unit.
Limit values are displayed for numeric machine parameters. If you attempt to enter a value
outside of these limits, a message is issued and the entry is not accepted.
 After you have edited one or several parameters, press the SAVE soft key to load the changed
values.

Note
Certain data cannot be stored while an NC program is running.

In this event the message Data was not fully saved is displayed together with the error
Cannot change parameter during program run.
The program must be stopped and exited before the data can be saved.
Some data are transferred directly.
Others require that the axes be referenced again, or that the system be restarted. This is
indicated in a corresponding message.
If the error message Data change without effect is generated while the changed config objects
or machine parameters are being saved, these machine parameters are superimposed in the
process memory. In most cases this happens by means of MP subfiles that are activated by the
PLC program of the machine.
How can you proceed?
 Use the END soft key to exit the basic data.
 Press the SELECT DATA RECORD soft key.
 Press the GOTO key and place the cursor on Temporary data.
 Press OK and then again the CONFIG DATA soft key.
 Now edit the desired config objects and machine parameters in the temporary data.
--> These changes will have an effect on the machine!
Note
To check, whether the edited values were correctly processed by the control, press the
SELECT DATA RECORD soft key again, select effective data and call the configuration
editor.
Reaction to change The following reactions can occur when machine parameters are changed:
NOTHING
RUN
RESET
REF
Reaction NOTHING
Parameters with this reaction can be changed at any time, including during program run.
Reaction RUN
Changes are only possible during a PLC strobe or NC stop.
Reaction RESET
After a machine parameter to which this reaction is assigned has been changed, the error
message Machine parameters were changed. Shut down and restart the control.
is displayed.
This message cannot be cleared. The machine must be restarted. (However, further parameters
can be edited before the restart.)
Parameters with this reaction must not be changed during program run.
Reaction REF
After a machine parameter connected to this reaction has been changed, the affected axis is set
to "not referenced".
A new reference run must be made for this axis.
Parameters with this reaction must not be changed during program run.
January 2008 28 – 303

Switching In the configuration editor the display can be changed from tree view to table view.
between screens Advantage of the table view: Values of several axes can be compared in this view.
 Place the cursor on a config object or a machine parameter.
 Press the VIEW TABLE TREE soft key.
 The table view is activated, as in the example below:
Operating the If the machine manufacturer agrees that the machine should be operated with the new
machine with settings...
the new values
 Back up the MP list in question, see “Backing up machine parameters” on page 28 – 299.
Possibly add your name (or the name of the responsible person) and the date of change.
 Create a new backup of the machine data. --> see “Data Backup on External Data
Medium” on page 12 – 113!!!
Restoring the When you have finished error diagnosis or various tests at the machine, you will normally restore
original values the original settings.
 For this purpose press the DATA BACKUP soft key in the main menu of the configuration
editor.
 In the window that is displayed now, place the cursor on Activate parameter files from
backup.

 Press the OK soft key. --> A window is displayed that contains one or several ZIP files.
Select the last active settings, for example BKUP2007-09-07_.ZIP.
 Press OK repeatedly until the saved values are activated.

 Restart the control.
January 2008 28 – 305

1 Annex: Monitoring Functions
1.1 Introduction
TNC 320 features comprehensive monitoring functions.
Values are defined for axis positions and dynamic response of the machine. If the specified
values are exceeded, the control displays an error message and stops the machine.
DANGER
Active monitoring functions are essential for safe machine operation!

Safe machine operation is not possible if the monitoring functions are switched off.
Uncontrolled axis movements are not detected.
Deactivated monitoring functions or changed tolerance values may result in damage to
persons or equipment.
You must not switch off any of the monitoring functions!
In this chapter you can look up which monitoring functions exist and how they are defined.
1.2 During Start-Up
EMERGENCY In the event of hazardous errors the control switches off the Control-is-ready output.
STOP test An EMERGENCY STOP must be generated. --> The EMERGENCY STOP chain must be
interrupted.
Since this is a function important for the safety on the machine, it is checked via the
EMERGENCY STOP test every time the line power is switched on.
Note
The circuitry recommended by HEIDENHAIN is illustrated in the Basic Circuit Diagram.

The Control-is-ready signal acknowledgment has to occur within 1 s.
January 2008 1–1

Flowchart
X41/34
X42/4
1 2 3 4 5 6 7 8 9
Step Function Screen display

1 Waiting for machine control voltage RELAY EXTERNAL DC VOLTAGE
MISSING
2 Recognition of the machine control voltage
at input X42/4 and switch-off of the control-is-
ready signal at output X41/34 by host computer
(t < 66 ms)
3 Maximum time within which the control-is-ready If exceeded:
acknowledgment on X42/4 must go to zero EMERGENCY STOP defective
(t < 380 ms)
4 Recognition of acknowledgement and setting of
X41/34
5 Waiting for machine control voltage RELAY EXTERNAL DC VOLTAGE
MISSING
6 Normal operation of control; “Control-is-ready”
output and acknowledgment are high
7 Control voltage is switched off externally EXTERNAL EMERGENCY STOP
8 After switching on again, the machine control
voltage can be switched off, and then the control
operates normally
9 After detecting a fault, the control switches off the Error message (reset error)
control-is-ready output (X41/34)
1.3 During Operation

During operation, the TNC 320 monitors:
Amplitude of encoder signals
Edge separation of encoder signals
Absolute position for encoders with distance-coded reference marks
Current position (position monitoring or following-error monitoring)
Actual path traversed (movement monitoring)
Position deviation at standstill (standstill monitoring)
Checksum of safety-related functions
Power supply
Buffer battery voltage
Operating temperature of MC and CPU
Run time of the PLC program
If the "Control is ready" signal output and the "Control is ready" signal acknowledgment input are
correctly connected to the emergency-stop loop, the control interrupts the loop via the "Control
is ready" signal output as soon as a hazardous error occurs.

1.4 EMERGENCY STOP Monitoring
On the control there is a PLC output (X41/34) with the designation “control-is-ready,” and a PLC
input (X42/4) with the designation “control-is-ready-acknowledgment” for the EMERGENCY
STOP loop.
If a functional error is detected in the control, the control switches the control-is-ready output
off. An error message appears and the PLC program is stopped. You cannot clear this error
message:
 Correct the error and restart the power-on routine. --> see “During Start-Up” on page 1 – 1
If the control-is-ready-acknowledgment input is switched off by a process external to the control,
the error message EXTERNAL EMERGENCY STOP appears.
The NC sets NN_GenNcEmergencyStop. The nominal speed value 0 is output and the drives
are switched off. You can clear this error message after switching the machine control voltage
back on.
The “control-is-ready signal acknowledgment” input is passed directly onto the NC; it cannot
be manipulated by the PLC (I3).
Set
MNN_GenNcEmergencyStop
Control in “external emergency stop” state
0: Control is not in external emergency stop state
1: Control is in external emergency stop state
January 2008 1–3

1.5 Position or Following-Error Monitoring
Settings in the configuration editor:
Axes
ParameterSets
Key for parameter set
CfgPosControl
servoLagMin1
servoLagMax1
servoLagMin2
servoLagMax2
CfgControllerAuxil
driveOffLagMonitor
CfgReferencing
endatDiff
The axis positions are monitored by the control as long as the control loop is closed.
The input values for position monitoring depend on the maximum possible following error (servo
lag). Therefore the input ranges for operation with following error and velocity feedforward are
separate.
For both modes of operation there are two range limits for position monitoring.
If the first limit (MP_servoLagMin1, MP_servoLagMax1) is exceeded, the warning Excessive
servo lag in [axis] appears. The machine stops.
This message can be cleared. An actual-to-nominal value transfer is then executed for the
respective axes.
If the second limit (MP_servoLagMin2, MP_servoLagMax2) is exceeded, the emergency-stop
error message Excessive servo lag in [axis] appears.
The control-is-ready signal output is reset. The machine stops. You cannot clear this message.
You must restart the control to correct the error.
With the attributes given below, the machine manufacturer defines two range limits for position
monitoring. He adjusts the input values to the machine dynamics.
Sa (V)
servoLagMax2
v
servoLagMax1
servoLagMin2
servoLagMin1
servoLagMin1/2 applies for constant feed rates, servoLagMax1/2 during changes in feed rate.

MPservoLagMin1
Minimum for following-error monitoring (clearable)
Format:
Input: 0.000 000 000 to 100 [mm] or [°]
1 [mm] or [°]
MPservoLagMax1
Maximum for following-error monitoring (clearable)
Format:
Input: 0.000 000 000 to 100 [mm] or [°]
5 [mm] or [°]
MPservoLagMin2
Minimum for following-error monitoring (emergency stop)
Format:
Input: 0.000 000 000 to 100 [mm] or [°]
1 [mm] or [°]
MPservoLagMax2
Maximum for following-error monitoring (emergency stop)
Format:
Input: 0.000 000 000 to 100 [mm] or [°]
5 [mm] or [°]
Clamped axes, Clamped axes or hanging axes are monitored when the drive motor is switched off if
hanging axes driveOffLagMonitor is activated. The value from servoLagMax2 is monitored.
MPdriveOffLagMonitor
Following-error monitoring with drive switched off
Format:
On
Monitoring of hanging axes is active
Off
Monitoring of hanging axes is not active
Off
Note
The monitoring functions for hanging axes cannot be switched off with
I32stopsMonitoring.
Difference between When the control is switched off, the actual position of the axes is saved with an absolute
position at switch- encoder. During switch-on it is compared with the position values read by the encoder.
on and shutdown
If the positions differ by more than the difference defined in MP_endatDiff, a pop-up window
appears with both positions. The new position must be confirmed with a soft key. If it is not
confirmed, the error message Check the position encoder <axis> appears.
January 2008 1–5

The pop-up window may appear, stating that the positions at switch-on and shutdown differ by
more than MP_endatDiff. If the motor is located at the correct position, you can confirm the
message.
Note
The cause for one of the above listed messages can also be a defect in the encoder or
control.
MPendatDiff
Permissible difference of EnDat encoders during switch-on
Format:
Input: -100 000.000 000 000 to +100 000 [mm] or [°]
0 = Off
Default: 0

1.6 Movement Monitoring
Settings in the configuration editor MP number

Axes
ParameterSets
[Key name of the parameter set]
400705
CfgEncoderMonitor 400706
movementThreshold
thresholdDistance
Movement monitoring is possible during operation both with velocity feedforward and with
following error.
If the MP_movementThreshold parameter is set to a value greater than 0, the manipulated
value of the position controller is totaled in the IPO clock as soon as the threshold configured in
the parameter is exceeded. In MP_thresholdDistance you enter the distance at which the
comparison is to be performed, and so define the monitoring cycle.
The control now calculates a nominal path and compares it with the actual path traversed after
every 5 mm.
An error message is output if the actual path traversed is…
less than a quarter of the nominal path
or
four times greater than the nominal path.
If the encoder is defective, the axis moves no more than the distance defined in
MP_thresholdDistance.
Intentional movements smaller than indicated in MP_movementThreshold are ignored.
 In MP_movementThreshold, enter the distance over time at which movement monitoring is
to start.
 Enter in MP_thresholdDistance the distance at which the nominal and actual paths are to be
checked.
Caution
If MP_movementThreshold = 0 movement monitoring is not active.
Threshold as of which movement monitoring becomes active
0.000 000 000 to 36 000 000 [mm/min] or [°/min]

0: Monitoring switched off
5 [mm/min] or [°/min]
Tolerance at and above which the following error is included
0.000 000 000 to 36 000 000 [mm] or [°]

5 [mm] or [°]
January 2008 1–7

1.7 Standstill Monitoring
Axes
ParameterSets
CfgControllerAuxil
checkPosStandstill
Standstill monitoring is effective during operation both with velocity feedforward and with
following error, as soon as the axes have reached the positioning window.
If the position deviation is greater than the value defined in MP_checkPosStandstill, the blinking
error message Standstill monitoring in [axis] appears. The message also appears if, while
moving to a position, an overshoot occurs that is larger than the value entered in
checkPosStandstill, or if the axis moves in the opposite direction when beginning a positioning
movement:
 In checkPosStandstill, enter a threshold from which the standstill monitoring should go into
effect.
MPcheckPosStandstill
Standstill monitoring
Format:
Input: 0.001 000 000 to 10 000 [mm]
10 000 [mm]

1.8 Positioning Window
Axes
ParameterSets
CfgControllerTol
posTolerance
timePosOK
The config object CfgControllerTol is not required for:

Virtual axes (axisMode=Virtual)
Axes that are for display only (axisMode=Display)
If the axes have reached the positioning window after a movement, the status is shown
in NN_AxInPosition. This also applies to the status after the machine control voltage is
switched on.
The NC resets NN_AxInPosition as soon as you start a positioning movement or traverse the
reference marks.
In the EL. HANDWHEEL mode of operation NN_AxInPosition for the current handwheel axis
is reset.
NN_AxInPosition is not set for contours that can be machined with constant surface speed.
DANGER
Incompatibility with earlier TNC controls!

When an NC program is run, the TNC 320 does not set the operand NN_AxInPosition until
the beginning of the following NC block. It is not set at the end of the current block! Example
of Program Run, Single Block mode of operation:
Program:
.....
N5 L W+30
N6 L X+10
N7 L W+60
.....
If the block N5 is run in Single Block mode,
the program cursor is located on block N6.
the W axis is located at +30.
the status of the operand is:
NN_AxInPosition = 0
In this example the PLC clamps the W axis and the marker NN_AxInPosition is set. But the
marker is not set until the next block N6 is run. (With earlier TNC controls, the marker is
already set at the end of block N5.)
Please take this status into account in your PLC program.
Axes in position The control reports that the axis is in position (NN_AxInPosition) when the axis has remained
within the positioning window MP_posTolerance for the period of time defined in
MP_timePosOK. After the position has been reached, the control begins running the next block.
The position controller can correct a disturbance inside this window without activating the
“Return to the Contour” function.
 In MP_posTolerance, define the size of the positioning window.
 In MP_timePosOK, define the period of time which the axis is to remain within the positioning
window.
January 2008 1–9

MPposTolerance
Positioning window
Format:
Input: 0.001 000 000 to 2 [mm]
0,005
MPtimePosOK
Hysteresis time reached for positioning window
Format:
Input: 0.000 000 000 to 20 [s]
0.01 [s]
Set
MNN_AxInPosition Axes in position

0: Axis not in positioning window
1: Axis in positioning window
Axes in motion During an axis movement, the NC sets NN_AxInMotion.
Set
MNN_AxInMotion Axes in motion

0: Axis not in motion
1: Axis in motion

1.9 Temperature Monitoring
Temperature The internal temperature of the MC is continuously monitored. At about 55 °C the early warning
of the MC Temperature warning appears. If the temperature does not fall below 55°C, the warning is
reactivated after two minutes. Beginning at about 60 °C the error message Temperature too
high <temperature> °C appears and an emergency stop is triggered. If the temperature does
not fall below 60 °C when the machine is switched on again, the error message reappears after
10 to 20 seconds.
January 2008 1 – 11
2 Annex: Principle of Function of the TNC 320 Control
2.1 Introduction
This chapter gives you brief explanations of the principle of function of the TNC 320 control.
Of course fundamental knowledge about controls, encoders, drives, electronics and mechanics
simplifies error diagnosis and is often indispensible for successful servicing.
Please ask your machine manufacturer for detailed or special explanations (e.g., machine
functions, circuit diagram of the machine)!
2.2 Block Diagrams with Brief Explanations
The control loop Machine tools normally function on the principle of cascade control. Here the position control
for analog axes / loop is prior to the speed and current control loops.
spindle
Benefits of cascade control:
Transparent structure of the individual control loops.
Disturbances can be compensated through the subsequent controllers.
This relieves the prior controller.
The respective outer control loop protects the inner control loop by limiting the command
variable.
The position controller is integrated in the control. The speed controller, current controller and
power module are located in the servo amplifier. The speed command signal is sent by the
control to the servo amplifier through an analog interface.
Nominal and actual The position controller receives its nominal value, e.g., from the NC program; the actual value
values for the is normally provided by a linear encoder (scale). In the machine parameters is set, at which
controllers position the machine table is after how many counting pulses.
The speed controller receives its nominal value from the position encoder. Thus the output
quantity of the position controller is the input quantity of the speed controller. This is why this
interface is also referred to as "nominal speed command interface". With analog axes, the control
leads the nominal speed command interface (±10 V) "to the outside" to the analog servo
amplifier.
The actual speed value is determined by means of a speed encoder (tachometer, motor encoder)
in or on the motor.
January 2008 8 – 13
The current controller receives its nominal value from the speed controller. The actual value is
provided, e.g., by current sensors in the power module.
The interpolator The interpolator operates at a prescribed clock rate. The axis-specific nominal position values are
calculated at this clock rate from the feed rate profiles transferred by look-ahead.
The position The position controller uses the axis-specific nominal position values transferred by the
controller interpolator. The nominal speed values are determined and transferred to the speed controller.
The control operates with following error (servo lag) or with velocity feedforward. The setting is
made in the config object CfgPosControl / attribute feedForwardFactor.
If feedForward=0, operation with 100% following error is in effect.
feedForward>0 activates velocity semifeedforward control (for analog axes).
If feedForward=0, operation with 100% velocity feedforward is in effect.
Position feedback Following error (also known as servo lag) is a gap that remains between the nominal position
control with commanded by the NC and the actual position of the axis.
following error
Simplified representation:
The nominal position value snoml for a given axis is compared with the actual position value sactl
and the resulting difference is the following error sa:
sa = snoml – sactl
sa = Following error
snoml = Nominal position value
sactl = Actual position value
The following error is multiplied by the kv factor and passed on as nominal velocity value:
v = kv · sa
vnoml = Nominal velocity value
kv factor during The loop gain, known as the kv factor, defines the amplification of the position control loop.
control with
The kV factor is defined by the machine tool builder.
following error
For axes that are interpolated with each other, the kv factors must be equal to prevent contour
deviations.
2– 14 HEIDENHAIN Service Manual TNC 320

Interrelation of The following formula shows the interrelation of kv factor, feed rate, and following error:
kv factor, feed rate,
and following error v v
k v = ----e- or s a = ----e-
sa kv
kv = kv factor [(mm/s)/mm]
ve = Rapid traverse [mm/sec]
sa = Following error [mm]
MPkvFactor
kv factor (proportional component of the position controller)
Format: Number
Input: 0.000 000 000 to 1000 [1/s]
Feedback control For feedback control with velocity feedforward, the nominal velocity value consists of an open-
with velocity loop and a closed-loop component.
feedforward
The machine-adjusted nominal velocity value is the open-loop controlled component. The
closed-loop velocity component is calculated through the following error. The following error is
small.
In most cases, machines are controlled with velocity feedforward, since it makes it possible to
machine exact contours even at high speeds.
From the value of feedForwardFactor you can see, whether the machine is operated with
feedforward control or with following error. --> For velocity feedforward control the value is
greater than zero.
Unlike operation with following error, the machine manufacturer sets the optimum kv factor for
each axis for operation with interpolating axes.
January 2008 8 – 15
2.3 Basic Circuit Diagrams
TNC 320 with Analog Drive System
In preparation

2.4 Interchange Possibilities on TNC 320
Note
For details, constraints and specifics, see see “Encoder Interface” on page 16 – 171 and see
“Interface to the Analog Drives” on page 19 – 199.
Note
Always exchange both, the cable and the interface assignment by means of machine
parameter!
January 2008 8 – 17
638142_00_a_01.pdf 2 11.12.2007 08:07:01

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January 2008 HEIDENHAIN Service Manual TNC 320

HEIDENHAIN Service Manual TNC 320

January 2008 HEIDENHAIN Service Manual TNC 320

HEIDENHAIN Service Manual TNC 320

Ensure that the equipment grounding conductor is continuous!

In order to be able to judge the behavior of an NC controlled machine, service engineers

HEIDENHAIN assumes no liability for indirect or direct damage caused to persons or

National regulations for power installations must be adhered to!

January 2008 1–7

These boxes contain important and useful information.

1–8 HEIDENHAIN Service Manual TNC 320

2.1 About this Manual

This manual is valid for:

Update service This Service Manual is updated at irregular intervals.

January 2008 2–9

It is extremely important that you read the safety precautions in chapter 1!

2 – 10 HEIDENHAIN Service-Handbuch TNC 320

Example:  Select the Programming mode of operation.

 Enter and confirm the code number.

3 – 12 HEIDENHAIN Service Manual TNC 320

The machine manufacturer can define his own code numbers!

Type of error PLC error messages

Operating-system error messages

Display of an Error messages are displayed...

Reaction of Display only

4.2 Error Window

4 – 16 HEIDENHAIN Service Manual TNC 320

 Press the DELETE soft key (or the CE key).

To delete all errors listed in the error window:

Overview of error handling in the control:

Error class Reaction Display Log file Ack- Error

4 – 18 HEIDENHAIN Service Manual TNC 320

Ev_class_18 is used to report that service files were saved.

4 – 20 HEIDENHAIN Service Manual TNC 320

4 – 22 HEIDENHAIN Service Manual TNC 320

5.2 Overview of Possible Errors

Error Possible Error Cause Measures for Error Diagnosis and/

5 – 26 HEIDENHAIN Service Manual TNC 320

6.2 Sequence for Finding Errors in the Control Loop

If you need information on lubrication, mechanics, hydraulics, pneumatics, brakes, coupling

Inspection of lubrication, tools, mechanics, e.g.:

Lubrication, NO Ensure proper lubrication,

Inspection of hydraulics, pneumatics, brakes with e.g.:

Inspection of coupling system, e.g.:

Inspection of drive system, e.g.:

Inspection of control, e.g.:

Call machine tool manufacturer or a HEIDENHAIN service agency.

6 – 30 HEIDENHAIN Service Manual TNC 320

 Interchanging interface assignments of position encoders -->

 Interchanging interface assignments of analog axes -->

 Interchanging identical servos and motors -->

6.4 Error Localization by Process of Exclusion

 The monitor remains dark after the machine is switched on -->

 Errors occur that concern the handwheel -->

 Errors occur that concern a certain axis -->

Switch off the machine.

Disconnect the encoder for the axis

Press the EMERGENCY STOP button and

Do not acknowledge the Power interrupted

In the attribute axisMode, select NotActive

The errors are not limited to one axis!

The PLC program may prohibit the deselection of individual axes.

Interchanging interface assignments of position encoders -->

Interchanging interface assignments of analog axes -->

Interchanging identical servos and motors -->

The monitor remains dark after the machine is switched on -->

Errors occur that concern the handwheel -->

Errors occur that concern a certain axis -->

All entries show the date and the local time.

Tasks of the PLC Interfacing of various types of machines to HEIDENHAIN controls