Service Manual

TASC 200
Service Manual

TASC 200

Edition 03/99
 Please state title of document, desired language and date of
Ordering Information edition.

TRUMPF GmbH + Co.

D-71254 Ditzingen
Johann-Maus-Straße 2
Telephone (07156) 303-0
Telefax (07156) 303-309, Telex 7245201
Internet: http://www.trumpf.com
E-mail: [email protected]

This document was compiled by the Technical Documentation Dept. of TRUMPF

GmbH + Co.

All rights, in particular the right to reproduce, distribute or translate this

documentation, are reserved to TRUMPF GmbH + Co, even in case of patent and
industrial rights applications. No part of this documentation may be reproduced,
processed, duplicated or distributed by means of electronic systems in any form
whatsoever without the prior written consent of TRUMPF GmbH + Co. Subject to
errors and technical changes.

 TRUMPF GmbH + Co.

TRUMPF GmbH + Co. cannot be held responsible for possible mistakes in this
documentation. Any warranty for direct and indirect damages, arising in connection
with the delivery or the use of this documentation, is excluded, as far as this is in
conformity with the law.
 Before You Proceed...

Control system series Fast and dependable information processing coupled with easy
programming and operation are just some of the features of the
controller concept as developed by TRUMPF for their machines :

T A S C

TRUMPF Advanced Specialised Control

The TASC series comprises the following controls, differentiated

according to design and scope of function:

TASC 100 Control for TRUMPF automation components and handling

systems. Serves to control the:
• TRUMATOOL
• TRUMASORT
• TRUMALIFT SheetMaster

TASC 200 Control system for TLF lasers

TASC 250 PLC control with SERCOS interface for PalletMaster

TASC 300 Operating panel for the TASC 300 laser control

TASC 500 TRUMPF-CNC control for laser machines of the TLC 105 and
L5005 series

TASC 900-010 Controller for operating and monitoring functions

TASC 900-500 Controller for operating and monitoring TRUMPF Drilling and
Routing Centers

H120E0.DOC Before You Proceed... 0-5

 Contents This manual addresses itself to persons entrusted with TASC 200
service and maintenance. The structure and function of the
controller are documented here. The appendix is intended as a
personal collection of service documentation on the TASC 200.
Jumper and spare parts lists are provided with the manual.

Notes on format Operating sequences at the control are indicated as follows:

• Step 1 ... (starting from the main menu in that mode)
• Step 2 ...
• Step 3 ...

Special symbols and a uniform format throughout the manual

facilitate explanations:

Menu function with information on activation. In this example, menu

function I/O DIAGNOSTICS is accessed by first activating LASER
DIAGNOSTICS. Menu functions within the text are identified by
capital letters.

Keys at the operator’s panel of the control.

Keys on the keyboard of the operator’s panel are identified by <...>,

Example: <ENTER>

Notes and important remarks

[...] Necessary inputs are indicated between square brackets, e.g.:

[autoexec]: Type the word "autoexec" at the keyboard.

Reference Guides • TASC 200 User’s Guide

• Operator’s manuals for the laser and RF generators
• Service Manual for the laser

0-6 Before You Proceed... H120E0.DOC

 Table of Contents

Chapter 1 Components

1. Overview of Hardware Modules.................................... 1-3

2. Backplane ....................................................................... 1-4

3. Power supply unit .......................................................... 1-6

4. KSP M17 Board............................................................... 1-8

5. Motherboard ................................................................. 1-11

6. Bitbus Modules ............................................................ 1-14

7. Process I/O.................................................................... 1-16

8. 32 Bit I/O Boards .......................................................... 1-19

9. Control panel: TASC 300 ............................................. 1-22

10. TCO-HF1 PCB ............................................................... 1-24

Chapter 2 Software

1. Software Modules .......................................................... 2-3

2. EPROM slots................................................................... 2-5

3. Software exchange ........................................................ 2-7

3.1 Exchanging EPROMS ...................................................... 2-7
3.2 Exchanging Melcards ....................................................... 2-8
3.3 Changing software on the TASC 300............................... 2-9

4. Software Releases and Versions................................ 2-13

H120E0.DOC Table of Contents 0-7

 Chapter 3 Controller Processing Routines

1. Bus systems ................................................................... 3-2

2. Overview: Interfaces ...................................................... 3-4

Chapter 4 Diagnostics

1. Power-up cycle............................................................... 4-3

2. Troubleshooting from the operation environment ..... 4-7

3. Troubleshooting by means of LEDs ............................ 4-9

4. I/O Diagnostics at TASC 300 Terminal ....................... 4-13

5. Telegram Diagnostics.................................................. 4-15

5.1 Viewing telegrams received and transmitted.................. 4-15
5.2 Status Telegrams ........................................................... 4-18

6. Diagnostic functions for the RF generator................ 4-19

7. Diagnostics via machine data..................................... 4-21

8. Logbook errors............................................................. 4-22

9. Incorrect machine data................................................ 4-22

10. Serial number ............................................................... 4-23

Chapter 5 Settings and Routine Maintenance

1. Changing the hardware ................................................. 5-3

2. Examining the power supply module (ID 105495) ...... 5-4

0-8 Table of Contents H120E0.DOC

 3. Modifying machine data ................................................ 5-5

4. Control Reset.................................................................. 5-8

5. TASC 300: Changing to the operating system level... 5-9

6. Setting the language...................................................... 5-9

7. Special diagnostic tool: Service Card........................ 5-10

8. Changing batteries....................................................... 5-11

8.1 Motherboard ................................................................... 5-11
8.2 TASC 300 Terminal........................................................ 5-12

9. Calibration curves for TLF lasers ............................... 5-14

Chapter 6 Setup

1. Setup ............................................................................... 6-2

2. TASC 300: Setup ............................................................ 6-4

3. Setup of DIAS height regulation with

Lasermatic 1.5 ............................................................... 6-6

Chapter 7 Schematics

Interface description

Bitbus connections

Jumper lists

Safety circuit

RF generator

DIAS I with Lasermatic 1.5

H120E0.DOC Table of Contents 0-9

 Chapter 8 Error messages

0-10 Table of Contents H120E0.DOC

 Chapter 1

Components
1. Overview of Hardware Modules.................................... 1-3

2. Backplane ....................................................................... 1-4

3. Power supply unit .......................................................... 1-6

4. KSP M17-Board .............................................................. 1-8

5. Motherboard ................................................................. 1-11

6. Bitbus Modules ............................................................ 1-14

7. Process I/O.................................................................... 1-16

8. 32 Bit I/O Boards .......................................................... 1-19

9. Control panel: TASC 300 ............................................. 1-22

10. TCO-HF1 PCB ............................................................... 1-24

H120E1-2.DOC Components 1-1

 The TASC 200, as is the case of all TRUMPF controllers, is based
on a modular concept. The components may be classified into
various functions groups:

Functions groups • Controller housing with backplane, ventilator assembly

• Power supply modules
• Processor PCB’s (KSP M17 board, Process CPU for height
regulation, TCO-HF1 module)
• Module for signal compilation and distribution:
32 Bit I/O PCB’s
Process I/O board
Bitbus module
• Motherboard for system monitoring:
• Motherboard
• Two options are available for the user interface of the TASC
200: either the panel of the CNC control (TASC 500 or BOSCH
CC220/CC 320) or the TASC 300, a control panel specially
developed for this application.

1-2 Components H120E1-2.DOC

 1. Overview of Hardware Modules

1 2

+ 5
+ 1 2
-1 2
3

1 0 9 8 7 6 5

1 24V Power supply for ventilator 6 KSP M17 board

2 Ventilator assembly 7 Socket for second I/O card (BCD
interface, i.e. digital interface)
3 Bitbus module to CNC control
8 I/O board
4 Bitbus module to RF generator
9 Process I/O
5 Motherboard
10 Power supply unit

TASC 200 (configured for TC L3030) Fig. 16788

H120E1-2.DOC Components 1-3

 2. Backplane

The backplane is the central bus PCB for the controller. This is a 6-
layer multi-board which may be fitted with components on both
sides using either the press or soldering techniques. This Printed
Circuit Board has the primary function of establishing the electronic
signal transfer circuits required for correct controller function.

Bus Systems This PCB carries two bus systems (see Controller Processing
Routines), and all necessary power supply lines.

AMS Bus The AMS bus features a total of 5 slots. Of all the modules used for
the TASC 200, the Motherboard, KSP M17 Board and the power
supply unit are interfaced with the AMS bus.

SMP Bus The SMP bus serves as the communication medium for processor
card KSP M17 and the modules for signal input and output (I/O
cards, Process I/O with piggy-back modules).

Voltages at test connector Pin a b c

X2 (AMS Bus)
1
...
10
11 +5 V
12 +5 V +12 V +12 V
13 GND
14 +5 V -12 V -12 V
15 +5 V
16
...
32

Voltages at test connector Pin a b c

X1 (SMP Bus)
1 -12 V
2 GND
3 +5 V
11
...
30
31 GND
32 +5 V +12 V

1-4 Components H120E1-2.DOC

 1

1 AMS Bus slots (X2) 2 SMP Bus slots (X1)

Bus systems on the backplane Fig. 7923

H120E1-2.DOC Components 1-5

 3. Power supply unit

2
3
4

1 LED +5 V OK 4 LED -12 V OK

2 LED +12 V OK 5 Potentiometer -12V...-15V
3 Potentiometer +12V...+15V 6 Fuse M 3,15A
Power supply unit until 09/97 (ID 105495) Fig. 7906

1 2 3

1 LED +5 V OK
2 LED +12 V OK
3 LED –12 V OK
Power supply unit from 10/97 (ID 143161) Fig. 20529

A SIEMENS power supply unit is used on the TASC 200. This

module supplies and monitors all the voltages required for controller
function.
• +12V DC ± 10 %
• -12V DC ± 10 %
• +5V DC ±5%

1-6 Components H120E1-2.DOC

 Power supply unit Effective October 1997, the TASC 200 will have a new power
from 10/97 supply unit (ID 143161). In terms of connections and functionality,
this module offers full downward compatibility. The old unit can
therefore be replaced without any hardware modifications.
The primary power circuit (network input) is protected electronically.
No more visible-type fuse is used. The cover of the power supply
system may no longer be opened and is therefore fixed with a rivet.

Technical data This power supply module is normally designed for connection to a
single-phase AC system of 230 V. All output voltages are short-
circuit-proof and stable at no load.

ID 105 495 ID 143161

Input values
AC input voltage 187 - 264V 88 - 264V
93 - 132V internal changeover
Input frequency 47 - 63 KHz 47 - 63 KHz
Efficiency at full load ≥ 70% ≥ 70%
Inrush current limit standard, < 35 A at ≤ 27 A
Uε = 230 V, Tu = 25 °C
Recommended fuse 5SN1 006-8B, U-Automat, 6A -
Input current at full load UN = 115 V: 1.8 A
UN = 230 V: 1.0 A 1.2 A
Output values
DC output voltage V1 V2 V3 V1 V2 V3
5.1 V +12...15 V -12...15 V 5.1 V +12 V -12 V
(V2 and V3 can be set via
potentiometer on front panel)
DC output current 10 A 1.5 A 1.5 A 10 A 1.5 A 1.0 A
Ripple content ≤ 50 mVSS ≤ 50 mVSS ≤ 180 mVSS < 0.5% < 0.5% < 0.5%
Interference voltage in 0 - 30 Mhz range < 250 mVSS < 120 mVSS < 120 mVSS < 1% < 1% < 1%
Dynamic response
Control precision, static ≤ ±0.2 % ≤ ±0.2 % ≤ ±0.2 % ±3 % ±3 % ±3 %
Control precision, dynamic ≤ ±5 % ≤ ±2 % ≤ ±2 % ±3 % ±3 % ±3 %
Sudden load variation 50...100%, ≤ 2 msec ≤ 3 msec ≤ 3 msec 2 msec 2 msec 2 msec
recovery time
Protection and monitoring functions
Current limitation > 10.5 A > 1.7 A >1.7 A > 10.5 A > 1.7 A >1.5 A
Uε limitation standard standard
Mains buffering > 30 ms (rated voltage, full load) >120 msec (230 V)
> 80 msec (187 V)
Power-Fail signal Open-Collector, low active < 0.6 V, Open-Collector, low active
max. 50 mA, cut-off voltage max. 30V
Buffer period after Power Fail ≥ 3 msec > 3 msec
Integrated fuse M 3.15A in primary circuit, 5 x 20 mm electronic
Ambient temperature during operation 0 - 70 °C 0 - 55 °C

H120E1-2.DOC Components 1-7

 4. KSP M17-Board

4 9

1 0
5
1 1
1 2

1 RAM chips 5 Processor 8031 9 EEPROM sockets

2 LEDs 6 Interface X4 (laser panel) 10 EPROM socket (interface)
3 Melcard (software) 7 AMS-Bus connector 11 SMP-Bus connector
4 Interface X5 8 Gold foil capacitor 12 Processor 80186

KSP M17-Board Fig. 16731

1-8 Components H120E1-2.DOC

 The KSP M17-Board assumes all central control and monitoring
functions for the TASC 200. The necessary application software
and the operating system are stored on a Melcard (memory card).

OTPROM Melcard Until about October 1997, an OTPROM-Melcard was used as the
data medium. New software can be programmed to this card only
twice.

New: As of November 1997, the software is stored on a FLASH-

FLASH-EEPROM-Melcard EEPROM-Melcard which can be reprogrammed with software as
often as required. The existing Melcard must be sent to TRUMPF
for software updates.

A static RAM (1 MB) serves as the working memory. Portions of

this RAM (laser operation and maintenance data), are buffered by a
3V battery on the Motherboard. A gold foil capacitor buffers the
RAM against data loss for approx. 10 min. in case of a power
failure. The data in the RAM is automatically saved to EEPROM
every two hours.

All memory addresses not used by this PCB are addressed by the
AMS bus and accessed through the AMS bus.

The SMP bus can be addressed through an address window above

the local RAM area for the data. This is an address area of 64 KB
and is reserved for communication via the SMP bus.

There are two serial ports (V24) on this PCB, these being two 25-
pin D-subminiature sockets at the front of the PCB. On the TASC
200, the bottom port serves as the interface for communicating with
an external panel (TASC 300) (V24 with LSV2 protocol).

The upper interface is used for diagnostic purposes (debugger for

RMOS system, printer interface).

The AmZ8530A interface is served by a dedicated processor

(8031) and can run in both synchronous and asynchronous modes.

A Watchdog circuit monitors the card and energizes an LED if a

fault occurs. A bus time-out circuit prevents bus blockage in case of
unauthorized AMS bus address access. A 8259A interrupt
controller is present.

H120E1-2.DOC Components 1-9

 Technical Data Processor 80186 (16 Bit, 16 MHz)
Cycle time: 5 ms
Operating system: RMOS (Realtime
Multitasking Operating System
Memory capacities: 1 MB SRAM
512 KB PROM on Melcard
512 KB FLASH-EEPROM on Melcard
Transmission rates 1 MB/s (synchronous mode)
19.2 KB/s (asynchronous mode)
Input frequency 5SN1 006-8B, U-Automat, 6A
Efficiency at full load UN = 115 V: 1.8 A
UN = 230 V: 1.0 A
Power supply +5 V ± 5% type 3.5 A
+12 V ± 10% type 40 mA
-12 V ± 10% type 40 mA

1-10 Components H120E1-2.DOC

 5. Motherboard

6
1
2

3
4

1 LED: READY 4 E-STOP circuit connection 7 SMP-Bus connector

(X6 to K20 or +22-K1)
2 Reset-Pins (X7) 8 Lower Bitbus module
5 AMS-Bus connector
3 Lithium battery (to RF generators)
6 Bitbus module connector(CNC)

Motherboard with Bitbus module, up to March 1995 Fig. 7899

H120E1-2.DOC Components 1-11

 4

5
1
2

3 6

Plug X6

1
24V
emergency-off
circuit
+22-K1
2
K1
7
5

8
arm
6
24V

1 LED: READY 4 AMS-Bus connector 7 SMP-Bus connector

2 Reset-Pins (X7) 5 Bitbus module connector (CNC) 8 Lower Bitbus module
3 E-STOP circuit connection 6 Battery (to RF generators)
(X6, to K20 or +22-K1)

Motherboard with Bitbus module, from March 1995 Fig. 20526

1-12 Components H120E1-2.DOC

 The following are located on the motherboard:

• A real time clock which outputs the system time; this serves as
the basis for the laser fault alarm times.
• A lithium battery for buffering not only the real time clock but
also the RAM areas for laser operation and laser maintenance
data.
• Battery monitoring: Initially, a warning to the operator is issued
if a drop in battery voltage becomes noticeable; an alarm
follows if voltage drop is excessive. In addition to this, a battery
failure check is run during controller boot-up.
• An Interrupt memory register where the A/D converter Interrupt
is stored.
• A Watchdog module; the address of this module is overwritten
during each PLC cycle. An error during PLC program run
causes a hardware shutdown of the 24V DC supply to the laser
control.

The Motherboard can be fitted with up to two Bitbus modules:

• Bitbus module for communicating with higher-level SIEMENS

or BOSCH CNC control system: Upper slot.
• Bitbus module for communicating with the RF generator (TCO-
HF1 module): Lower slot.

1 Bitbus module for machine control (BBM2)

2 Bitbus module for RF generators (BBM1)

Bitbus modules on the Motherboard Fig. 16735

H120E1-2.DOC Components 1-13

 6. Bitbus Modules

1 2 3 4 10

5
6

8
9

1 Dual-Port-RAM 5 Fiber optic receiver (blue) 8 Electrical connection (free)

2 EPROM socket 6 Fiber optic transmitter (gray) 9 LEDs for function monitoring
3 8344 processor 7 V24 interface (free, LSV2) 10 Module configuration jumpers
4 Serial interface chip

Bitbus module (until fall 1994) Fig. 7901

1 2 3

4 5 6 7

1 Dual-Port-RAM 4 8344 processor 7 LEDs

2 Transmitter parameter jumpers 5 Software chip 8 Fiber optic transmitter
3 Fiber optic receiver 6 Module configuration jumpers 9 5 V supply test points
Bitbus module II (from fall 1994) Fig. 9902

1-14 Components H120E1-2.DOC

 At TRUMPF, every device connected to a Bitbus interface has a
Bitbus module (serial communication module) fitted with a special
processor (8344) for data transmission and processing of individual
user programs.

The Bitbus consists of a Master which controls the bus, and several
Slaves; the latter can access the bus only if commanded to do so
by the Master.

For details on of Bitbus transmission, please refer to the Description

of Faults and Alarms in Chapter 7 (from Fault 55 onward).

TRUMPF uses fiber-optic cables for the bit bus as these cables are
not susceptible to interference; in addition to these, bit bus module I
also had electrical connections for communication with other
devices.

Attention! The fiber-optic cables must be at least 3 m long,

with a bend radius of min. 5 cm. The optical fiber must have
a polished plastic core which terminates flush with the front
end of the connector.

Technical Data Clock frequency 12 MHz

Length of optical fiber ca. 30 m

Optical transfer rate 2 MBit/s

Jumper configuration Jumpers are used to set the addresses of each Bitbus module (see
Jumper Lists in the appendix).

Bitbus module I and Generally speaking, both Bitbus modules can be used at the same
Bitbus module II together time. At exception to this is the Bitbus module with ID 133054 in
combination with laser software ≤ V1.21.

H120E1-2.DOC Components 1-15

 7. Process I/O

b
c

2
3
7

1 Analog inputs/outputs (X2) 5 4 fiber optic cables (outputs for pulse signals)
2 24 V supply (X5) 6 Connector for Process I/O (DIAS I Height
Regulation)
3 Fuses SI 701, FF 5A
4 Digital inputs/outputs (X3), Byte 100 7 DC/DC converter

a Press. transducer Resistor 220 Ω

b Height regulation Resistor 10 kΩ
Capacity 10 nF
c Calorimeter Resistor 10 kΩ

Process I/O Fig.16737

1-16 Components H120E1-2.DOC

 The process I/O PCB serves to collect and route both analog and
digital signals. Communication with the laser is controlled via:

4 fiber optic outputs Transmission of gating frequency and duty cycle to the generators.

6 digital inputs Reading digital signals "Beam ON without delay", "Shutdown ramp
active" and the height regulation signals (only DIAS I with
Lasermatic 1.5).

4 digital outputs Transmission of digital signals for ’RF ON’ and height regulation
signals (only DIAS I with Lasermatic 1.5).

8 analog inputs Reading the input signals (analog) for system pressure, sensor
signal for height regulation (only DIAS I with Lasermatic 1.5), the
actual laser power value, nominal frequency and nominal power.

4 analog outputs Output of analog values for nominal amplitude to the generators
and signals for height regulation (only DIAS I with Lasermatic 1.5).

A square-wave generator produces rectangular-pulse signals of

100 Hz up to a frequency of 100 kHz. These signals transmit the
gating frequency and duty cycle to the RF generators through fiber-
optic cables. One fiber-optic cable is provided for each RF
generator (i.e. maximum 4). The target of this transmission is the
oscillator and regulator board of the recipient generator.

The input resistance of each analog input can be adapted to the

sources through the use of soldered-in resistors.

H120E1-2.DOC Components 1-17

 Process CPU for height The process I/O card features a socket for a piggy-back process
regulation CPU (ID 111977). This CPU is needed by the Process I/O for
controlling the DIAS I height regulation (intelligent digital distance
system: DIAS) with Lasermatic 1.5.

A 80C186 processor with 80C187 coprocessor comprises the

process CPU. This IC has direct access to all process I/O
components. A process CPU address window in the SMP bus
enables communication with other control components.

1 Co-processor 80C187 3 Connection to Process I/O

2 Processor 80C186 4 EPROM

Process CPU for Dias I with Lasermatic 1.5 Fig. 16732

Technical Data Process I/O

Resolution of analog channels 12 bit (1 bit for prefix)

DC-DC converter Input: 18 - 36 V DC
Output: +15V, -15V

Process CPU

Processor 80 C186 with coprocessor 80C187

CPU clock frequency 16 MHz

Memory capacity 64 KB RAM

128 KB EPROM
8 KB EEPROM
2 KB Dual-Port-RAM

1-18 Components H120E1-2.DOC

 8. 32 Bit I/O Boards

1
A 101.0
A 101.1
a A 101.3
A 101.5
A 101.2
A 101.4 4
A 101.7 A 101.6
A 102.0 GND.0
A 102.1
A 102.2
b A 102.4
A 102.3
A 102.5
A 102.6
GND.1 A 102.7
A 103.1 A 103.0
A 103.2
c A 103.3
A 103.5 A 103.4
A 103.7 A 103.6
A 104.0 GND.2
A 104.1
A 104.2
d A 104.4 A 104.3
A 104.5
A 104.6
GND.3 A 104.7

E 101.0
E 101.1
a E 101.3
E 101.5
E 101.2
E 101.4
E 101.6
E 101.7
E 102.0 GND.0
E 102.1
E 102.2
b E 102.4
E 102.3
E 102.5
E 102.6
E 102.7
GND.1
E 103.1 E 103.0
E 103.2
c E 103.3
E 103.5 E 103.4
E 103.7 E 103.6
E 104.0 GND.2
E 104.1
E 104.2
d E 104.4
E 104.3
E 104.5
E 104.6
GND.3 E 104.7

A Outputs a: Byte 0 1 LED Mother board power supply OK

E Inputs b: Byte 1 2 LED Piggy-back power supply OK
c: Byte 2 3 Fuse (ID 091717)
d: Byte 4 4 Connection for +24 V input and GND
5 Jumper array 1

32 Bit I/O Board 1 Fig. 7797

H120E1-2.DOC Components 1-19

 This TRUMPF development has been incorporated in all TRUMPF
controllers since spring of 1990 and is addressed via the SMP bus.

The I/O card consists of a 16 bit mother and a 16 bit piggyback

PCB. Fully loaded, there are 32 digital 24 V inputs and 32 digital
24 V outputs at your disposal. These are galvanically insulated via
opto-couplers. The inputs are routed to a 37-pin sub-miniature
male, the outputs to a 37-pin sub-miniature female interface on the
front of the PCB.

The outputs are protected against short-circuit, over-temperature,

overload and power interrupt. Errors can be localized bit-wise and
cause an SMP bus interrupt. The card must be cooled.

The outputs are galvanically insulated. They are, however, at the

same potential (they share a common ground) and can, therefore,
by controlled simultaneously.

Digital output, block diagram Fig. 7957

The inputs are also galvanically insulated but lie byte-wise to

ground (each byte has an individual ground).

Digital input, block diagram Fig. 7958

1-20 Components H120E1-2.DOC

 Maximum 2 cards are employed on the TASC 200. The address
codes are set by means of jumpers (jumper array 1, see Fig. 7797):

I/O card 1 I/O card 2

Inputs/Outputs for: BCD interface

Laser to machine
Gas supply
Vacuum system
Resonator
Byte 105-108
Byte 101-104

Technical Data Signal level

Inputs log "1": +24 V (13V...33V)

Ietyp = 7 A

log "0": 0 V (-3 V...+7 V)

Outputs log "1": +24 V

(Uext ≥ UA ≥ Eext ≥ 1,5 V)

5mA ≤ 1A ≤ 500mA

log "0": 0 V...+3 V (under load)

0 V...+7 V (no load)
Power supply (via connector at the front)

+5 V (via SMP bus)

+24 V (+19 V...+30 V)

(at Imax=16A)

Fuse

Special type: FF 16A quick blow

F1: Mother PCB

F2: Piggyback PCB

H120E1-2.DOC Components 1-21

 9. Control panel: TASC 300

The operating panel for the TASC 200 is a TASC 300, an industrial-
standard PC with keyboard and electro-luminescent display:

TASC 300 (control panel) Fig. 7922

The panel interfaces with the TASC 200 via a serial port (COM 2)
and is available in three versions:
• V 40 processor, system software on exchangeable Melcard,
operating system on EPROM.
from 1994 • INTEL 80386SX processor, system software on FLASH-
EPROM, operating system on EPROM.
from 10/97 • INTEL 486DX4, TFT color display, operating system and
applications on FLASH-EEPROM

All versions are fitted with key switches for laser operation in
conformity with standards; the panel is integrated in the safety
circuit of the laser.

1-22 Components H120E1-2.DOC

Technical data:

ID 141963 ID 111337 ID 104618

Processor 486DX4 80386SX, 16MHz V 40, 10 Mhz

RAM 4 MB 2 MB 640 KB

Interfaces 2 serial, 1 serial (V24) = COM2 1 serial (TTL,V24)

1 parallel
1 serial (TTL) = COM1

Field bus adapter _ can be connected _

via Bitbus module

Data medium for 2 MB FLASH-EEPROM, not exchangeable FLASH- exchangeable Melcard

system software removable, EPROM (1 MB), data can be (1 MB)
contains operating system stored via serial interface
and applications
128kB BIOS EPROM 256 KB EPROM memory for 256 KB EPROM memory for
DOS operating system DOS operating system

Display TFT-Color 10.4“with Gray-scale EL-Display with Gray-scale EL-Display with

640 x 480 pixels 600 x 400 pixels 600 x 400 pixels

Graphic controller VGA VGA EGA

Buffer battery yes * yes no

Fuse 4 A/T 4 A/M 4 A/M

Connections and fuses

2X43
(+29-X2)
DC NOT - AUS

X43
(+29-X1)
COM 2

COM 1
LPT 1

Connections on cover, Panel ID 141 963 Fig. 7919

* BIOS in CMOS-RAM and in extra FLASH module (bootable), not battery exchange needed.

H120E1-2.DOC Components 1-23

 10. TCO-HF1 PCB

The TCO-HF1 PCB contains a CPU with program and data

memory, analog inputs, digital inputs and outputs, a Watchdog
module, a safety relay plus an interface to a Bitbus module.

b18 b1
a18 a1

5
6
1 7

a24 b24

2 10

a1 b1 11

4
12
b30 b1
a30 a1

1 Digital inputs 7 Relay K2: Watchdog

2 Interface to Bitbus module (X3) 8 Digital outputs
3 EPROM 9 LED: Watchdog-Error (L4)
4 RAM 10 80C186 Processor
5 Digital inputs/outputs (X1) 11 Analog-Digital converter
6 Relay K1: Sum error 12 Analog inputs (X2)

TCO-HF1 PCB Fig. 20525

1-24 Components H120E1-2.DOC

 The TCO-HF1 PCB is a Piggyback module for the master board
(oscillator and regulator board) of the generators.

This PCB, employed with both tube and transistor type amplifiers, is
provided with a dedicated CPU for performing control and
monitoring functions for the generators. By means of an executive
routine (on EPROM), the status of digital and analog inputs are
continuously compared with defined limit values. The results of
these comparisons are retransmitted via bit bus to the control
where they are processed and evaluated.

Signals at analog inputs are read in sequentially with the aid of a

controllable Multiplexer. When this process is completed, an A/D
converter triggers an Interrupt on the processor, and the signal is
stored.

Digital input, block diagram Fig. 7956

Digital output, block diagram Fig. 7956

As the digital outputs have no power transistor, they can only be

used to switch CMOS inputs on the Oscillator and Regulator PCB.

H120E1-2.DOC Components 1-25

 TCO-HF1 PCB and the bit bus module it carries are supplied with
current by the oscillator and regulator PCB:

TCO-HF1 PCB ⇔ Interface on TCO-HF1 PCB Pin Voltage

Bitbus module
X3 A3 +5 V_D

X3 A4 +5 V_D

X3 A1 GND
X3 A23 GND

X3 A24 GND

Oscillator and regulator ⇔ Interface on TCO-HF1 PCB Pin Voltage

TCO-HF1 PCB
X2 B1 +15 V_D

X2 A2 GND_A
X2 B2 GND_A

X2 B3 -15 V_A

X2 B28 +5 V_D

X2 B29 GND_D
X2 A28 GND_D
X2 A30 GND_D

X2 B30 +5 V_D

This PCB interfaces with the PCBs in the card rack of the TASC
200 via a bit bus link; communication is established by means of a
piggyback bit bus module.

Technical Data Processor 80C186,

Cycle time (without telegram) 5 msec
(with telegram) 15 msec

Program memory EPROM (1 MB)

RAM 512 KB RAM

Analog inputs 24, max. ± 10 V

Digital inputs 16, max. 24 V level

Digital outputs 8

1-26 Components H120E1-2.DOC

 Chapter 2

Software
1. Software Modules .......................................................... 2-3

2. EPROM slots................................................................... 2-5

3. Software exchange ........................................................ 2-7

3.1 Exchanging EPROMS ...................................................... 2-7
3.2 Exchanging Melcards ....................................................... 2-8
3.3 Changing software on the TASC 300............................... 2-9
Panel ID 104618 ......................................................... 2-9
Panel ID 111337 / 141963 .......................................... 2-9

4. Software Releases and Versions................................ 2-13

H120E2.DOC Software 2-1

 The same TASC 200 software is used for all laser models.
Customization for each laser is effected by setting the appropriate
machine data at the time of controller setup (see Chapter on
Settings).

Software modules for the TASC 200 are located on PCBs in three
different areas:

• Software on the PCBs in the controller rack

• Panel software (TASC 300)
• Software on the TCO-HF1 PCB

2-2 Software H120E2.DOC

 1. Software Modules

The modular design of the TASC 200 is reflected in the structure of

its software:

Task Designation in software Data medium PCB

selec. sheet

Executive routine for TASC 200 TASC 200, Vx.x Melcard (512 MB) KSP M17-Board

Operating system for control CPU

Interface module LSV2 M17-A16 Vx.x EPROM KSP M17-Board

Executes and supervises the LSV2
procedure on the KSP M17 Board

Generates the user interface TASC 300 Vx.x Melcard (1 MB) TASC 300 (ID 104618)
including language versions (GEM,
(GEM application by TRUMPF
FLASH-EPROM TASC 300 (ID 111337)
or ID 14 1963

Operating system (DOS) for TASC 300 not listed (not to be EPROM or
exchanged) FLASH EEPROM TASC 300

Executive routine for height regulation of DIAS Vx.x EPROM Process-CPU

machine (DIAS)

Executive routine for the processor on the HF2BBN Vx.x EPROM TCO-HF1- module
TCO-HF1 PCB

Executive routine for processor on Bitbus Vx.x EPROM Bitbus module

module (not to be exchanged)

Software selection sheets Please refer to the TASC 200 software selection sheets for the
necessary ID numbers. Reference: Drawing number 9558-892.

New editions supplement the predecessor software selection

sheets. The cover sheet accompanying the latest version always
lists the complete contents and should therefore be replaced as
well.

H120E2.DOC Software 2-3

 Modification descriptions Control modification descriptions are published under the following
drawing numbers:

Modification descript. Drawing number

TASC 200: 9558-895
TASC 300: 9558-1005
Machine data: 9558-896
Height regulation: 9558-967
(DIAS I with Lasermatic 1.5)
TCO-HF1: 9558-1042

New editions always supplement the predecessor modification

descriptions. The cover sheet accompanying the latest version
always lists the complete contents and should therefore be
replaced as well.

2-4 Software H120E2.DOC

 2. EPROM slots

1 DIAS Vx.x

EPROM slot, Process CPU Fig. 16790

A B

A Bitbus module I 1 EPROM V X.X slot

B Bitbus module II 2 Logic chip with Software V X.X

EPROM slot, Bitbus module I and II Fig. 13085

H120E2.DOC Software 2-5

 1

1 TASC 200, Vx.x (Melcard)

2 LSV2 M17-A16, Vx.x

EPROM slots, KSP M17-Board Fig. 16789

1 HF2BBN V1.2

EPROM slots, TCO-HF1 PCB Fig. 7898

2-6 Software H120E2.DOC

 3. Software exchange

3.1 Exchanging EPROMS

The following precautions must be taken to prevent electrostatic

charging and related damage to the electronic cards:

• Power down the control

• Spread an anti-static mat on the workbench (Anti-static set, ID
133753)
• Attach the anti-static wristband to yourself and the anti-static
mat
• Ground the anti-static mat.
• Place the PCB on the anti-static mat
• Use either an EPROM puller or an angled screwdriver to
remove the EPROM you wish to replace
• Carefully plug in the new EPROM in its socket. Caution: make
sure that notches and other markings between socket and
EPROM are properly aligned.
• Check the EPROM contacts for proper socket fit and that none
have been bent.

H120E2.DOC Software 2-7

 3.2 Exchanging Melcards

• Power the control down by turning the main switch OFF

• Carefully loosen and remove the old Melcard
• Insert the new Melcard in its place:

Melcard (1 MB, panel software) Fig. 7921

• Power the control up

Remarks Melcards with a dark brown border are standard OTPROM (One
Time Programmable Read Only Memory) cards.

Melcards with a white border are generally reprogrammable RAM

cards with a battery and a write-protect switch on the back.

2-8 Software H120E2.DOC

 3.3 Changing software on the TASC 300

Panel ID 104618

If a panel with ID number 104618 is installed, the entire panel

software is stored on a Melcard (1 MB) located at the back of the
panel.

To change the software, remove the small cover plate at the panel
rear; the Melcard slot is located behind this plate (remember to turn
the main switch OFF first!).

Panel ID 111337 / 141963

The software is stored on a FLASH-EPROM disk which is a small

exchangeable PCB which, besides the FLASH-EPROM modules (1
MByte), also carries an EPROM containing the MS-DOS operating
system.

Software versions • Software for TASC 300 ID 111337: ≥ V1.x

• Software for TASC 300 ID 141963: ≥ V2.0
An error message is issued if the wrong software version is
used.

Programming through the The FLASH-EPROM disk can be re-programmed through the serial
serial interface port (COM 2) of the TASC terminal. This procedure requires a
standard PC with serial port and with communication program
SEND.EXE installed.

In the case of panels with ID number 111337, the COM1 port

cannot be used for programming the FLASH-EPROM disk as
it is designed only for TTL level and not for V24 level.

The panel is connected to the PC by means of a serial NULL

MODEM cable (3-wire connection with transmit and receive lines
crossed:

a 9-pin socket b 9-pin socket

Cable between PC and panel (view of soldered side) Fig. 7782

H120E2.DOC Software 2-9

 All existing data on the FLASH-EPROM disk must be erased and
the memory area released before the new software an be
transmitted.

Formatting the FLASH- • Press <ESC> and key string [end] to switch to the operating
EPROM disk system level.
(Panel ID 111337)
• Type in "FORMAT D:" in the DOS prompt line.
• Press <ENTER>. Press <ENTER> a second time to
acknowledge the displayed message.
The FLASH-EPROM disk is now formatted.
• In reply to prompt "FORMAT ANOTHER (Y/N)?", enter [N].

Erasing the FLASH- The PC Hardware includes a FLASH-EPROM disk which is

EPROM disk organized like a hard disk. This means that all actions are executed
(Panel ID 141963) with standard DOS commands. However, this also means that:
The [format] command may not be used here !

• Press <ESC> and key string [end] to change to the operating

system level.
• Change to directory C:\T300.
• Enter the command [del *.*]
• Press <ENTER>. Then press <ENTER> again to acknowledge
the displayed message.
All data is erased from directory C:\T300.

Attention: Never use command [del] in directory C:\ !

Loading new software • Set the transmission parameters:

Panel ID 111337 • At the operating system level: Enter [empf d: /[Baud rate]]
Panel ID 141963 • At the operating system level: Enter
[empf c:\T300\ /[Baudrate]]
Syntax:
[Baud rate] Code for the transmission rate and may have the
following values:
"/0" 300 bauds
"/1" 1200 bauds
"/2" 2400 bauds
"/3" 4800 bauds
"/4" 9600 bauds
"/5" 19200 bauds
"/6" 38400 bauds
"/7" 57600 bauds
"/8" 115200 bauds (default)

[port] Serial port at the PC for data transmission to the

panel
"/a" COM 1
"/b" COM 2 (default)

2-10 Software H120E2.DOC

 The above mentioned transmission rate of 38400 bauds (/6)
results from the relatively slow read and write process at the
FLASH-EEPROM. If a higher transmission rate is used,
transmission at the Color Panel is often aborted when
sending long files.
A space must be entered between the destination drive (C:)
and the desired baud rates (/...).
Example: C:\ EMPF D: /6 for panel ID 111337
∪ ∪
Example: C:\ EMPF C:\t300\ /6 for panel ID 141963
∪ ∪
As a rule, parameter [baud rate] needs to be stated only if
you need to decrease the baud rate after a transmission fault
(see below).
• At the PC, activate program ’SEND.EXE’ and select the files to
be transferred (the program must be located on the data file).

Syntax:
[send [path] [file name] /[baud rate] /[port]]
[path] Drive and directory specifying the location of the
files to be transmitted.

[file name] Name of file to be transferred; DOS conventions

must be observed, wildcards are allowed.
[port] "/a" COM 1
"/b" COM 2 (default)

[baud rate] "/0" 300 bauds

"/1" 1200 bauds
"/2" 2400 bauds
"/3" 4800 bauds
"/4" 9600 bauds
"/5" 19200 bauds
"/6" 38400 bauds
"/7" 57600 bauds
"/8" 115200 bauds (default)
The full path must be specified if file 'SEND.EXE‘ is not located
in the same directory as the files being transferred (see
example)
A space must be entered between the file name and the
options (/...).
Example: A:\ send *.* /6 /a
∪ ∪
All files in the current directory will be transmitted to the panel
through serial port COM 1 at a transmission rate of 38400
bauds.

H120E2.DOC Software 2-11

 When all transmission parameters have been set, both
programs must be started within 20 sec by pressing the
<ENTER> key; failing this, error message "No connection
with partner" is displayed at the receiving panel.

• Once all data has been transmitted, program ’SEND.EXE’ at

the PC indicates the number of files transferred. To terminate
data transfer:

• Press <ESCAPE> to cancel program ’EMPF.EXE’ at the panel.

What to do if transmission If errors occur during data transfer, the transmission programs at
fails? both sides are aborted; the process must then be repeated.
If transmission is still faulty despite several attempts, try reducing
the transmission rate for the serial port by changing parameter
[baud rate]. Example: Data transfer at 19200 bauds:
Panel: empf c:\t300\ /5
PC: send *.* /5 /a
Although this increases the transmission time, it also reduces
susceptibility to interference.

2-12 Software H120E2.DOC

 4. Software Releases and Versions

The current software status is indicated in the software selection

sheets.

The current version of the software installed can be checked at the

operation environment of the control:

Verifying the software • Activate DIAGNOSTIC mode. The display now shows which
version software version is installed:

Software version number Fig.7784E

TASC300 Panel software

TASC200 System software for TASC 200 laser control
TCO-HF1 System software on the TCO-HF1 module

Height regulation DIAS I The software version is shown in the height regulation menue.
Operating mode selection:
• manual
• start up
• height regulation

H120E2.DOC Software 2-13

 Chapter 3

Controller Processing
Routines
1. Bus systems ................................................................... 3-2

2. Overview: Interfaces ...................................................... 3-4

H120E3.DOC Controller Processing Routines 3-1

 1. Bus systems

Bus systems are used for data communication within the controller
itself:

AMS Bus The AMS-Bus has been developed as a general application 16-Bit
system bus for Mulitprocessing systems and features standardized
connectors and electrical signals. Electrically, the bus is identical to
the Multibus from INTEL but has different connectors. This bus
system is fitted with 5 slots on the backplane (see Chapter on
Components, Backplane).

SMP Bus The SMP bus provides the communication link with the I/O modules
and features a total of 5 slots on the backplane (see Chapter on
Components, Backplane). The 16 bit bus can accommodate only
one CPU as Master.

Bitbus Through the open structure of the bitbus specified by INTEL,

networking of different automation systems within one production
and manufacturing process is possible.

The TASC 200 uses the bitbus (transmission rate: optically up to 2

MBit/s) as a field bus for communicating with the RF generators
and with a higher-level CNC controller:
• Lower bitbus module: Master module for communicating with
RF generators
• Upper bitbus module: Slave to the master module of the higher-
level CNC controller (BOSCH CC 320, CC 220, SIEMENS
840D)

The laser function module of the control communicates with the RF

generators through a Master module of the Bitbus ring located
piggy-back on the motherboard. The processor on the Master
module processes the incoming information, converting them into
optical pulses which it transmits to the next module in the ring.
From there, the pulses are routed to the next module. At the same
time, this data is evaluated by the processor of the Slave module
which recognizes the RF generator node address from the Jumper
configuration.

3-2 Controller Processing Routines H120E3.DOC

 BOSCH
SIEMENS
TASC 200

AMS - Bus

BBM

DPR

CPU
80186
BBM Fiber-optic cable

KSP-M17 DPR Mother board

DPR

TASC CPU
300 8031
BBM Fiber-optic cable

TCO-HF1
SMP - Bus
BBM BBM

Process I/O I/O cards DPR DPR

CPU CPU
80186 80186

DPR

80C186

Process
CPU
DIAS I
Digital Analog Digital Analog
I/O inputs I/O inputs

Oscillator and Oscillator and

regulator regulator
Digital generator 1 generator 2
I/O
Digital BCD
Digital Analog I/O interface
I/O I/O card 1 card 2

DPR Dual-Port-RAM BBM Bitbus module

TASC 200 bus systems Fig. 20530E

H120E3.DOC Controller Processing Routines 3-3

 2. Overview: Interfaces

TASC 200: Communication with external assemblies Fig. 7927E

3-4 Controller Processing Routines H120E3.DOC

 Chapter 4

Diagnostics
1. Power-up cycle............................................................... 4-3

2. Troubleshooting from the operation environment ..... 4-7

3. Troubleshooting by means of LEDs ............................ 4-9

4. I/O Diagnostics at TASC 300 terminal ........................ 4-13

5. Telegram Diagnostics.................................................. 4-15

5.1 Viewing telegrams received and transmitted.................. 4-15
5.2 Status Telegrams ........................................................... 4-18

6. Diagnostic functions for the RF generator................ 4-19

7. Diagnostics via machine data..................................... 4-21

8. Logbook errors............................................................. 4-22

9. Incorrect machine data................................................ 4-22

10. Serial number ............................................................... 4-23

H120E4.DOC Diagnostics 4-1

 The following procedure is recommended for identifying and
locating control system errors:

Trouble-shooting • Check the power-up cycle: Are any messages displayed while
the control is booting up?
• Check the LEDs: Any change from normal condition? (see Fig.
7924)
• Activate service and diagnostic functions in the operation
environment.
• Use special diagnostic equipment.

4-2 Diagnostics H120E4.DOC

 1. Power-up cycle

When the main switch is turned on, a power-up cycle is initiated at

the control which offers valuable aid in fault diagnostics:

Sequence at TASC 200 Observed as

System power supply is turned ON Power supply unit: Green LEDs illuminated (¥ ¦ §* )
⇓ TCO-HF1 PCB: Red LED illuminated**
(in RF generator)
KSP M-17-Board and Bitbus modules KSP M17 Board: Red LED blinks
are reset Bitbus modules: Red and green LED flash briefly at the same time
⇓
Software is loaded KSP M17 Board: Green LED turns ON («)
⇓
Memory test Yellow LED flashes 8 times at 0.5 sec. intervals
⇓
Laser operating software is loaded Yellow LED flickers
⇓
Watchdog for DIAS with
Lasermatic 1.5 is activated
⇓
Watchdog on Motherboard is Motherboard: Green LED turns ON (®)
activated
⇓
Relay K 20 (+22-K1, (E-STOP relay) Motherboard: Audible noise made by relay
energized Control cabinet: K20 (+22-K1) Green LED turns ON
⇓
24 V supply is turned ON 32 Bit I/O card 1: Green LEDs turn ON (¨, ©)
⇓
A Hardware Reset is output for TCO-HF1 PCB: Red LED turns OFF
the generators (A 104.7) (in RF generator)
(rectangular pulse 370 ms)
⇓
Bitbus link TASC 200 ↔ Bitbus modules: Red and green LEDs light up and then
TCO-HF1 is established extinguish again
⇓ Green LEDs turn ON (LED 11)

Machine-dedicated generator data are

transmitted to the generators
through the bitbus
⇓
Control initialization ends KSP M17-Board: Yellow LED on the left flickers (50 msec) , (¬)

* The figures indicate LED positions on the TASC 200 as per Fig. 7798 (see Pages 4-10 and 4-11).
** Red LED is illuminated for approx. 20 s until Hardware-Reset for the generators

H120E4.DOC Diagnostics 4-3

 While the above steps are taking place, the user interface (TASC
300) is started at the control:

Sequence at TASC 300 Monitor display

Operating system is loaded Information on internal tests
⇓ Green operating modes LEDs illuminated

Graphic user interface GEM Screen and color change

is loaded ID 111337: "D:\BOB.APP" appears
⇓ ID 141963: "C:\T300\BOB.APP" appears

User interface is started TRUMPF logo appears

⇓
Communication with TASC 200 The text "Time" is displayed in the title bar
⇓ First telegrams are exchanged

KSP-M17-Board: Loading The greater part of the system software for the TASC 200 is stored
software on the Melcard of the KSP M17-Board. When the controller boots
up, the complete software, together with the requisite data records
from the EEPROM, are read into the controller’s RAM:

Melcard EEPROM

-Boot program -Machine data

-Executive routine -Reference curves
-Operating system -Valid cycles
-Setup data -Maintenance data

Load software
TASC 300 Softkey
Save
Machine Data
Enter
Softkey

RAM Adopt

RAM

Loading software modules into the RAM Fig. 20527E

The software is run exclusively from the RAM during controller

operation.

4-4 Diagnostics H120E4.DOC

 Invalid data records: The data records loaded from the EEPROM are checked for
Setup mode validity. If any invalid data (wrong machine data, invalid power
cycles) are detected during the booting cycle, the controller will
switch to SETUP mode where the data must be corrected (see
Chapter SETUP):

Controller boot-up: Loading software Fig. 7857E

H120E4.DOC Diagnostics 4-5

 Each CPU performs a self-test when the controller is booting up;
part of this procedure can be observed by noting the LEDs. The
table below provides an overview of LED reactions on each PCB
when the control is powered up:

Power supply I/O PCB KSP M17 Board Motherboard Bitbus modules

Green LEDs +5 V,
+12 V and -12 V
illuminated
⇓
Red LED blinks Red (Reset)
(Reset) and green LED
⇓ blinks

Green LED turns ON

(ready for
operation)

⇓
Yellow LED blinks 8x Green LED blinks
⇓ (500 ms cycle)

Yellow LED flickers

(system software
being loaded)
⇓
Green LEDs turn Yellow LED flickers Green LED turns ON
⇓ ON (power
supply)
(50 ms cycle)

Green LED turns ON

4-6 Diagnostics H120E4.DOC

 2. Troubleshooting from the operation
environment
Error messages are displayed when malfunctions occur:

Error window Fig. 6039

The error window is retained even when the display changes. To

have the full display area at your disposal despite the fault, press
the <ENTER> key to close the window.
Only the number of the last error registered by the control is
displayed in the window. Quite often, a number of error messages
exist for one fault; all of these error messages can be viewed in
plain text by activating DIAGNOSTIC mode:

Error messages Fig. 6352E

Use menu function DISPLAY ERROR PAGES to scroll through the

display. The last page shows the Info messages received.

H120E4.DOC Diagnostics 4-7

 The message must be cleared after eliminating the fault.

• Press softkey RESET ERRORS or key <RESET>. The error

message is cleared if the laser fault has been eliminated.
or

4-8 Diagnostics H120E4.DOC

 3. Troubleshooting by means of LEDs

As the LEDs indicate the results of internal function checks at the

control, they are an excellent diagnostic tool.

If the control is functioning properly, the following LEDs will be

illuminated once the power-up cycle is over:

11 12

4 5 6 7

1
+5
2 +12 8 9
3 -12

10

11 12

LEDs during trouble-free controller operation Fig. 20528

The yellow LED on the KSP M17-Board "flickers" (interval: 20 times a second)

Any deviations from normal condition indicate a fault in the control.

H120E4.DOC Diagnostics 4-9

 11 12

1 4 5 6 7

2 8 9

10

11 12

Power supply unit 32 Bit I/O PCB KSP M17-Board

1 LED (green) ON: 4 LED (green) ON: 6 LED (red) ON or blinking:
+5 V voltage supply OK +24 V voltage supply to basis Processor cannot access the RAM
PCB OK
2 LED (green) ON: 7 LED (green) OFF:
5 LED (green) ON:
+12 V voltage supply OK Watchdog circuit has been tripped. The
+24 V voltage supply to processor on the PCB has shut down.
3 LED (green) ON:
Piggyback PCB OK
8 LED (yellow) blinking in fixed cycles
-12 V voltage supply OK
Data backup from RAM to EEPROM.
Executive routine of TASC 200 has
halted, operating system for PCB is still
LED 1,2,3 are not ON: running.
Power supply unit is OFF, LED (yellow) permanently ON or OFF:
the fuse is defective,
Executive routine and operating system
short-circuit in power supply unit
of the PCB have halted
LED (yellow) "flickers" 20 x per sec:
Controller OK, no fault messages
present
LED (yellow) "flickers" 4 x per sec:
Controller OK, fault messages present
LED (yellow) is OFF:
Software will not be loaded

LED Diagnostics Fig. 7798

4-10 Diagnostics H120E4.DOC

 11 12

1 4 5 6 7

2 8 9

10

11 12

KSP M17-Board Motherboard Bitbus modules

9 LED (yellow) ON: 10 LED (green) not illuminated: 11 LED (green) ON:
PCB memory is defective. Watchdog circuit has been tripped Bitbus communication active
Bitbus modules are not being 12 LED (red) ON:
addressed correctly (wrong
Processor on module has shut
slots) ⇒ Errors 46 and 57 - 59)
down
If height regulation is active: from 05/96: LED (red) blinks
briefly:
Process CPU does not respond to
KSP M17-Board: Error 49 Telegram is transmitted

LED Diagnostics Fig. 7798

H120E4.DOC Diagnostics 4-11

 Watch-Dog-Error TCO-HF1 A Watch-Dog circuit on the TCO-HF1 PCB monitors the program
PCB cycle times at regular intervals:

LED (red) ON:

• Voltage supply has dropped below 4.75 V

• Software failure:
No response from controller, analog values no longer
displayed. Verification by explicitly triggering faults:
No more error messages are displayed

• Hardware-Reset A104.7, 370 ms pulse missing

• Motherboard defective

TCO-HF1 PCB Fig. 11529

4-12 Diagnostics H120E4.DOC

 4. I/O Diagnostics at TASC 300 terminal

I/O DIAGNOSTICS monitors the signals at the digital inputs and

outputs of the TASC 200:

• Press softkey I/O DIAGNOSTICS.

• Select signal monitoring for outputs or inputs.

• Use NEXT BYTE, PREVIOUS BYTE to select the byte to be

monitored (dark highlight) or combine any 8 bits for monitoring.
In the latter case, activate BIT SELECTION:

An input mask appears:

Input fields for single bit selection Fig. 6956E

Enter the byte and bit numbers, and the code for inputs [i] or
outputs [o]. Press <ENTER> to confirm.
User cursor keys <↑ > and <↓> and the <BACK-SPACE> key to
correct any mistakes during input.
Activate DIAGNOSTICS mode again to complete your selection
of bit combinations for signal monitoring.

H120E4.DOC Diagnostics 4-13

 • The selected byte is enlarged in the display:

Enlarged byte display Fig. 6957E

green: Energized input or output

• Signals can be monitored in MANUAL or AUTO mode while the

control is running:

• Choose PERMANENT DISPLAY

• Activate AUTO or MANUAL mode again. Signal monitoring

continues as long as the machine is in operation:

I/O monitoring in MANUAL mode Fig. 6958E

• Press PERMANENT DISPLAY again to cancel this function.

4-14 Diagnostics H120E4.DOC

 5. Telegram Diagnostics

On TRUMPF systems, data exchange between various hardware

assemblies takes place in the form of telegrams.

5.1 Viewing telegrams received and

transmitted

Since the telegrams are recorded, it is possible to monitor the flow

of communication between the controller and external assemblies.
For this purpose, the telegrams are stored in a ring buffer, the
contents of which can be viewed at the user interface:

• Activate DIAGNOSTICS mode

• Press softkey TELEGRAM DIAGNOSTICS (via key

<CONTINUE>).
This function allows you to monitor the laser control:

• V24 on processor PCB M17 (bottom)

• OEM bitbus module on motherboard

• HFG bitbus module on motherboard (bottom)

• DPR-M17

• AMS window

The display shows the last 20 telegrams received or sent from

the panel, complete with the relevant information:

H120E4.DOC Diagnostics 4-15

 Display showing telegrams transmitted Fig. 7783E

1 Time telegram was sent or received

2 Code indicating whether telegram was sent ("S") or received ("E") at the panel
3 Mnemonic (memory prompt) of telegram
4 Number of telegram in buffer. The very last telegram that was registered is
denoted by an arrow.
5 Telegram header. The second byte shown here corresponds to the telegram
command number (see filter functions described below)
6 Length of user data field
7 User data field

• If the telegram data does not fit on one page, use menu
function PAGE + to view the next page. FIRST PAGE returns
you to the first page display of the buffer.

When the buffer is full (maximum 20 telegrams), its contents either

remain unchanged (if no further telegrams are recorded and
displayed), or are overwritten, starting with the first item (first-in
first-out buffer).

A distinction is consequently made between a single query of the

completely or partially full buffer and the cyclic display of the ring
buffer:

4-16 Diagnostics H120E4.DOC

 Single query • Select menu function FILL BUFFER ONCE. The buffer
contents are output and displayed once.

Delete buffer: The buffer for single-time recording can be erased with an
<ESC> "tds" <ESCAPE> sequence <ESCAPE>"tds" and subsequently filled
again. The ESCAPE sequence can be called up from any screen of
the user interface; this allows you to selectively start recording the
telegrams.

Query in cycles • Select menu function RING BUFFER ACTIVE. The ring buffer
works as a first-in first-out buffer and the contents output and
displayed in cycles. The ring buffer is activated as default.

Filter functions The filter function allows you to selectively choose telegrams to be
recorded:
• Select function FILTER OF TELEGRAMS. An input box is
offered.
• Set the filter mode in the first line of the editor:
"1": only the designated telegrams will be recorded.
"0": telegrams thus designated will not be recorded.

H120E4.DOC Diagnostics 4-17

 5.2 Status Telegrams

Status telegrams inform the panel (TASC 300) of the current

system status. As these telegrams are crucial in trouble-shooting,
their bit codes are converted directly into plain text:

• Activate DIAGNOSTIC mode.

• Choose function DIAGNOS. TELEGRAMS (via key

<CONTINUE>).

• Select function DIAGNOSTIC OF STATUS. The contents of the

latest status telegrams received at the panel are displayed. A
"1" stands for the activated status while "0" indicates
deactivated status:

Telegram status display Fig. 7785E

1 Resonator status: "1" At rest

"2" Powering up
"3" In operating condition
"4" Powering down
"5" Switch units active
"6" Leak test active
"7" Start-up active

2 Mode: "0" LPC MANUAL

"1" Alignment ON
"2" Alignment OFF
"3" LPC analog
"4" LPC cycles
"5" LPC BCD

3 Operating mode: "0" CW

"1" Pulsing F
"2" Pulsing T

4-18 Diagnostics H120E4.DOC

 6. Diagnostic functions for the RF
generator

The operating data of the RF generators can be viewed either in

Manual or in Automatic mode.

• Select function RF GENERATOR DIAGNOSTICS.

• If several generators are installed, use this function to choose

the desired generator.

• If activating from MANUAL mode, specify the regulating

variables:

CW mode: Set the RF amplitude.

Pulsing F mode: Set the RF amplitude, pulse duty factor and
Specifying variables Fig. 6353E gating frequency

To prevent damage to the transistors, remember that the

transistor amplifiers may be run in CW mode only in a range
of 0% to 2% and 70% to 100% of maximum RF-amplitude !
The quiescent currents of the generator can be picked up at
a pulse duty factor of 0%. (A value of 0.1% must be input if
coupled to a CNC controller from BOSCH).
If no data is specified here, the control will use the data
records of the currently active laser mode (set in MANUAL
mode).

• Press <ENTER> to confirm each entry!

• Specifying the operating mode.

CW unregulated is an operating mode where the laser power is
not set at the controller but by means of a potentiometer at the
generator (see: Technical Description of RF Generator). The
laser can be operated in test mode with the resonator on a 50
Ω ballast resistor.

• The data is adopted by the control and transferred to the

generator.

H120E4.DOC Diagnostics 4-19

 Subsequently, the operating data is requested once from the RF
generator and displayed:

Generator Diagnostics (TIS-Generator) Fig. 6354E

Pi Actual value, forward power

PR^ Peak value, reflected power
PR= Mean value, reflected power
UDS Drain-Source voltage
UB Operating voltage
NVPi Nominal value, forward power
I1-I10 Pre-stage and end stage currents (see Technical
Description of RF Generator)

When you exit the generator diagnostics, the control reverts

to the data records of the currently active laser mode (as set
in MANUAL mode).
Attention! If operating the laser from the Bosch user
interface, remember that you must use the Level Return key
to exit from the "RF generator diagnostics" menu; the system
will not otherwise accept any more data records.

Cyclic display of generator data

• Select function CYCLIC DISPLAY.

At given intervals the RF generator queries the operating data

which are then displayed. This allows operating data to be
monitored over a longer period.

4-20 Diagnostics H120E4.DOC

 7. Diagnostics via machine data

Causes of missing beam enable

If beam enable is missing, machine datum 126 can be used to

determine the cause. The corresponding bit is set if any one
requirement for beam enable is not met.

Laser faults are present: Bit 0 (1)

Resonator status is not OPERATION: Bit 2 (2)
Generators are not ready: Bit 3 (4)
Beam disable is active: Bit 4 (8)
Gas circulation start-up not yet completed: Bit 5 (16)
Nominal speed of gas circulation not attained: Bit 6 (32)
High voltage is not OK: Bit 7 (64)
Aerodynamic window is not ready: Bit 8 (128)
In case of integrated laser, machine status not OK: Bit 9 (256)

To determine why beam enable is missing, look for the largest

number in brackets which goes into (divides) machine datum 126.
The corresponding cause is effective. The number in brackets is
subtracted from the machine datum value. Continue in like manner
with the remaining value until no remainder is left.

Example: The machine datum has a value of 126.

To determine the causes:

64 is the largest number in brackets which goes into 126:

Å The high voltage is not OK.
Remainder: 126-64=62.
32 is the largest number in brackets which goes into 62.
Å The nominal speed of gas circulation has not been attained.
Remainder: 62-32=30.
16 is the largest number in brackets which goes into 30.
Å Gas circulation start-up has not been completed.
Remainder: 30-16=14.
8 is the largest number in brackets which goes into 14.
Å Beam disable is active.
Remainder: 14-8=6.
4 is the largest number in brackets which goes into 6:
Å The generators are not ready.
Remainder: 6-4=2.
2 is the largest number in brackets which goes into 2:
Å Resonator status is not READY.

H120E4.DOC Diagnostics 4-21

 8. Logbook errors

The TASC 200 stores the last 40 errors, together with their date
and time of occurrence, in a ring buffer. This buffer can be viewed
in the "Logbook Errors" screen at the TASC 300 panel, with or
without status display.

Error logbook with active status display Fig. 16631

The status display shows the laser status at the time the fault
occurred. This is not the current laser status.
Errors are re-entered in the ring buffer if they are still active
after a RESET.

9. Incorrect machine data

If message "Error in machine data" (sum error 110034) is issued

during Setup mode, menu "Incorrect machine data" may list the first
7 incorrect data out of 128 possible machine data.

The incorrect machine values are displayed with their upper and
lower limits which can be edited in this menu.

Message "No machine data errors" is displayed if all machine data

are correct.

No options are displayed in menu "Incorrect machine data"!

4-22 Diagnostics H120E4.DOC

 10. Serial number

The maintenance intervals and the serial number of the laser can
be viewed in the Maintenance screen. The numbers are composed
as follows:
• Machine datum 1: Resonator type plus
• Machine datum 74: Laser number

Serial number in the Diagnostics/Maintenance screen Fig. 16632

H120E4.DOC Diagnostics 4-23

 Chapter 5

Settings and Routine

Maintenance
1. Changing the hardware ................................................. 5-3

2. Examining the power supply module (ID 105495) ...... 5-4

3. Modifying machine data ................................................ 5-5

4. Control Reset.................................................................. 5-8

5. TASC 300: Changing to the operating system level... 5-9

6. Setting the language...................................................... 5-9

7. Special diagnostic tool: Service Card........................ 5-10

8. Changing batteries....................................................... 5-11

8.1 Motherboard ................................................................... 5-11
8.2 TASC 300 Terminal........................................................ 5-12

9. Calibration curves for TLF lasers ............................... 5-14

H120E5.DOC Settings and Routine Maintenance 5-1

 This chapter provides information on the more frequent servicing
work required at the control, including:

• Hardware change
• Editing machine data
• Control Reset
• Changing the user interface language
• Changing the panel and Motherboard batteries
• Generating calibration curves on TLF lasers

5-2 Settings and Routine Maintenance H120E5.DOC

 1. Changing the hardware

KSP M17-Board Proceed as described below to replace the central processor card
for the TASC 200:

• Attach an anti-static wristband (anti-static set, ID 133753) to

yourself before handling any PCBs.
• PCBs and components may be placed on grounded, anti-static
mats only. This also applies when making any kind of
adjustments to PCBs.
• When transporting PCBs (even for very short distances),
always use the special conductive packaging provided for them.
• Make a backup of the machine data, reference curves, valid
cycles and maintenance data to EEPROM: Activate menu
function SAVE MACHINE DATA EEPROM in DATA
MANAGEMENT mode.
• Switch the control OFF
• Remove the old PCB
• Check the jumpers and wrap pin arrays on the new PCB
• Transfer the EEPROMS from the old board to their assigned
sockets on the NEW board (see Chapter Components, KSP
M17-Board).

Caution! Be careful not to swap EEPROMs when you insert

them on the new board! If this happens with software of
Version 1.13 and earlier (TASC 200), the contents of the
EEPROMs will be erased; in the case of newer software, the
control will power up only in SETUP mode.
Controller setup is not possible if this happens on with lasers
with a Bosch user interface.

• Transfer the EPROM from the old board to its allotted socket on
the new board
• Plug in the new board
• Switch the control back ON.

H120E5.DOC Settings and Routine Maintenance 5-3

 2. Examining the power supply module

The +12V and -12V output DC voltages can be set between a

range of +12V...+15V and -12V...-15V, resp. using a front panel
potentiometer:

• +12 V DC ± 10 %

• -12 V DC ± 10 %

Use a Schroff test adapter 20800-177 (ID 088871) to verify the

voltages on the SMP bus (lower bus).

The connection conditions are shown in Chapter 1: Backplane.

5-4 Settings and Routine Maintenance H120E5.DOC

 3. Modifying machine data

The machine data contain information on the laser and on controller

configuration. A distinction is made here between protected and
unprotected data:

Protected machine data (for example all limit values) can be

saved to EEPROM only if a Service card is used instead of
the normal Melcard. Unprotected data can be saved to
EEPROM without any restrictions.

The stored values can be modified or viewed in two different ways:

• With menu guidance in DATA MANAGEMENT mode.

• Directly from any screen using an <ESCAPE> sequence.

Menu-guided editing of machine data

• Activate DATA MANAGEMENT mode.

• Select function MACHINE DATA. A list of machine data

appears:

Editing machine data Fig. 6351E

• Use PAGE - and PAGE + to find the desired machine data.

H120E5.DOC Settings and Routine Maintenance 5-5

 • Edit the machine data.

boole Boolean value: 1 = Function active

0 = Function inactive
digit numerical value

• Retrieve the next machine datum for editing.

• Confirm each change by pressing <ENTER>

• Select function ADOPT.
The edited machine data are transferred to the controller and
stored in the RAM.
• Press the key for DATA MANAGEMENT mode (level return).
• To edit protected machine data: Replace the Melcard on the
KSP-M17-Board with a Service card.

• Select function SAVE MACHINE DATA.

The data are read from the RAM of the controller to an
EEPROM where they are stored.

Data not stored on EEPROM is lost when the control is

powered down at the main switch! The data previously saved
to EEPROM is activated when the control is powered up
again.

• Switch the controller OFF.

• Return the Melcard to its slot if it was previously removed.
• Power the controller up again.

All machine data in the laser control can be viewed or edited

directly using an <ESCAPE> sequence:

5-6 Settings and Routine Maintenance H120E5.DOC

 To edit machine data via an <ESCAPE> sequence

<ESCAPE> [md] • Press the <ESCAPE> key and enter [md]. A window is offered
for data input.
• Enter the desired machine datum, press <ENTER>. The
chosen machine datum is displayed, with the current value.

Input window for machine data Fig. 16657E

• Key in the new value.

• <ENTER> saves the new value.

• Enter the number of the next desired machine datum.

<ESCAPE> [md] • Close the window by inputting <ESCAPE> [md] again.

The window is also closed when you activate function

MACHINE DATA in DATA MANAGEMENT mode.

• Save the machine data to EEPROM (see above).

• Here, too, a Service card is needed to edit protected machine
data.

H120E5.DOC Settings and Routine Maintenance 5-7

 4. Control Reset

The controller must be turned off at the main switch and then
powered up again if a simultaneous, defined reset of all control
modules is desired.

TASC 200 and TASC 300 can also be reset separately:

Hardware Reset TASC 200 To reset the controller, short two adjacent pins of plug X7
(Motherboard):

Pin Reset: Short two adjacent pins on the Motherboard Fig. 7795

The Hardware Reset was successful if:

• the red LED of the CPU on the KSP M17-Board lights up

• the red LED of the Bitbus module lights up.

Hardware Reset TASC 300 Press the <CTRL> <ALT> and <DEL> keys simultaneously to reset
the TASC 300; the system then reboots.

If Panel ID 104618 is installed, the controller possibly may not boot

up after being reset. In this case, disconnect the panel from the
voltage supply for approx. 10 sec.

5-8 Settings and Routine Maintenance H120E5.DOC

 5. TASC 300: Changing to the operating
system level

You must exit the user interface and enter the operating system
level if you have to change the panel software via the serial
interface (Panel ID 111337):

To exit the user interface: • Press keys <ESCAPE> [end].

<ESCAPE> [end]
You now exit the user interface; the operating system prompt
appears. The FLASH-EEPROM can now be addressed with
DOS commands.

To activate the user • Type in the command [autoexec] and press <ENTER> to
interface (ID 111337): confirm. The user interface boots up again.
[autoexec]

To activate the user • Type in the command [tt] and press <ENTER> to confirm. The
interface ID 141963): [tt] user interface boots up again.

6. Setting the language

The language at the user interface is set with machine datum 39.
Possible choices:

Setting Language
0 German
1 English
2 French
3 Italian
4 Spanish
5 Dutch

After editing the machine datum, exit the user interface and
start it again (see above). Optionally, a Hardware Reset may
be performed here.

H120E5.DOC Settings and Routine Maintenance 5-9

 7. Special diagnostic tool: Service Card

Protected machine data and linearization curves for height

regulation can be edited only if a Service card (current version:
V2.x) is used.

This card is similar in appearance to the Melcard for the KSP M17-
Board and is identified accordingly to avoid confusion.

Setting and maintenance work which require a Service card

can be performed only if the Melcard of the KSP M17-Board
was previously replaced (with the control running) with the
Service card.

A distinction is made between bootable and non-bootable cards:

Bootable Service cards The control can boot up with the Service card instead of the
Melcard. In this case, however, the laser cannot be turned on
because the Watchdog circuit is not energized.

Non-bootable Service cards The control cannot boot up if the controller and Service cards have
different software versions.

5-10 Settings and Routine Maintenance H120E5.DOC

 8. Changing batteries

8.1 Motherboard

As the voltage of the lithium battery on the Motherboard is

monitored, battery faults can be detected in time.

Battery change The lithium battery must be replaced every 2 years as described
below:
• Main switch OFF
• Detach and remove the Motherboard
• Replace the buffer battery

2 different types of batteries are in use:

• Lithium battery 3V Type CR½ AA CD (ID 109149), is soldered
in (see Chapter 1: Motherboard, Fig. 7899, item 3)
• Lithium button cell 3V Type Renata CR 2477N (ID 129563) is
plugged in

1 Lithium button cell

Motherboard with button cell Fig. 16734

The date and time must be reset after changing batteries.

Error messages Error 78: battery is emty, invalid data
by defective battery Error 79: wrong beam operation mode

H120E5.DOC Settings and Routine Maintenance 5-11

 8.2 TASC 300 Terminal

TASC 300 Terminals with 80386SL processors (ID 111337) have a

3 V lithium battery of Type CR½ AA CD (ID 109149) for storing the
Setup configuration when the system is OFF. The software cannot
boot up if the battery is too weak; the Setup parameters must be
reset (See Chapter 6).

Battery change The battery is designed to last 5 years. The entire rear housing
panel must be removed for the purpose of battery replacement.

During the warranty period, this panel may not be opened

without the explicit consent of SIEMENS in Ditzingen.

The sequence described below must be strictly observed when

opening the housing:

• Remove screws Sa1 and Sa2.

Heat sinks for the switched-mode power supply electronics

are attached to the rear housing panel with these two
screws. If you forget to undo them, damage to the
aforementioned power supply unit is possible when the rear
housing panel is removed.

Screws on the rear housing panel Fig. 7534

5-12 Settings and Routine Maintenance H120E5.DOC

 • Remove the three screws Sb1, Sb2 and Sb3 for mounting the
terminal plate.
• Remove 8 screws Sc1... Sc8 used to attach the rear cover
plate to the housing.
• Using a sharp flat knife, slit the insulation between rear cover
plate and housing.
• Make sure all necessary screws have been loosened before
you detach the rear housing panel.
• Remove the rear housing panel. The battery (3V CR½AA CD)
is located to the right of the terminal plate on the PCB:

1 Battery

TASC 300 with rear housing panel open Fig. 7903

• Solder out the old battery, and solder in the new battery in its
place; assure yourself that the polarity is correct.
• Apply insulation paste between housing and rear cover plate to
seal the housing.
• Remount the rear panel.
• Power up the TASC-Terminal and re-configure the Setup
parameters (see Chapter 6).

TASC 300 - Color This terminal functions even if the battery is depleted since the
ID 141963 BIOS is stored on the EEPROM. If the battery is empty, a message
is displayed during the boot-up procedure and must be
acknowledged by the operator.

H120E5.DOC Settings and Routine Maintenance 5-13

 9. Calibration curves for TLF lasers

Proceed as described below to calibrate the TLF laser with the

TASC 200:

• Before starting calibration, let the laser run for 10 min. at 100%
CW

Pulsing mode, cutting lasers • Define the measuring frequencies and duty cycle for all 4
calibration curves.

Gating freq. [Hz] 100 500 2000 5000

4 4 8 8-10
Duty cycle [%] 8 8 15 15
45 45 45 45
65 65 65 65

• To verify the accuracy of the calibration curves, create a

diagram in which both the actual reference points and those
established by the control are input and interconnected.
• Correct the laser power or duty cycle at the reference points, if
necessary (the changes must be recorded in the laser log!).

CW mode The calibration curve for CW laser operation is determined by

entering the pair of values (calculated by the control) closest to
75%. The minimum RF amplitude is approx. 7500 mV.

• Here, too, the accuracy of the calibration curves is checked by

means of a diagram with laser power inputs for duty cycles of
75%, 80%, 85%, 90%, 95% and 100%.
• Adjust the mV value accordingly if any corrections are
necessary.

5-14 Settings and Routine Maintenance H120E5.DOC

 Pulsed mode, welding • Define the measuring frequencies and duty cycles for the 4
lasers calibration curves.

At high frequencies, the laser may not be started up at 1 % of

laser power.

At frequencies above 10 kHz, it is also not possible (due to

purely physical reasons) to start up at under 20 % of laser
power since at least 3-5 s are needed for the ignition
process.

Tube-driven generator
Gating freq. [Hz] 100 5000 30000 70000

4 8 20 30
Duty cycle [%] 8 15 25 45
45 45 45 60
65 65 65 75

Transistorized generators
Gating freq. [Hz] 100 5000 5000 20000

4 8 8 15
Duty cycle [%] 8 15 15 25
45 45 45 45
65 65 65 65

• Check the accuracy of the calibration curves as described for

cutting lasers; make corrections where necessary.

At a gating frequency of 99 kHz, laser ignition is not assured

for powers below 30 %. Through implementation of special
measures such as matching or modifying the shutoff
thresholds of the RF generator, lower laser powers can be
attained even at 99 kHz.
Initially, ignition is set and verified for laser power above
30 %, and subsequently set for 20 % laser power at 50 kHz.

H120E5.DOC Settings and Routine Maintenance 5-15

 Chapter 6

Setup
1. Setup ............................................................................... 6-2

2. TASC 300: Setup ............................................................ 6-4

3. Setup of DIAS I height regulation

with Lasermatic 1.5 ........................................................ 6-6

H120E6.DOC Setup 6-1

 1. Setup

When the controller is booting up, two consecutive memory cells of

the two EEPROMs on the KSP M17-Board are checked. Invalid
data sets or socket-exchanged EEPROMs can be detected in this
manner; the controller then goes into Setup mode.

Caution! In software versions 1.13 and earlier, the contents

of socket-exchanged EEPROMs were erased during the
controller booting process!

The Setup Mode (identified by the text "TASC -1" in the title bar of
the user interface) differs in many ways from normal controller
operation. For example:

• The 24 V supply for the I/O cards is not turned on

• The Watchdog circuit for the controller is not active
• Action telegrams are not recognized
• A machine data error is issued
• The laser cannot be turned on from the control panel

In Setup mode, therefore, only data can be edited at the control; the
controller cannot be powered up correctly until the data needed for
booting up has been re-entered and stored.

The procedure below must be observed for data input:

• When the user interface appears, enter the current time and
date (leading zeros must be input, the year must be specified
with 4 digits).
• Configure the machine data for your laser (see separate
description of machine data). All machine data presented here
with a value of 65535 must be edited!
Other machine data, such as Options, Calibration or Ramp
Cycles, may be edited if desired but are not of significance for
booting up the controller.

6-2 Setup H120E6.DOC

 Since all machine data can be edited in Setup Mode even if
you do not have a Service card, take this opportunity to enter
all requisite data now.

• Save the machine data to EEPROM.

If data backup is completed successfully, message "Turn main
switch OFF" will appear.
Message "Setup error" is displayed if some machine data are
incorrect. Check the machine data (see Chapter 4: Incorrect
machine data); and save the data again.

• Power down the controller at the main switch.

• Then power up the controller at the main switch again.

Setup mode is now terminated, the controller boots up with the

input (valid) machine data.

If the TASC 200 is integrated in another control (e.g. TASC

500), setup can only be performed without the Motherboard.

H120E6.DOC Setup 6-3

 2. TASC 300: Setup

Panel ID 111337 The panel is configured with the aid of the SETUP program (to start
the program: press the <CTRL> <ALT> <S> keys while the
controller is booting up). In order not to endanger faultless
operation of the terminal, neither the user nor the service personnel
are allowed to modify the system setup data unless this is
absolutely essential. In the event of data loss, the values listed
below must be input:

Page in Setup Parameter Setting

1 TIME Current time

DATE Current date

Diskette A “Not installed“

Diskette B “Not installed“

Fixed Disk C: “Not installed“

Fixed Disk D: “Not installed“

Base Memory 640

Extended memory as available
Display EGA / VGA

2 NumLock “On“
CPU Speed “Fast“
RAM Wait States “0“

EMS Memory “Disabled“

EMS Size “No EMS“
EMS BASE I/O Address 208h/209h

640K-1024K Relocation “Disabled“

Shadow System BIOS “Enabled“

Boot Device Order “C: “, “A: “
Password “Disabled“

6-4 Setup H120E6.DOC

 Page in Setup Parameter Setting

3 Manual Override Enabled

FDC Interface Disabled

IDE Interface Disabled

Primary Serial Port Enabled

Secondary Serial Port Enabled

Primary Serial addr “COM1“, “3F8H“

Secondary Serial addr “COM2“, “2F8H“

Parallel Port “278F“

Parallel Port Mode Printer

4 DMA Clk Source Select Ideal val. for max. performance

Bus Clk Source Select Ideal val. for max. performance

Refresh CMD Width Ideal val. for max. performance

CPU Clk Select “CPUX1“

(PROCCLK)

Parity Control “Enabled“

Dynamic Memory Sizing “Enabled“

DRAM Configuration as available

Base RAM Above 256K “Enabled“

Extd. Memory Boundary “No Boundary“

• Use either the <Page DOWN> and <PAGE UP> keys or the
<TABULATOR> key to scroll through the text.
Use the <CURSOR> keys to jog to the desired positions.
• Changes are made using the <SPACE> bar.
• Press <ESCAPE> if you want to quit the Setup program
without saving the changes.
• Press the <TWO-HAND OPERATION> key to exit Setup and
save the modified data.

Caution! Do not make any changes in window "CHIPSet

REGISTER CONTROL"!

TASC 300 - Color The Setup parameters are additionally stored on EEPROM. Manual
ID 141963 settings, therefore, are not necessary.

H120E6.DOC Setup 6-5

 3. Setup of DIAS I height regulation with
Lasermatic 1.5

DIAS I height regulation setup must be performed

• the first time the height regulation is started up

• if the height regulation Process CPU is replaced by a new
processor card
• if error message 501 "Variables not from EEPROM" is issued.

The processor card must be set up correctly before height

regulation can become operational!

Setup The height regulation is set up as follows:

• Change to Special Functions in the height regulation user

interface
• Insert the Service card
• Press softkey <MODIFY VALUES>
• Activate the cursor by pressing the <CTRL> and <ALT> keys
simultaneously
• Enter the machine type in the "Machine" field and press
<ENTER>
Type 1: TC L3003E, TC L4003E, TC L3030
Type 2: TC L2503
Type 3: TLC 105, TC L 5005
Type 4: TC L2503E
Type 5: TC LY 2500
Type 6: TC 600L

• Wait until message "Application ended" appears (max. 20 sec);

otherwise, repeat the last step

Verification • Back up one level (activate Manual mode)

• Press softkey <LINEARIZATION CURVES> (the markers for
the curves saved for cutting head 1 must be 1)
• Compare the settings in the Regulator, Spatter Compensation
and Special Functions levels with the parameters for height
regulation setup (Drawing No. 9558-967).
• Load the serial laser software
• Turn the main switch OFF, then ON again (with a brief pause in
between).

6-6 Setup H120E6.DOC

 Chapter 7

Schematics
Interface descriptions
Bitbus connections
Jumper lists
Safety circuit
RF generator
DIAS I with Lasermatic 1.5

H120E7.DOC Schematics 7-1

 Chapter 7

Interface description
The following interfaces are provided for external control of the
laser (see TLF Laser Operating Instructions, Chapter „Interface
Description“):
• X9: Digital interface
• X43: Interface TASC-Terminal connection
• X50: Safety interface
• X55: Standard interface

H120E7.DOC Interface description 7-3

 Resonator types

The following resonator types exist:

Resonator type Laser type

40000 TLF 700t - 1500t
44000 TLF 2200t - 3001t
44001 TLF 4001t - 5001t
48000 TLF 3000t - 6000t
49000 TLF 7000t - 12000t
50000 TLF 20000t

xx0xx Manufactured at TLT

xx5xx Manufactured at TAI

40000 Resonator frame of stainless steel

40001 Resonator frame of aluminium

7-4 Interface description H120E7.DOC

 Chapter 7

Safety circuit

H120E7.DOC Safety circuit 7-9

 K 1 K 2 C + 2 2 - K 2 (2 K 2 0 ) A
2 4 V 2 4 V
4 6
5 5
+ 1 0 -X 1
X 1 (X 3 0 )

7 2 0

1 a 1 b 2 a 2 b X 3 0
B

S 1 S 2
S 2

X 7 .8

X 7 .9
X 4 X 6 X 6
X 3 X 3 X 4 1 1 1 2 .1 8 .2 2 .2 3
.9 2 2 2 1 .2 1 .1 9 F 1

D E F

A System control C TCO-HF1 card D RF end stage

+22-K2 (2K20): Safety circuit K1 Sum error: S2 Circuit breaker for cover
The relay opens in the case of
B Oscillator and Regulator card E HV power supply
all generator error messages
detected via digital or analog F1 Overcurrent relay
inputs on the TCO-HF1 module.
F Power supply distribution
K2 Watchdog. The relay opens if a
S1 Circuit-breaker for rear door
Watchdog-Error occurs (red LED
is illuminated). S2 Circuit-breaker for front door

Safety circuit on tube-driven generators Fig. 16901

7-10 Safety circuit H120E7.DOC

 Chapter 8

Error messages

H120e8.doc Error messages 8-1

 Error messages can be divided into 6 different categories:

Error number Assembly in question

000 - 099 Laser
100 - 199 Generator 1
200 - 299 Generator 2
300 - 399 Generator 3
400 - 499 Generator 4
500 - 599 DIAS I height regulation
from 600 Laser

For analog errors, the messages include the valid limit values while
only text information is given for digital errors.

Note that Info messages (which are also displayed in the title bar)
are distinctive from error messages. Info messages have the
following structure:

xxxx: My „Message text“

xxxx Info number

My Characteristic of message M1 positive acknowledg.
M2 negative acknowledg.
M3 Operation messages
M4 Status messages

8-2 Error messages H120e8.doc

 Chapter 8

Generator error messages

H120e8.doc Generator error messages 8-5

 Error Messages

RF Generator IS11-22
Error messages

RF Generators IS11-22

Edition 03/99
 1. Digital errors RF generators IS 11/15/
17.5/18/22 kW with tube end stage
Error messages at generator 1

The error is generated if the input is open or if voltage U < 7V is

present.

No. Description Cause Effects Measures

162 T3 Excess temperat. The thermal switches The laser beam is Examine fans E1 and
HV transformer in the windings of switched off. E2 in the HV power
transformer T1 in the supply unit
Error if X1/11b at HV power supply unit High voltage K 5.2, K
TCO-HF 1 = 0 for have tripped. 5.3, K 5.4 or +10 - K 3, Check power supply
500 ms Error at 125°C-150°C +10 - K 4, +10 - K 5 is X 20/2 3x 400 / 3x 480
disconnected. V

163 T1 Excess temperat. Thermal switch F2 in Examine fan E1 in the

Tube end stage the RF end stage has RF end stage
tripped.
Error if X1/11a at Error at 71°C
TCO-HF 1 = 0 for
2000 ms

164 RF generators with Kobold flow monitors

(MD4 = 11000, 11001, 15000, 15001, 17500, 17501)

Q1 water flow 1. The water flow rate This causes not only 1. Check flow monitor
RF generator in the driver stage the high voltage but F1, driver stage,
or end stage is also the heater/grid flow rate for heat
Error if X1/12b at less than 10 voltage to be switched exchanger and
TCO-HF 1 = 0 for liters/min (reported off. The chiller will also cooler plate.
10000 ms by flow monitor F1) be deactivated. Check the end
or the flow rate in As a result, the stage, flow rates for
the tube is less turbine, too, is shut heat exchanger in
than 11 liters/min. down. the grid power
supply and coil L1
of the output
oscillating circuit

2. Flow monitor F2 2. Check flow monitor

or temperature T F2, check flow rate
of return water flow for the tube,
in tube ≥ 55°C sacrificial anode,
water-cooled
resistor and
collector cathode.

H120E8.DOC Error messages RF Generator IS11-22 11

 No. Description Cause Effects Measures

3. Thermal switch F3 3. Thermal switch F3

additionally
monitors flow rate
F2 of the tube

4. Forward flow 4. Check the water

temperature too temperature at the
high chiller

5. Water hose in RF 5. Visual check

generator burst

6. Pre-filter in copper 6. Replace the filter

circuit on Autolas cartridge
(-plus) is dirty.

164 RF generators with analog Sika flow meters

(MD4 = 11002, 11003, 15002, 15003, 17502, 17503, 22002, 22003, 40002)

T4 Excess temperat. 1. Forward flow Besides ”Beam OFF”, 1. Check the water
return water flow temperature too the heater and grid temperature at the
high voltage is also chiller
Error if X1/12b at switched off
TCO-HF 1 = 0 for 2. Flow rates too low 2. Check the hoses in
t • 2s (clogging?) the RF generator

Thermal switch F3 3. 24V supply for 3. Check the 24V

opens at T > 55°C laser controller power supply via
missing: then all connector X30
digital errors

4. Thermal sensor
defective

165 Excess current IB 1. Old, used tubes: Error 168/268 1. Check the load
Transistor driver through amplifi- Causes transistor exerted by the RF
stage cation regulation, driver stage sum error end stage on the
these tubes result after 500 ms output circuit of the
Error if X1/12a
in a driver power driver stage.
TCO-HF 1 = 0
higher than the Check RF cable W2
In the RF transistor allowed current driverÅend stage.
driver stage, the limit limit or:
value for the Drive stage Check the tubes,
preliminary stage (IB defective replace if necessary
5) or end stage (IB 1-
IB 4) current has Check the grid
been exceeded. power supply

Check driver stage

with external water
resistor in ”CW
unregulated".
operating mode

12 Error messges RF Generator IS11-22 H120E8.DOC

 No. Description Cause Effects Measures

Preliminary stage: IB 5 2. Fuse F2 2. Check fuse F2

(-15V) on the (1.6A / M)
1 kW 6.0 A electronic power (-15V) on the
1.2 kW 7.0 A supply unit electronic power
2 kW 6.0 A defective supply unit

End stage: IB1 - IB4

1 kW IB1 36 A
1.2kW IB1-IB4 14 A
2 kW IB 1;IB2 36 A

Fault if limit value is

exceeded for 500 ms.
Red LED V 56 on
monitoring and
regulation PCB of the
transistor driver stage
lights up.

166 RF power 1. Output circuit of Error 168/268 1. Check output circuit

PBR too high transistor driver Sum error transistor – of transistor driver
Transistor driver stage has no 50 Ω driver stage is issued stage
stage after 500 ms

Error if X1/13b TCO- 2. RF cable between 2. Check RF

HF1 = 0 driver and end connection cable
stage defective W2 between RF
In the RF transistor driver stage and
driver stage, reflected end stage
power PBR
exceeded the limit 3. Input circuit of RF 3. Check input circuit
value. end stage has no of RF end stage
50 Ω, e.g. small
Driver stage / PBR matching capa-
0.6 kW 95 W citors at cathode
input defective;
1.0 kW 195 W
line coil L3 loose
1.2 kW 195 W or bent
2.0 kW 395 W
4. Tube heater 4. Check the tube
Error message is
defective heating (5.8 V AC)
issued if limit value is
overshot for
t=500ms. Red LED V
60 on monitoring
and regulation PCB
of the transistor
driver stage lights up.

H120E8.DOC Error messages RF Generator IS11-22 13

 No. Description Cause Effects Measures

167 Power-combiner SPC 1. At least one of Error 168/268 Sum 1. Transistor-driver

asymmetrical several end stage error of Transistor stage 1.2 kW Type:
Transistor driver modules generates driver stage, issued End stage currents
stage. insufficient power after 500 ms IB1 - IB4

Error if X1/13a TCO- 2 kW Type: Check

HF 1 = 0 end stage currents
IB1-IB2 for
1,2 kW and 2.0KW- symmetry.
Transistor driver
stage. Compare the
If an end stage analog values in
module fails, signal Service mode / RF
SPC is formed in the Generator
power combiner diagnostics with CW
(A11). Error message 0%, 1%, 2%
if the limit value is
2. Power combiner 2. Inspect, visual
overshot.
defective check or exchange
P 29/X4 > 3 V
Monitoring and
regulation PCB (C40- 3. Fault in 1.0 KW 3. Solder in the bridge
0851 /C40-1514) driver stage: bridge
TP15-TP29 on
Red LED V 52 Monitoring and
on Monitoring and Regulation PCB
regulation PCB of the C40-1514 missing.
transistor driver stage
lights up (C40-
0851/C40-1514)
Not processed on
1 kW transistor driver
stage (contains only
1 module)

168 Transistor driver 4. This sum error is a 1. The triggering error

stage sum error series connection is displayed at the
of all error monitors TASC terminal.
Error if X1/14a TCO in the transistor
–HF1 = 0 for t=500 driver stage.
ms
Is triggered with
faults:
173/273 Excess
water temperature
TB2
170/270 Excess air
temperature TB1
167/267 Power-
combiner SPC
asymmetrical
165/265 Excess
current IB
166/266 RF power
PBR too high

14 Error messges RF Generator IS11-22 H120E8.DOC

 No. Description Cause Effects Measures

2. On monitoring 2. No error display if

PCB C40-1417, there is a fault on
relay K1 de- the monitoring
energized because PCB.
of +/- 15 V DC Check +/- 15 V DC
supply is missing supply to transistor
driver stage

• Check power
supply unit A2
C40-0709
+/- 15V, +24V
• Inspect the
fuses of the RF
driver stage F1
(+15V) and F2
(-15V) 1.6 A
• Test points:
Check the
monitoring and
regulation PCB
C40-0851 (old)
C40-1514
+15 V TP 36
GND TP 38
-15 V TP 35

3. Fuse F3 (+24V) in 3. Inspect fuse F3 on

transistor drive the RF driver stage
stage defective
(incl. error 173)

169 Front door open Cover of HV power • The second contact Check interlock switch
supply unit open opens the safety S2 on cover of HV
Error if X1/15a TCO- Interlock switch S2 circuit . power supply unit, front
HF = 0 Error message "73"
Switch not correctly See power distribution
The cover of the HV Safety Circuit Open
mounted diagram B 35-xxxx
power supply unit is is issued with
monitored by safety Cover of HV power "Beam ON” or while
interlock S2 supply unit not the beam is active.
properly closed • Cover of HV power
There are two circuits
supply unit not
with two contacts for
properly closed
monitoring it
• Error messages

• Safety circuit

From Week 17/98: For better safety circuit

HV power supply diagnostics, the switch
open has been re-located.
(No error is issued
when the front door is
opened)

H120E8.DOC Error messages RF Generator IS11-22 15

 No. Description Cause Effects Measures

170 Excess air temper- 1. The control was Error 168/268: 1. Either ”Chiller ON”
ature TB1 at ON for a long time As a result, transistor via switch elements
Transistor driver without "Laser driver stage sum error for 10 min or ”Laser
stage ON". The air heats is issued after 500 ms ON”
up because there It should be
Error if X1/15b TCO-
is no cooling. possible to clear the
HF 1 = 0 for t=2000
error when the laser
ms
is ready.

The self-heated air

2. Fan E1 defective 2. Check fan E1 of the
temperature sensor
RF Driver stage
C40-0807 in the
transistor driver stage
(RF module) tripped. 3. Temperature 3. Check the air
The air flow of fan E1 sensor defective temperature sensor
is monitored. C40-0807
Error if T•40°C
4. No 24V supply in 4. Check the 24V
Red LED V 46 on driver stage power supply unit
Monitoring and C4-0709 in the RF-
Regulation PCB of driver stage.
transistor driver stage Check via TASC-
(C40-0851/C40- Terminal
1514) lights up. Diagnostics, RF
generator
UB1 = 24 V

• Fuse F3

5. Coolant 5. Check the chiller

temperature too
high (>25°C+5°C)

171 RF housing open The cover of the RF end The safety circuit is Inspect safety switch
(end stage) stage is open. opened by the second S2 of the RF end stage.
Interlock switch S2 contact.
Error if X1/16a TCO-
• Cover incorrectly Error message:
HF 1 = 0
mounted, so that ”73” Safety circuit
The RF end stage the switch does open is issued with
cover is monitored by not close "Beam On" or while
interlock switch S2. the beam is active.
It is monitored with
two contacts in two
circuits.
• Error message
• Safety circuit

172 Rear door open The rear door is open. See 169 / 269 Inspect door contact S1
Error if X1/16b TCO - Interlock switch-S1 at the rear of the RF
HF 1 = 0 • Switch not generator
accurately See power distribution
The rear door is diagram B 35-xxxx
monitored by safety mounted
switch S1 • Rear door not
See 169 / 269 properly closed

16 Error messges RF Generator IS11-22 H120E8.DOC

 No. Description Cause Effects Measures

173 Excess water temper- 1. Coolant As a result, sum error 1. Check the coolant
ature TB2 at temperature too 168/268 Transistor circuit of the RF
Transistor driver high. driver stage is issued driver stage
stage Flow rate too low after 500 ms
Error if X1/17a TCO- Flow sensor
HF 1 = 0 (digital) defective
Thermal switch F1
60°C in the RF 2. 24V supply (UB1) of 2. Check the 24V
module of the the drive stage power supply unit
transistor driver stage defective C4-0709 in the RF-
tripped (opened). driver stage.
The heat sink Check via TASC-
temperature is Terminal
monitored Diagnostics, RF
generator UB =24V
Error if T ≥ 60°C
• Fuse F3
Green LED V 41 on
Monitoring and
Regulation PCB of
Transistor driver
stage
(C40-0851/C40-
1514) extinguishes.

174 Printed circuit board At least one Check the Interlock-

not in slot. connection from a RF circuit in the circuit
Error if X1/17b TCO- generator module to diagram of Oscillator
HF1=0 the Oscillator- and Regulator card
The connections from Regulator card is C40-1557 Page 5
the loose or missing. (C40-1363/C40-
1438/old versions)
• RF driver stage
• HV power supply
• RF end stage
to the Oscillator and
Regulator card are
checked in a series
circuit.

162-174 Digital sum error

1. 24 V error monitoring
Digital errors 162-174 Check fuse F1: Check
voltage from switch
are issued together cabinet defective
1A/M on Oscillator/
Regulator card (C40-
1363 / C40-1438/C40-
1557 Page 7)
2. Connection from 2. Inspect connector
control cabinet to RF X30
generator X30
disrupted
3. Fuse F1 on Oscill.-
3. Check the 24V
Regulator card C40–
1363 / C40–1438 /
supply from the
C40–1557 page 7) control cabinet
defective

H120E8.DOC Error messages RF Generator IS11-22 17

 4. Analog errors RF generators IS 11 to
22 kW with tube end stage Error
messages at RF generator 1

Unless indicated otherwise, the values apply in the sequence for

IS 11/15/17.5(=18)/22 kW

No. Description Cause Effects Measures

131 Prss reflected RF 1. RF cable RF generator cannot 1. Check cable

power (peak value) (generator – laser) correctly transmit its connections, check
not connected output to a load with cable plugs; if
> 5950 W / IS 11
Cable plug or an impedance of 50 •. necessary, replace
> 8100 W / IS 15 cable defective the cable
> 9500 W / IS 17.5 / (flashover) Reflected power too
18 high.

> 11700 W / IS 22 2. Laser incorrectly or Measured values are 2. Check laser

Error if analog poorly matched incorrect. matching.
voltage at X2/5a and Check the gas
5b or test point X8/7 Analog values of pressure, gas
TCO-HF 1 reflected power mixture, gas quality,
U = 10 V for t ≥ 600 increase with „Beam gas type and gas
ms ON“ until limit values temperature
3. Pi/Pr connection are reached. 3. Check W4/W5 cable
cable from connections and
reflectometer to replace, if necessary
Oscillator and
Regulator PCB
(W4/W5) swapped
4. Impulse signals 4. Inspect the fiber
interrupted, optic cable, check
Process I/O or the impulse signals
Oscillator and on the Oscillator and
Regulator PCB Regulator PCB at
defective test point X20.
5. Gating frequency > 5. Modify the operation
10 kHz and low values
laser power
6. TCO-HF1 6. Replace it
defective
7. NVPI nominal 7. Check NVPI via
value missing Diagnose, Analog
values, RF
generator
8. Incorrect 8. Check, see
calibration acceptance protocol

9. Water leakage 9. Visual check

18 Error messges RF Generator IS11-22 H120E8.DOC

 No. Description Cause Effects Measures

132 Prm Reflected RF See error 131 See error 131 See error 131
power (average value)

> 1450 W / IS 11
> 2000 W / IS 15
> 2390 W / IS 17.5/
18
> 2950 W / IS 22

Error if the analog

voltage at X2/6a and
6b or test point X8/8
U = 10 V for t ≥ 600
ms

134 IA 1 end stage 1. Short circuit / Excess current IA> 1. Replace the high
current flashover in HV voltage cable
cable between
> 2450 mA / IS 11 power supply and
> 3650 mA / IS 15 end stage (W3)
> 3650 mA /
IS 17.5 / 18 2. All capacitors in the High voltage 2. Replace the
> 3650 mA / IS 22 end stage / anode flashover capacitors
circuit

Error if the analog

voltage at X2/8b and 3. Insulators in power High voltage 3. Clean insulators
8a or test point X8/24 supply unit and in flashover with alcohol or
the end stage
U = 10 V for t ≥ 600 replace them
ms
4. High voltage cable High voltage missing 4. Replace the cable
on the oscillating or is too low
circuit coil
5. Grid voltage 5. Inspect grid voltage
missing power supply unit,
grid connector, grid
voltage, UG-IG test
card defective

6. Poor coolant quality 6. Replace the cooling

(>200•S) water

7. Capacitor C4 in HV 7. Replace the

power supply unit capacitor
defective
8. HV power supply 8. In Diagnose RF-
unit, transformer T1 Generator, com-
control missing one pare analog values
phase, mains UA1 with those in
terminal transform- the acceptance
er T1, filter Z1-Z3 protocol.
and HV rectifier U1
defective

H120E8.DOC Error messages RF Generator IS11-22 19

 No. Description Cause Effects Measures

136 IG 1 Grid current at 1. Flashover in the 1. Gas fuse at A2 1. Replace the gas
end stage tube ignites fuse, install new
> 980mA / IS 11 tube if necessary
> 1250mA / IS 15
> 1450mA / IS 17.5 2. Capacitors C4 2. Grid voltage UG1 2. Replace the
/ 18 (8x2nF) defective short circuits capacitors, dry
> 1470 mA / IS 22 them if there is any
water damage
Error if analog
voltage at X2/10a 3. Load circuit 3. High IG1 grid 3. Check connection
and 10b or test point interrupted current from oscillating
X8/6 and 5 circuit to RF output
U = 10 V
for t ≥ 600 ms
4. Regulating circuit 4. Connection from
(IS 11, 15, 17.5, 18)
open, connection AVPI reflectometer
or for t ≥ 100ms AVPI to Oscillator-
on the IS 22: then Regulator card
error
5. Tube defective 5. Replace the tube
Monitoring function
currently active only
for IS 22

145 PBr reflected power 1. Output of driver 1. Inspect connection

at the driver stage stage not matched cable (W2)
to a 50 Ω load,
> 99 W (only IS 11 • Cable length
with 600 W driver e.g. defective
correct?
stage MD4= connection cable
11000) between driver
stage and end
> 195 W (IS 11 with stage (W2).
1 kW driver stage
MD4 = 11001 ....
2. Input circuit of tube 2. Check components
11003)
end stage defec- in input circuit of
> 195 W (all IS tive (capacitors) or tube end stage.
15/17.5/18) mismatched Check the input
resistance (VIM)
> 395 W (IS 22 with and correct it, if
2 kW driver stage) necessary.
IS 11: 58 •
IS 15: 58 •
IS 17.5/18: 52 •
IS 22: 70 •

3. Tube heater 3. Check the RF end

defective stage, heater
transformer T1,
control and output
voltage AC 5.8V

20 Error messges RF Generator IS11-22 H120E8.DOC

 No. Description Cause Effects Measures

147 Flowrate Q1 Ruptured hose in the Not only the high Immediately inspect the
< 10 l/min (MD4 = water circuit of the voltage but also the RF generator for water
....002) driver stage or of the heater/grid voltage leaks or clogging.
switch cabinet cooler. and the chiller are
or switched off.
< 8 l/min (MD4 = Water circuit of driver Consequently, the
.....003) stage is clogged turbine is shut down
as well.
Error if flowrate drops
below the limit value
for t ≥ 10 sec.

Lower limit value

needed if using
switch cabinet cooler
with water.

148 Flowrate Q2 < 11 Ruptured hose in Not only the high Immediately inspect the
l/min (MD4=...002, water circuit of the end voltage but also the RF generator for water
003). stage. heater/grid voltage leaks or clogging.
and the chiller are
Error if flowrate drops Water circuit of end switched off.
below limit value for stage is clogged. Consequently, the
t • 10 sec turbine is shut down
as well.

H120E8.DOC Error messages RF Generator IS11-22 21

 RF driver stage fault indication

Driver stage faults are indicated by means of LED's located behind

the window at the front of the driver stage.

V60

V56

V52

V46 V41

LED’s for fault indication Fig. 20531

The LED messages are explained below:

LED Color Explanation

V41 green Water temperature, UB1 OK
V46 red Error: Air temperature
V52 red Error: Power Combiner
V56 red Error: Current
V60 red Error: Reflected power

Details about the type of fault can be obtained via diagnostic menu
„RF Generator“ at the laser controller.

22 Error messges RF Generator IS11-22 H120E8.DOC

 Chapter 8

DIAS I error messages

H120e8.doc DIAS I error messages 8-23