Electronics Manual CNC
Uploaded by
Дмитрий КоваленкоElectronics Manual CNC
Uploaded by
Дмитрий КоваленкоP.
Ingold
Electronics Manual CNC97/98
All machines for construction glass and automobile glass
Industriestrasse5
Maschinen AG
INC.
30,CommerceDrive
CH-4922Bützberg Hauppauge,NY,11788
Telephone+41629587777 Phone+15162311212
Telefax+41629587700 Fax+15162311040
E-Mail [email protected] email [email protected]
http:/www.bystronic.ch
ELEKTRONIK.CNC.BA.V2.USA V-1
Electronics Manual CNC 97/98
Copyright of the edition © 1999 Bystronic Maschinen AG
The work, including all its parts, is protected by copyright. Any use outside the narrow limits ofthe copyright law is not permitted
without Bystronic’s consent.
Information on operating instructions
Author:P.Ingold Date:2.2.1999 Initials:PI
Version: 2.0
Order-No.: ELEKTRONIK.CNC.BA.V2.USA
Checked & Approved
Technology:Th.Plüss Date:29.1.1999 Initials:TP
Documentation:R.Fankhauser Date:5.2.1999 Initials:rf
When reordering, always state the above order number and version of this Manual. Information concerning errors and
proposals for changes should be sent to:
Bystronic Maschinen AG
Abt. Dokumentation
Industriestrasse 5
CH-4922 Bützberg
Telefax +4162-958 77 00
E-Mail [email protected]
Trade marks:
Bystronic would like to draw attention to the fact that the company names and trade names mentioned and product
designations may be protected by patent and trade mark law.
V-2 ELEKTRONIK.CNC.BA.V2.USA
Using this Manual
Page organization
The pages of the operating instructions have the following structure.
Information on structure of the operating instructions
1 The header contains the name of Title 1
2 Title1
3 Brief summary of the present chapter
4 Contents of the chapter contains threestages
1st stage Main title, this appears only in the contents at the beginning of the Manual and in the
contents of the chapter.
2nd stage Title 1, these chapters deal with a topic on a certain machine or assembly.
3rd stage Title 2, this subsection always deals with a topic which is discussed in the corresponding
Title 1.
5 Order number of the operating instructions. This number reveals the machine type, the typeof
instructions, the version of the operating instructions and the language.
6 Page numbering of the current chapter.
7 Table caption and brief explanation.
8 Figure caption and brief explanation.
9 Information with preceding pictogram must be complied with.
10 Refers to pages with moredetailed information.
11 Explanation of a technical word used or of an abbreviation.
ELEKTRONIK.CNC.BA.V2.USA V-3
Important information
Before you begin working on the machine, it is essential to read the
general safety requirements in the maintenance instructions.
This Electronics Manual is designed for service personnel with a
thorough knowledge of industrial electronics. It is t herefore not
necessarily suitable for t he operator.
V-4 ELEKTRONIK.CNC.BA.V2.USA
Table of Contents
1 Block diagra m 1-1
2 Electronics rack 2-1
3 Stepping motor rack 3-1
4 Peripheral cards 4-1
5 Panel PC 5-1
6 Drive system 6-1
7 Drive supply module 7-1
8 Drive module 8-1
9 Pressure controller 9-1
10 Positioning module UNIPOS 10-1
11 Adjustment instructions 11-1
12 Appendix 12-1
ELEKTRONIK.CNC.BA.V2.USA V-5
V-6 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter 1
Block diagram
1.1 Block diagram ................. ................. ................ ................. ..... 1-2
1.1.1 XYZ97/98
1.1.2 XYZF97/98
1.1.3 XYZF97/98R
1.1.4 XYZF97/98DS
1.1.5 PSM-XYZF98
1.1.6 KSM97/98
1.1.7 KSBM97/98
1.1.8 PSM97/98 (Stand alone)
1.1.9 PSM97/98 Compact
1.1.10 PBM98
ELEKTRONIK.CNC.BA.V2.USA 1-1
Block diagram XYZ97/98
1-2 ELEKTRONIK.CNC.BA.V2.USA
Block diagram XYZF97/98
ELEKTRONIK.CNC.BA.V2.USA 1-3
Block diagram XYZF97/98R
1-4 ELEKTRONIK.CNC.BA.V2.USA
Block diagram XYZF97/98DS
ELEKTRONIK.CNC.BA.V2.USA 1-5
Block diagram PSM-XYZF98
1-6 ELEKTRONIK.CNC.BA.V2.USA
Block diagram KSM97/98
ELEKTRONIK.CNC.BA.V2.USA 1-7
Block diagram KSBM97/98
1-8 ELEKTRONIK.CNC.BA.V2.USA
Block diagram VSM97/98
ELEKTRONIK.CNC.BA.V2.USA 1-9
Block diagram PSM97/98 (Stand alone)
1-10 ELEKTRONIK.CNC.BA.V2.USA
Block diagram PSM97/98 Compact
ELEKTRONIK.CNC.BA.V2.USA 1-11
Block diagram PBM98
1-12 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 1-13
For your notes
1-14 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Electronics rack
2.1 The CNC Rack ..................................................................... 2-2
2.1.1 RACK SUPPLY 2
2.2 CPU ....................................................................................... 2-8
2.2.1 CPU 386SX
2.2.2 Light emitting diodes on CPU
2.2.3 CPU switches
2.2.4 CPU Jumpers
2.3 ROM/RAM2 ...................................................................... 2-12
2.3.1 ROM/RAM2 Jumper
2.4 CUTCON2
2.5 IMPGEN ...................
2.5.1 Impgen switches .......................................................... 2-18
2.6 POSCON ........................................................................... 2-22
2.7 SERCOM2 .......................................................................... 2-28
2.7.1 Adapter cards for SERCOM2
2.8 DIOCOM ........................................................................... 2-36
2.8.1 Adapter cards for DIOCOM
2.9 POSCAD ............................................................................ 2-44
2.9.1 POSCAD switches
ELEKTRONIK.CNC.BA.V2.USA 2-1
2.1 CNC rack
2.1 The CNC Rack
The " CNC rack has space for the power supply, a CPU card and
cards for
peripherals.
The card guides() are equipped with spring contacts which provide optimal
Electrostatic discharge protection from ESD. As soon asthe peripheral cards havebeen inserted, the ESD
protection compone nts of the peripheral cards are connected to groundand can
thus eliminate any static charges before the bus connection is made.
Electrostatic discharge
The discharge of static electricity from an external source, e.g. as a result of touching
with the hands, often leads to destruction of the circuit
Themetallic plug fa stening rail () at the back of the rack permits extensive contact
with the cable screens via the plug hous i ng of the incoming and outgoing cables.
The back panel ) (makes the connection between power supply, CPU and the
other peripheral cards used. A slot number for addressing is available for every
slot.
The back panel (NCBUS) is in the form of a multilayer circuit board with 3 signal
layers and 5 supply layers. A signal layer is enclosed between every two supply
layers. The screening effect of the supply layers results in optimal attenuation of
the cross-talk of
impedance betwee n the signa
the signal l line
lines to s.
theIt is also pos
driver ICssible
on in
thethis way to ada
peripheral pt the
cards.
2-2 ELEKTRONIK.CNC.BA.V2.USA
2.1 CNC Rack
Fig. 2.1a (Electronics rack)
ELEKTRONIK.CNC.BA.V2.USA 2-3
2.1 CNC rack
2.1.1 RACK SUPPLY 2
The RACK SUPPLY 2 provides the rack wit h the stabilized volt ages, 5 V/20 A
digital part, ± 12 V⁄1.5 A analogue part, and the unstabilized voltage14 V/6 A of
the encoder supply.
Computer Numerical Control To ensure satisfactory operation of the CNC control, all voltages are monitored.
If the mains voltagefails, an AC powe
rfail is generated after two half-waves (one
period, 20 ms). The CNC control detects this and can save the most important
data a
nd bring the system to a safe state before the DC volt agefails.
The RACK SUPPLY 2 isequipped with 3 signal inputs. The inputs ALARM A
and ALARM B() are managed by the watchdog of the CPU, which is activated
by the machine software. The third signal RESET is triggered by the reset switch
on the CPU. If oneof the 3 signals responds, the relay K3 (in the CNC cabinet,
NC Ready) will drop out. The relay K3 is used for communicating the failure of
the supply voltage (in the CNC rack) to a superior control (NC Ready).
The presenceof the four volt ages is indicated by means of LEDs,( , , ) on
the front panel and can additi onally bemeasured via 5 VDC(), ± 12 VDC (,
) and 14 VDC () test jacks. If one of the controlled DC voltages falls below its
minimum reference value, a DC powerfail is generated. The situation currently
leads to a system reset. At the same time, the relay K3 (in the CNC cabinet) will
drop out.
The RACK SUPPLY 2 requires 4 different input voltages. These voltages are
supplied by a mains transformer which is electrically isolated from the mains input.
The four inputs are protected by fuses
). (
The housi ng of the RACKSUPPLY 2 contains four reserve fuses)( which, if
required, can be used as a replacement for the faulty
). fuses (
2-4 ELEKTRONIK.CNC.BA.V2.USA
2.1 CNC rack
Fig. 2.1b (RACK SUPPLY 2)
Legend:
1R eserve
fuses 7 -12 VDC LED
2 Fuses 8 -12 VDC test jack
3 +5
VDCLED 9 14 VDC LED
4 +5VDCtestjack 10 14 VDC test jack
5 +12
VDC LED 11 Alarm A + B LED
6 +12 VDC test jack
ELEKTRONIK.CNC.BA.V2.USA 2-5
2.1 CNC rack
Fig. 2.1c (Block diagram of RACK SUPPLY 2)
2-6 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 2-7
2.2 CPU
2.2 CPU
2.2.1 CPU 386SX
The CPU card is equipped with an 80386 SX microprocessor from Intel. The
processor is operated ta20 MHz clock frequency . The system thus achieves a
Abbreviation for processing speed of approx. 5 MIPS. The processor loses little power and therefore
millions of instructions per second needs no cooling system. Owing to the intensive computational use in calculation
and for working through the NC program, the CPU card is equipped with an
80387SL coprocessor from Intel. The efficiency of the system is greatly increased
especially in floating point calculations. The CPU card is equipped with a univer-
sal port module. 2 independentports are thusavailable, channelA and cha nnelB.
Channel Ais connected as an RS232C port and is used for connection of a CMR
terminal (Console Monitor). This port serves for program development and
testing and is used exclusively by the Bystronic Development Department.
Channel B can be operated as an RS 232C or as a fibreoptic port (TOS link).
When configured as an RS232C port, channel B conne ctsthe AT terminal to the
older (CNC89/92) machines. When configured as a TOS link (Opto port),
channel B connects the CNC by mea ns of a fibreoptic cable to the operator
terminal (Panel PC) of the CNC 97/98 machine generation. The 2 ports are
electrically isolated from the rack and from one another. The transmission rate is
115.2 kbit/s.
Fig. 2.2a (CPU 386SX)
2-8 ELEKTRONIK.CNC.BA.V2.USA
2.2 CPU
2.2.2 Light emitting diodes on CPU
LED H1 yellow
BUSY indicates by means of its luminous intensity the level of utilization of the
processor.
LED H2 green
IDLE indicates by meansof its luminousintensity the time for which the processor
has been waiting in a queue for work.
LED H3 red
HALT indicates that the processor has encountered aHALT instruction when
executing theprogram and cannot continueperforming the current task. This error
can be eliminated only by a cold system start or by an interrupt.
LED H4 red
SHUTDOWN indicates that a serious error has occurred during execution of the
program. Possible causes are the interrupt 8, 13 or a stack overflow. The system
can berecovered from the situation only by an NMI N( on M askable
I nterrupt)
or a cold start.
LED H5 yellow
Bus timeout. The proce
ssor hasunsuccessfully wait ed for a ready signalfrom an
addressed
waiting time. interface card andfurther
In this situation, has itself terminated
execution the
of the bus cycle
program after thewithout
is possible maximum
problems, but this is a warning that an interface card is not present in the system
or is faulty.
LED H6 red
INT ERRUPT REQUES T lights up during execution of an interrupt routine. It
is activated by the INTA signal of the processor and si cleared again by the software
at the end of the interrupt routine.
ELEKTRONIK.CNC.BA.V2.USA 2-9
2.2 CPU
2.2.3 CPU switches
S1
The CPU performs a cold start and triggers a system reset.
S2
Position of the memory on the CPU card. (Standard setting: No. 1 at ON/No.
2 at OFF applies to all machines.)
S3
Serves for switching channel B from RS 232C to the fibreoptic (Opto).
Position 1: Fibreoptic(Tos link)
Position 2: RS 232C
2.2.4 CPU Jumpers
J5
Configuration of external interrupts:
Pin 1 with 8 external N on M askableInterrupt (NMI) connected to internal
NMI
Pin 2 with 7 external AC powerfail (ACPF) connected to internal NMI
Pin 4
Pin 3 with
with 56 external IN
external ACT9
powerfail (ACPF)
connected connected
to internal IN T9to INT9
Factory settings for all machines
Pin 1 connected to 8
Pin 4 connected to 5
Fig. 2.2b (CPU 386SX)
2-10 ELEKTRONIK.CNC.BA.V2.USA
2.2 CPU
Fig. 2.2c (Block diagram of CPU 386SX)
ELEKTRONIK.CNC.BA.V2.USA 2-11
2.3 ROM/RAM2
2.3 ROM/RAM2
Read Only Memory/RRead Access The ROM/RAM2 is the main memory and progra m memory card of the CN
Memory control. The card is equipped with 1 MB memory chips . It is divided into 4
memory banks(bank 0 to bank 3). Thefirst bank (bank 0) is equipped with RAM.
The 4thbank (bank 3) is equipped with flash EPROM and thus serves as a read-
only memory for holding the CNC software. The 2nd and 3rd banks (bank 1
and bank 2) are not used at present and thus serve for later memory extension.
The RAM section, bank 0 to bank 2, is protected with a lithium battery to prevent
data loss. The battery capacity is sufficient for maintaining the data for about 5
years.
2.3.1 ROM/RAM2 Jumper
J1
The RAM section of the card is connected to the lithium battery() by jumper
J1 (). When the card is stored, jumper J1 must be removed to protect the battery.
Fig. 2.3a (ROM/RAM2)
2-12 ELEKTRONIK.CNC.BA.V2.USA
2.3 ROM/RAM2
Fig. 2.3b (Block diagram of ROM/RAM2)
ELEKTRONIK.CNC.BA.V2.USA 2-13
2.4 CUTCON2
2.4 CUTCON2
Cut
Cutting Con
Controller The CUTCON2 generates path-depe
ndent real-timecontrol signals for thevarious
working processes.
The card contains four RS422 outputs and one 16 bit TTL output and one
analogue (0-10 VDC) input and output. With the PLD CUT2-A, the switches
SW1, SW2 and SW3 are inactive.
Information!
In the glass machines, the 3 switches (SW1, SW2 and SW3) are never
used. T he switch settings are therefore unimportant.
LED`s
The four LEDs (1, 2, 3 and 4) are not actuated and thus have no function as error
or status indicators.
2-14 ELEKTRONIK.CNC.BA.V2.USA
2.4 Cutcon2
Fig. 2.4a (Cutcon2)
ELEKTRONIK.CNC.BA.V2.USA 2-15
2.4 Cutcon2
Fig. 2.4b (Block diagram of CUTCON2)
2-16 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 2-17
2.5 IMPGEN
2.5 IMPGEN
Im
Impuls Gen
Generator The feed pulse generator card IMPGEN generates all feed frequencies required
Master card for controlling the for the axis system and controls the connected axis cards (CUTCON2/
POSCON cards POSCON).
A green light emitting diode shows when the IM PGEN actuates the cards
connected to it. The red LEDindicates that the maximum acceleration hasbeen
reached. The pulse generatorcard can control up to max. 7 axe
s.
2.5.1 IMPGEN switches
Interrupt:
The switch block SW1 defines the interrupt address of the card. The default setting
(SW1) of the third switch on all machines is ON (switched on). The remaining
switches must be set to OFF (switched off ).
Master frequency:
The switch block (SW2) defines the divider ratio of the master frequency. The
default setting of all switches is OFF (switched off ). The more switches set to
ON (switched on), the slower the axes of the machine travel sincethe frequency
for actuating the Poscon is lower.
Encoder input:
The switch block (SW3) defines the multiplication factor with which the encoder
inputs of the hand wheel on the remote control are multiplied. This option is
not used at present in the glass machines.
Tab. 2.5a (IMPGEN)
2-18 ELEKTRONIK.CNC.BA.V2.USA
2.5 IMPGEN
Overview of the switches according to machine type:
Tab. 2.5b (IMPGEN switch settings)
LED 1:
The IMPGEN actuates one or more POSCONs.
LED 2:
The maximum acceleration was reached.
Fig. 2.5a (IMPGEN)
ELEKTRONIK.CNC.BA.V2.USA 2-19
2.5 Impgen
Fig. 2.5b (Block diagram of IMPGEN)
2-20 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 2-21
2.6 POSCON
2.6 POSCON
Pos
Position Con
Controller The position control card POSCON controls a complete servo axis. The required
analoguevalueof ± 10 Vis output via a 12 bit D/A conve
rter to thespeed controller
(drive module). While working through the CNC code (cutting, drilling or
grinding plan), the path is interpolated under IMPGEN control.
The approach to the reference and movement by means of the hand keysis
performed independently by the POSCON; these actions are indicated by means
of the green light emitting diode (RUN).
When the axis is exactly on the zero mark of the encoder, the red LED lights up.
If the maximum required value of ± 10 VDC is present, the red LED also lights
up.
Potentiometer P2:
The potentiometer P2 is used for symmetrical adjustment of the ± 10 volt required
value.
LED 1: Red
• The maximum required value is present (overflow)
• The axis is exactly on the zero mark of the encoder
LED 2: Green
• The
and Pos
con actuates
manual the axis without Impgen control (approach to reference
movement)
Fig. 2.6a (Output voltage POSCON)
2-22 ELEKTRONIK.CNC.BA.V2.USA
2.6 POSCON
Fig. 2.6b (POSCON)
ELEKTRONIK.CNC.BA.V2.USA 2-23
2.6 POSCON
Switch block SW1:
The multiplication factor of the encoder channels is set with switch block S
W1.
Tab. 2.6a (POSCON switch positions)
Information!
T he encoder channels A + B are rotated (interchanged) electronically w
ith
switch 9. This changes the counting direction of the channel (±). The
procedure for correct setting of switch 9 is described in the instructions for
commissioning.
2-24 ELEKTRONIK.CNC.BA.V2.USA
2.6 POSCON
Wire wrap configuration
Tab. 2.6b (Wire wrap configuration)
ELEKTRONIK.CNC.BA.V2.USA 2-25
2.6 POSCON
Key to wire wrap configuration
Fig. 2.6c (Wire wrap connections)
2-26 ELEKTRONIK.CNC.BA.V2.USA
2.6 POSCON
Fig. 2.6d (Block diagram of POSCON )
ELEKTRONIK.CNC.BA.V2.USA 2-27
2.7 SERCOM2
2.7 SERCOM2
Ser
Serial Com
Communication Card The SERCOM2 board is a serial interfacecard. It has four indepe ndent ports which
are electrically isolated from the rack and from one another.
These four ports can be adapted to the port required in each case by mounting
different interface adapters (SER232, SER422, SERCUL, SERCOPT). The
parameters of the ports (baud rate, parit y ...) are configured on the panel PC in
the MMC program (hardware config.).
The transmission rate is determined by the interface adapter. The upper limit of
the transmission rate limits the USART 16C552 on the SERCOM2 board. It is
1.5 Mbit/s. There is only oneconfiguration switch on the SERCOM2 card. It
fixes the address for the master interrupt controller.
Interrupt:
Switch block SW1 defines the interrupt address of the card. The default setting
of theseventh switch is ON (switched on) for all machines. The remaining switches
must be at OFF (switched off).
Tab. 2.7a (SERCOM2 switch positions)
2-28 ELEKTRONIK.CNC.BA.V2.USA
2.7 SERCOM2
Fig. 2.7a (SERCOM2)
ELEKTRONIK.CNC.BA.V2.USA 2-29
2.7 SERCOM2
Fig. 2.7b (Block diagram of SERCOM2 )
2-30 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 2-31
2.7 SERCOM2
2.7.1 Adapter cards for SERCOM2
SEROPT
Ser
Serial Opt
Optical Adapter Card The SEROPT moduleis a bidirectional optical port. It is capable of transmitting
data at a rate of upto 60 Mbit/s, over a maximum transmission distance of 1
km.
The data transmission takes place optically in a optical fibre. This method of
transmission is insensitive to electromagnetic and electrostatic interference. This
method of data transmission is very suitable for achieving a fast and safe link in
an environment with strong electrical disturbances. Another advantage is the
complete electrical isolating of the communicating devices, since no screen
connection is required.
However, the fibreoptic cables are not so resistant to any mechanical stress. It is
advisable to handle the fibreoptic cables carefully, i.e. notto bend them excessively
and especially not to buckle them. There are no configuration facilities (switches)
on the SEROPT module.
Fig. 2.7c (SEROPT)
2-32 ELEKTRONIK.CNC.BA.V2.USA
2.7 SERCOM2
Ser232
Ser
Serial 232 Adapter Card The SER232 module is a bidirectional interfacewith a V24 port referred to 0 V
(ground). The module is capable of transmitting data at a rate of max. 115,200
bit/s. The line length is dependent on the cable characteristics. The capacitive load
Abbreviation for picofarad may not be greater than 2500 pF with a maximum load of 3000 ohm. This
corresponds a pproximately to a cable length of 30 metres.
richt ungefähr einer Kabellängevon 30 Metern.
The module supports the port specifications according to DIN 66020. There are
no configuration facilities (switches) on the Ser232 module.
Fig. 2.7d (Ser232)
ELEKTRONIK.CNC.BA.V2.USA 2-33
2.7 SERCOM2
SER422
Ser
Serial RS 422 Adapter Card The SER422 module is a bidirectional interface with a symmetrical port which is
not referred to ground. The module is capable of transmitting data at a rate of up
to 100 kbit/s over a maximum transmission distance of approx. 1 km. With shorter
links, the maximum rate increases. At a length of 100 m, it is thus possible to
communicate at a transmission rate of up to 1 Mbit/s. However, these values can
be achieved only if the impedance of the transmission line is 120 ohm and the
data lines are terminated at both ends with the corresponding end-of-line resistor.
Fig. 2.7e (Ser422)
2-34 ELEKTRONIK.CNC.BA.V2.USA
2.7 SERCOM2
SERCUL
Ser
Serial Cu
Current Loop Adapter Card The SERCUL module is a bidirectional interface between the DUART 16C552
and an external device. The module is capable of transmitting data at a rate of
max. 19200bit/s over a maximum transmission distanceof 1 km. However, these
values can be achieved only in an optimal environment (no interfering electrical
fields).
The interface is in the form of a current loop. Signal state 1 is indicated by a current
of 20 mA. If no current flows in the loop, the signal state is 0.
The transmission circuit can be configured as an active or passive signal source
using switch S1. The receiving circuit, too, can be selected as active or passive with
switch S2. The 2 loops are in the form of a constant current source or constant
current drain and are thus short-circuit-proof.
The two green LEDs indicate whether the current is flowing in the transmission
circuit and/or in the receiving circuit.
The LED H1 indicates the current in the transmission circuit and LED H2 that in
the receiving circuit.
Tab. 2.7a (SERCUL switch position)
Fig. 2.7f (SERCUL)
ELEKTRONIK.CNC.BA.V2.USA 2-35
2.8 DIOCOM
2.8 DIOCOM
Digital Input Output The DIOCOM board is an interface card for the Bystronic CN control. It serves
Com
Communications Card as a basis for the input/output communication of the CNC.
Variouscommunication modules can be mounted in the 4 slots (DIOPORT 1-
4).
The 16-bit DIOCAN module permits communication with a CAN field bus
(SELECAN protocol).
With the 16-bit DIOSSI module, external devices, such as the manual control,
the cutting pres
sure control, etc.,are actuated.
The DIOPAR module esrves for communication with PARCOM-compatible
devices.
Interrupt:
Switch block SW1 defines the interrupt address of the card. The default setting
of the 4th switch (SW1) is ON (switched on) in all machines. The remaining
switches must be at OFF (switched off ).
DIOCOM slot STD
DIOCOM slot STE
Tab. 2.8a (DIOCOM switch positions)
2-36 ELEKTRONIK.CNC.BA.V2.USA
2.8 DIOCOM
Fig. 2.8a (DIOCOM)
ELEKTRONIK.CNC.BA.V2.USA 2-37
2.8 DIOCOM
Fig. 2.8b (Block diagram of DIOCOM)
2-38 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 2-39
2.8 DIOCOM
2.8.1 Interface boards for DIOCOM
DIOPAR
Digital Input O utput Par
Parallel The DIOPAR moduleis a simulation of a PARCOM port. It makes it possible
Adapter to actuatePARCOM-compatible terminals of the CNC89 generation via the
DIOCOM board.
The DIOCOM is used exclusively for actuating the auxiliary keyboard (manual
control keysX+/X-).
Information!
The DIOPAR module contains no switches or LEDs.
Fig. 2.8c (DIOPAR)
2-40 ELEKTRONIK.CNC.BA.V2.USA
2.8 DIOCOM
DIOSSI
Digital Input Output Synchronous TheDIOSSI moduletransmits two 16 bit ports (port 1&2). TheDIOSSI module
Serial Interface is used as a connection to the pressure controller and to the input/output assemblies
(MODULE RAIL S3, I/O M ODULE SSI).
The settings of jumper block J1 are determined by the board layout (cannot be
changed) and relate to the following parameters:
• Data inverted (e.g. with open collector actuation)
• Transmission rate (250 kbit /s or 500kbit/s)
• Master/slaveconfiguration (timing line)
• OE (Output Enable). Determines whether the data are to bewritten directly
to the output after reception. The output module rail should, for example,
output the received data immediately; however, the input module rail may
not write its input signals directly to the bus. The data are scanned by the
CPU.
Fig. 8.2d (DIOSSI)
ELEKTRONIK.CNC.BA.V2.USA 2-41
2.8 DIOCOM
DIOCAN
Digital Input Output Controller The DIOCAN module transmits and receives data from a SELECAN network
Area Network and is thusthe connection between the CN control and a Selectron PLCcontrol.
The communication to the CAN bus is achieved on the DIOCAN module by a
microproce ssor in conjunction with a CAN controller. The nodeaddress of the
DIOCAN in the CAN network is set together with other properties of the node
on configuration switch S1. Owing to its size, the DIOCAN module can be used
only in the slots DIOPORT 1 and 2 on the DIOCOM. The green LED lights
up briefly to confirm that the initialization procedure after a restart has been
successfully completed. The red LED lights up if a communication error has
occurred on the CAN bus.
Information!
The DIOCAN module is currently (October 1998) not used in the glass
machines.
Fig. 8.2e (DIOCAN)
Fig. 2.8b (Switch 1)
2-42 ELEKTRONIK.CNC.BA.V2.USA
For youe notes
ELEKTRONIK.CNC.BA.V2.USA 2-43
2.9 POSCAD
2.9 POSCAD
Pos
Position Controller Acceleration The position controller card POSCAD serves for movement of CNC auxiliary
Deceleration axes.
Through the various configuration possibilities, the POSCAD card can be used
for the following drive concepts:
• 2 stepping motorswithout actual value recycling
• 1 stepping motor with actual value recycling
• 1 servo motor
2.9.1 POSCAD switch
Frequency:
The switch block (SW1) defines the divider ratio of the master frequency. The
more switches at ON (switched on), the slower the down circuit auxiliary axes
(motor) travel sincethe freque
ncy for actuating the stepping motor cards is smaller.
Encoder input:
The switch block (SW2) defines the multiplication factor with which the encoder
pulses are multiplied.
2.9.1 (POSCAD switches)
2-44 ELEKTRONIK.CNC.BA.V2.USA
2.9 POSCAD
Fig. 2.9b (POSCAD switch positions)
*) With switch 9, the encoder channels A and B arerotated (interchanged)
electronically. This causes a changein the counting direction of the channel
(±). The procedure forcorrect setting of switch 9 is described in the
commissioning instructions.
Fig. 2.9a (POSCAD)
ELEKTRONIK.CNC.BA.V2.USA 2-45
2.9 POSCAD
Fig. 2.9c (POSCAD configuration)
2-46 ELEKTRONIK.CNC.BA.V2.USA
2.9 POSCAD
Fig. 2.9b (Block diagram of POSCAD)
ELEKTRONIK.CNC.BA.V2.USA 2-47
For your notes
2-48 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Stepping motor rack
3.1 Stepping motor rack .......................................................... 3-2
3.2 Stepping motor cards D900 ............................................ 3-4
ELEKTRONIK.CNC.BA.V2.USA 3-1
3.1 Stepping motor rack
3.1 Stepping motor rack
The stepping motor rack is a 19" sub-rack provided with a Bystronic back panel.
It permits the integration of the Berger-Lahr stepping motor control cards of Series
D550 and D900 in the Bystronic CN controls.
The stepping motor rack can hold one voltage supply module
) and up( to o
f ur
stepping motorcontrol cards ().
The required supply voltage (3 x 85 VAC) is delivered by an external transformer
which is connected to plug X1 (POWER IN) on the stepping motor rack.
Fig. 3.1a (Front view of Berger stepping motor rack)
Fig. 3.1b (Back of Berger stepping motor rack)
3-2 ELEKTRONIK.CNC.BA.V2.USA
3.1 Stepping motor rack
Control signals:
The control signals of the CNC drivecards (POSCAD) areconnected to the 25-
pin D-SUB jacks.
X8: Stepping motor control card 1
X9: Stepping motor control card 2
X10: Stepping motor control card 3
X11: Stepping motor control card 4
Power output:
The stepping motors(power output) are connected to the 4-pin jacks.
X12: MOTOR 1
X13: MOTOR 2
X14: MOTOR 3
X15: MOTOR 4
Error messages:
The 3-pin plug X2: ERROR is connected to a potential-free changeover contact
relay on each control card. In the event of a fault, the relay on the relevant card
will pick up or drop outand thusshort-circuit or open the ERROR bus.
Voltage supply module:
The3 x 85 VAC (POWER N) I arerectified to 120 VDC and filtered by the o
v ltage
supply module () in the stepping motor rack. A fuse
) protects
( the DC voltage
circuit from
test jack (, ).short-circuit. The output
The light emitting voltage
diode ( (120
) lights upVDC) can be
as soon asme asure
the d at thevoltage
AC-side
is min. 10 V.
Information!
T he LED ( ) provides no information about the level and quality of the
voltage. It serves merely for indicating that a voltage is present.
ELEKTRONIK.CNC.BA.V2.USA 3-3
3.2 Stepping motor cards D900
3.2 Stepping motor cards D900
The Berger card D900 se rves for actuating 3-phas
e stepping motors. They are us
ed
in the following applications:
• Positioning stops (KSM/VSM/KSBM/PSM)
• Spindle height adjustment (PSM)
• Drill feed (PBM)Spindelhöhenverstellung (PSM)
The card is actuated with the pulse, direction, door, current zeroing and micro
step signals by a superior control (POSCAD). With these control signals and the
(120VDC) supply voltage, the card drives a 3-phase stepping motor with a current
consumption (adjustable) between 1.35 A and 5.5 A.
Light emitting diodes:
LED 1 (green) = Ready (the supply voltage is above 80 VDC)
LED 2(red) = Short-circuit between 2 phases
LED 3(red) = Excess temperature (> 75°C) at heat sink
LED 4(red) = Overvoltage (> 140 V)
LED 5(red) = Undervoltage (< 80 V)
LED 2, 3, 4, 5 = Pulse frequency too high or interfering pulses.
Attention!
In the event of a fault (LED 2 to LED 5), the current to the motor is cut
off and the card
A currentless reports
motor „Not ready“
no longer has a (LED 1 goes
holding out). This can lead to
moment.
undesired reactions.
Fig. 3.2a (Dip switch settings on Berger card D900)
Factory setting:
S teps: 1O FF2O N(500steps)
C urrent lowering: 3 OF F current lowering on
3-4 ELEKTRONIK.CNC.BA.V2.USA
3.2 Stepping motor cards D900
Rotary switch for motor phase current
Tab. 3.2b (Rotary switch for motor phase current)
Information!
The value
The set printed
phase in bold
current mustinbethe Table
equal to corresponds
or less than to
thethe factory
rated phasesetting.
current
shown on the motor rating plate.
Fig. 3.2a (Stepping motor card D900)
ELEKTRONIK.CNC.BA.V2.USA 3-5
For your notes
3-6 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Peripheral cards
4.1 TERMIF ................................................................................. 4-2
4.1.1 TERMIF plugs
4.2 PARAN ............................................................................... 4-4
4.2.1 PARAN plugs
4.3 Speed limit monitor SLIM ................................................. 4-6
4.4 SSI module bus S3 ........................................................... 4-10
4.5 I/O Module SSI ................................................................ 4-12
4.5.1 Light emitting diodes SSI
4.5.2 Plugs on module SSI
ELEKTRONIK.CNC.BA.V2.USA 4-1
4.1 TERMIF
4.1 TERMIF
Ter
ermminal Interffface Adapter The TERMIF is an interface between the hand terminal (HANDTERM) and
the CN/PLC control. On the TERMIF, the variousHANDTERM signals are
divided and are transmitted to the corresponding superior controls (IMPGEN,
DIOCOM and PLC).
The two channels A/B of the handwheel incremental encoder are transmitted to
the IMPGEN card.
The key channels1 and 2 and the timing of the SSI link areconnected to the
DIOCOM card.
The contacts of the emergency stop switch are looped in the safety circuit of the
line control.
In addition, detection of whether a function key ha
s been pressed is performed
on the key channel 2 of the SSI link. This information is additionally fed into the
safety circuit via a relay contact.
This permissive function is possible only wit h HANDTERM2 since HAND-
TERM3 transmits the key to channel 1 (howe ver, only channel 2 si monitored).
Fig. 2.10a (TERMIF)
4-2 ELEKTRONIK.CNC.BA.V2.USA
2.10 TERMIF
4.1.1 TERMIF plugs
X1
Terminal 1 +24 VDC
Terminal 2 0 VDC (ground)
Terminal 3 PE (ground)
X2
Plug for connection to hand terminal (HANDTERM).
X3
Plug for connection to DIOCOM card (DIOSSI module on Dioport 1).
X4
Plug for connection to IMPGEN card.
X5
Function keys contact
These lines are only looped on theTERMIF. The contact is on the HANDTERM.
X6
Permissive contact
These lines are only looped on theTERMIF. The contact is on the HANDTERM.
X7
Not-Aus
Emergency stop
These lines are only looped on theTERMIF. The contact is on the HANDTERM.
ELEKTRONIK.CNC.BA.V2.USA 4-3
4.2 PARAN
4.2 PARAN
Par
Parallel An
Analogue Converter The PARAN board provides two isolated analogue voltages (0 VDC - 10 VDC)
at plug X3. The voltages are generated by a digital input signal which is 2 x 8 bits
wide (plug X1).
Fig. 2.11a (PARAN electronics card)
4.2.1 PARAN plugs
X1
Plug X1 connects PARAN to the DIOPAR card on the DIOCOM board.
X2
Power supply input for the PARAN board:
Terminal 1 24 VDC
Terminal 2 0 VDC
X3
Analogue voltage output:
Reference value1 Terminal 1 0-10 VDC
Terminal 2 Ground
Reference value2 Terminal 3 0-10 VDC
Terminal 4 Ground
4-4 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 4-5
4.3 Speed limit monitor SLIM
4.3 Speed limit monitor SLIM
Speed Lim
Limit The speed limit monit or SLIM monit orsthe grinding disc speed as a function of
the grinding disc diameter and detects whether or not the spindle is rotating.
LE D s
H1 = V max, theset speed has not been exceeded
H2 = Stop, spindle is stationary
H3 = Coding switch B active
H4 = Coding switch A active
H5 = V1 low speed
H6 = V2 high speed
H7 = Thespeed limit indicator of thespindlelightsup if theswitch (S1 speed
monitor) in the spindle is operated.
P1:
Frequency oscillator of this potentiometer is set at the factory and may not be
changed.
Speed setting
Switch S12(50 mm) and S2 (150 mm) coding switches A + B
Information!
T he value printed in boldin the Table corresponds to the factoryetting.
s
Tab. 4.3a (Speed setting)
4-6 ELEKTRONIK.CNC.BA.V2.USA
4.3 Speed limit monitor SLIM
X 1.1 = +24 VDC supply
X1.2 = 0V
X 2.1 = +24 VDC from coding switch A
X 2.2 = +24 VDC from coding switch B
X 2.3 = Signal from thespindle
X 3.1 = +24 VDC Enable
X3.3 = 0V
X 4.1 = Output Limit / K1 contact closed if
X 4.2 = Output Limit / n <Limit
X 4.3 = Output Stop / K2 contact closed at
X 4.4 = Output Stop / Spindle stop
Information!
This terminal assignment serves only as an example. The correct
assignment is shown in the connection diagram of the machine.
Fig. 4.3a (Speed limit monitor SLIM)
ELEKTRONIK.CNC.BA.V2.USA 4-7
4.3 Speed limit monitor SLIM
Fig. 4.3b (Block diagram of speed limit monitor SLIM)
4-8 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 4-9
4.4 SSI module bus S3
4.4 SSI module bus S3
The IO MODULE BUS is a devicefor conve rting the external binary signals of
switches, contacts or processes into a communication signal according to Bystronic
Synchronous Serial Interface SSI specifications (INPUT) or for converting the SSI signals of the CNC into
the external signal levels required for the process (valves, relays, ...) (OUTPUT).
The device is designed for mounting on a C bus in the CNC cabinet. The jumpers
J1 and J2 on the module bus can be used for selecting the available number of
inputs or outputs. The module bus is always configured for 16 inputs and 16
outputs at the factory.
Possible settings
16 + 16 Inputs and outputs (24 V)
32 Inputs(24V)
32 Outputs(24V)
The green LED H1 lights up when the TTL supply voltageis at least 4.75 volt
and the res
et signal for the SSI-ASIC hasbeen cleared.
The LED pairs H3 - H5 (green) and H2 - H4yellow)
( indicate the configuration of
the channels 1 (H3, H2) and 2 (H5, H4):
• Yellow standsfor output (LED H2 and H4)
• Green standsfor input (LED H5 and H3)
If the SSI master is not connected or the communication terminates for any reason,
the SSI-ASIC (U36) automatically switches both channels to input. This ensures
that the connected output modules and their actuated outputs are immediately
deactivated.
4-10 ELEKTRONIK.CNC.BA.V2.USA
4.4 SSI module bus S3
Fig. 4.4a (Module bus S3)
ELEKTRONIK.CNC.BA.V2.USA 4-11
4.5 I/O module SSI
4.5 I/O module SSI
The IO MODULE SSI is a device for conve rting the external binary signals of
switches, contacts or processes into a communication signal according to Bystronic
SSI specifications(INPUT) or for converting the SSI signals of a control system
into the external signal level required for the process (OUTPUT).
Thanks to its compact dimensions, it can be used both in a switch cabinet and in
a ventilated terminal box. The internal modular concept permits a simple design
as a decentral IO unit with alternatively:
16 + 16 Inputsand outputs (24 V)
32 Inputs(24V)
32 Outputs(24V)
4.5.1 Light emitting diodes SSI
Power:
The green LED POWER lights up if the I/O moduleis supplied with 24 VDC,
the TTL supply volt ageis at least 4.75 volt and the reset signal for the SSI-ASIC
has been cleared.
CH1LED
The andpa CH2:
irs CH1 and CH2 underneath indicate the configuration of cha nnels
1 and 2: yellow stands for output and green for input. If the SSI master is not
connected or the communication is terminated for any reason, the SSI-ASIC
automatically switches both channels to input: this ensures that theoutput modules
connected to the IO-SSI board or their actuated outputs are immediately
deactivated if the cable breaks or the master fails.
X1 - CH1 output:
To the right of each output terminal is the corresponding yellow signal LED. This
lights up if the output circuit is actuated by theTTL logic and is supplied from
outside (terminals 17 and 18), independently of whether a load is connected to
the output.
Each of the 16 outputs is provided with short-circuit protection: as soon as the
output current is more than 3.5 A, the actuation of all outputs is blocked on the
TTL side and the red LED to the right of terminal 17 lights up. To restore the
normal function, the cause of the overload must be eliminated and the supply of
the outputs must be briefly interrupted. The short-circuit protection is sluggish
so that the actuation of capacitive loads is possible without problems.
4-12 ELEKTRONIK.CNC.BA.V2.USA
4.5 I/O Modul SSI
X2 - CH2 Input:
To the right of each input terminal is the corresponding green signal LED. These
light up if a voltageis applied between theinput terminal and thereferencepotential
terminal, independently of whether the IO MODULE is switched on or not. Each
input on the TTL side is made bounce-proof wit h a 5 mstime constant.
Fig. 4.5a (I/O module SSI)
ELEKTRONIK.CNC.BA.V2.USA 4-13
4.5 I/O Modul SSI
4.5.2 Plugs on module SSI
Supply:
The external supply voltage is connected via the 3-pin plug X4. The protective
earth must be connected sinceotherwise the ESD protection is not effective.
Speisung:
Input:
The input signals are connected to the first 16 terminals of the 18-pin input plug
(X2 - CH2). The protectiveearth must beconnected to terminal 17 sinceotherwise
the ESD protection of the input circuit is not effective. The total 0 V reference
potential of the 16 inputs is connected to terminal 18.
Output:
Each of the 16 outputs (X1 - CH1) is provided with short-circuit protection: as
soon as the output current is more than 3.5 A, the actuation of all outputs on the
TTL side is blocked and the red LED to the right of terminal 17 lights up. To
restore the normal function, the cause of the overload must be eliminated and
thesupply oftheoutputs briefly interrupted. Theshort-circuit protection is sluggish
so that the actuation of capacitive loads is possible without problems.
Communication with CNC:
The SSI master is connected via the 9-pin plug X3.
Fig. 4.5b (I/O module SSI)
4-14 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 4-15
For your notes
4-16 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Panel PC
5.1 The Panel PC ....................................................................... 5-2
5.1.1 Overview of the interrupts and I/O addresses in the PPC
5.1.2 Description of Bystronic interface cards in the PPC
5.1.3 Jumpers and switches
5.1.4 Switch S1 I/O address
ELEKTRONIK.CNC.BA.V2.USA 5-1
5.1 Panel PC
5.1 Panel PC
The PPC is a universal industrial computer for use in a machine environment.
Depending on requirements, all commercial PC compone
nts from motherboard
to passive bus slot systems can be installed.
Failures of the standard PC components through excessively high temperatures,
dust, moisture, vibrations, interferenceand an aggressiveenvironment are prevented
by the following measures:
• Complete protection from electromagnetic fields
• Protection from dust and splashes
• Monitoring of the mains and compute r volt ages
• Controlled booting of the computer
• Improved cooling wit h excess temperature monit oring
• Vibration-damped installation of the drives
The Panel PC used in the Bystronic machines are tested for the following
requirements.
• Safety
• Noise volt ageand spuriousemission
• Noise immunity to ESD
•
•
Nois
Noise
e immuni
immunittyy to
to electroma gnetic fields
fast transients
The Panel PC si basically considered asa complete unit. Changing orreplacement
of individual plug-in cards, TFT display or other hardware components outside
the Bystronic parent company or its subsidiaries is not permissible.
5-2 ELEKTRONIK.CNC.BA.V2.USA
5.1 Panel PC
Fig. 5.1a (Front view of Panel PC)
1 TFT screen
2 100 MB ID E zip drive
3 1.44 MB drive
4 Indicator lampsand reset button
5 Mouse
6 Hand control keys
7 Pull-out PC keyboard
8 CNC control keys
ELEKTRONIK.CNC.BA.V2.USA 5-3
5.1 Panel PC
5.1.1 Overview of the interrupts and I/O addresses in the PPC
Tab. 5.1a (IRQ and I/O addresses in the Panel PC)
5-4 ELEKTRONIK.CNC.BA.V2.USA
5.1 Panel PC
Fig. 5.1b (Block diagram of Panel PC)
ELEKTRONIK.CNC.BA.V2.USA 5-5
5.1 Panel PC
5.1.2 Description of Bystronic interface cards in the PPC
PCOLA serial interface card with optical fibres
The PCOLA board is a serial interfacecard for installation in a 16-bit ISA slot or
an IBM-AT or compa tible personal computer. The card guarantees 100% addres s
and register compatibility with a standard IBM serial interfacecard and has two
16550 FIFO UARTs and an extended interrupt selection. The use of a PCOLA
board permits the addition of up to two electrically isolated serial connections via
a TOSLINK optical fibre.
5.1.3 Jumpers and switches
The jumper J1 defines the address range of the PCOLA board. When jumper J1
is not inserted, the 2 serial interfaces are configured as COM1 and COM2
(addresses 3F8h and 2F8h); when jumper J1 is inserted, they are configured as
COM3 and COM4 (addre sses 3E8h and 2E8h, actory
f setting). It is not possible
to switch off one of the two ports.
The interrupt for the first and the second port is selected with the slide switches
S1 (IRQ5, factory setting) and S2 (IRQ6, factory setting).
Fig. 5.1c (PCOLA board)
5-6 ELEKTRONIK.CNC.BA.V2.USA
5.1 Panel PC
PCTIF keyboard interface
The PCTIF board is a keyboard controller card for installation in an 8- or 16-bit
ISA slot of an IBM-AT or compa t ible personal computer.
The use of the PCTIF board permits the operation of the Bystronic CNC foil
keypad parallel with the standard PC keyboard.
The PCTIF board can operate the B
ystronic CNC keyboard with up to 88 keys
and 3 switching keys. This results in up to 160 unambiguous pieces of input
information. A key switch can be used to enable the keyboard. The PCTIF board
can directly actuateup to 24 LED lampson the CNC keyboard.
The PCTIF board is connected to ht e CNC keyboa
rd via a 50-pin flat cable not
more than 0.5 me
tre long.
Jumper J1 Interrupt configuration
Tab. 5.1b (Interrupt setting on PCTIF)
ELEKTRONIK.CNC.BA.V2.USA 5-7
5.1 Panel PC
5.1.4 Switch S1 I/O address
Fig. 5.1d (I/O address on PCTIF)
Switches S2 and S3 (scanning of parameter register)
These two switches are not used. All switches should be at OFF.
.
Fig. 5.1e (PCTIF board)
5-8 ELEKTRONIK.CNC.BA.V2.USA
5.1 Panel PC
PTCON (Power and Temperature Control)
The voltageand temperature monitor PTCON guarantees the operational safety
of the Panel PC in exceptional situations, such as sluggish switching on and off,
voltage fluctuations, switching on and off at short intervals or insufficient cooling.
The Panel PC is started up only when the +5 VDC and +15 VDC electronics
supply are within the tolerance limits for about five seconds.
The internal temperature of the Panel PC is monitored by atemperature sensor.
If the internal temperature of the Panel PC exceeds 45°C, the overtemperature
indicator lamp at the front of the Panel PC is actuated. This warning lamp indicates
that the cooling of the Panel PC is no longer sufficient. A reliable operation of
the Panel PC can no longer be guaranteed.
Fig. 5.1f (PTCON board)
ELEKTRONIK.CNC.BA.V2.USA 5-9
For your notes
5-10 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Drive system
6.1 AC drive system .................................................................. 6-2
6.2 AC motors........................................................................... 6-4
6.2.1 AC integrated synchronous motor
6.2.2 AC standard synchronous motor
6.2.3 Motor feedback unit
6.2.4 Incremental encoder
ELEKTRONIK.CNC.BA.V2.USA 6-1
6.1 AC drive system
6.1 AC drive system
The Bystronic drive system essentially consists of the POSCON axis card with
referenceinput generation and bearing control, the supply and drivemodule (VM/
AM) and the transducers, increme ntal generator and motor feedback unit .
The structure of the BYSTRONIC drive system is in principle identical for all
CNC axes equipped with AC motors.
Fig. 6.1a (Block diagram of drive system)
6-2 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 6-3
6.2 AC motors
6.2 AC motors
The use of AC motors completely dispenses with the need for servicing the motors
in future, since, apart from the rotor bearing (ball bearing), there are no longer
any mechanically stressed parts (carbons) in the motor.
We make adistinction between two different types of motors:
• AC integrated synchronousmotor
• AC standard synchronousmotor
6.2.1 AC integrated synchronous motor
The AC Einbau [integrated] synchronous motor AE...() is a direct drive motor
with high torque per unit weight (Nm/kg) and impressive dynamics. The design
involving direct integration of themotorin themachinepermits compact structure
and substantial weight savings. This continuously energized 12-pole synchronous
motor is used as a bridge drive.
Fig. 6.2a (AC integrated synchronous motor)
Legend:
1 Motor feedback unit
2 Incremental generator
3 Clamping device
4 Stator
5 Drive shaft
6 Rotor
6-4 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Signal diagram for AC integrated synchronous motor
The signals shown below are obtained when the motor is manually rotated on
the drive shaft.
Fig. 6.2b (Signal diagram for AC integrated synchronous motor)
ELEKTRONIK.CNC.BA.V2.USA 6-5
6.2 AC motors
6.2.2 AC standard synchronous motor
The optimized standard AC synchronous motor in the Llong or inAthe short
AK design with increased power data, compact dimensions and low torque
harmonic oscillationsmeets very high requirements in terms of dynamics, speed
range and centricity. These continuously energized 6-pole synchronous motor are
used on all machine axes with the exception of the beam axes.
Synchronous motor with motor feedback, large (Art. No.
)
Fig. 6.2c (AC standard synchronous motor)
Legend:
1 Motor feedback plug
2 Incremental generator
3 Motor feedback unit
4 Motor housing (stator)
6-6 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Signal diagram for AC standard synchronous motor with motor feedback, large
The signals shown below are obtained when the motor is manually rotated on
the drive shaft.
Abb. 6.2d (Signal diagram for AC standard synchronous motor)
ELEKTRONIK.CNC.BA.V2.USA 6-7
6.2 AC motors
AC standard synchronous motor with motor feedback, small
(Art.No. )
Fig. 6.2e (AC standard synchronous motor)
Legend:
1 Motor feedback unit
2 Incremental generator
3 Motor feedback plug
4 Motor housing (stator)
6-8 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Signal diagram for AC standard synchronous motor with motor feedback,
small
The signals shown below are obtained when the motor is manually rotated on
the drive shaft.
Fig. 6.2f (Signal diagram for AC standard synchronous motor)
ELEKTRONIK.CNC.BA.V2.USA 6-9
6.2 AC motors
Pin assignment for motor connection plug
(applicable for AK, AL and integrated motors)
Fig. 6.2g (Pin assignment for motor connection plug)
Tab. 6.2a (Pin assignment)
6-10 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
6.2.3 Motor feedback unit
The motor feedback unit performsthe function of supplying the drive module
with the following information.
• Speed of the drive
• Direction of rotation of thedrive
• Position of the rotor relative to the stator of the motor
The rotor of the motor feedback unit is clamped to the motor shaft by means of
). (The stator () of the motor feedback unit is screwed to the
a clamping device
motor housing by means of clamping jaws.
If the motor feedback unit is mounted on a motor, it must then be adjusted by
means of a tester. This adjustment is described in more detail in the service
instructions.
The adjustment by means of the tester can be performed only by a Bystronic
specialist. If a motor feedback unit or a motor is thought to befaulty, the entire
motor must be changed.
The motors are supplied by Bystronic, together with the adjusted motor feedback
unit.
Fig. 6.2h (Motor feedback unit, large Art. No. 218303)
Legend:
1 Plug
2 Cable
3 Stator
4 Rotor clamping device
5 Rotor
6 Cable
7 Plug
ELEKTRONIK.CNC.BA.V2.USA 6-11
6.2 AC motors
Signal assignment for plug )(
Absolute magnetic generator signal for determining the position of the rotor re-
lative to the stator in the motor.
Tab. 6.2b (Signal assignment for the motor feedback plug)
Signal assignment for cable )(
Feedback of speed and direction of rotation
Tab. 6.2c (Signal assignment for the motor feedback cable)
The signals of () and () are combined at the plug ) and
( fed together, wit hout
signal processing, by mea ns of a shielded cable to the AMFEED card (plug X53)
on the drive module.
Fig. 6.2i (Arrangement of the motor feedback unit in the motor)
6-12 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Pin assignment of motor feedback plug (Fig. 6.2i Pos 2)
PIN1 +15V PIN12 SE
PIN2 0VGND PIN13 TA
PIN
3 U PIN
14 TE
PIN
4 V PIN15 free
PIN
5 W PIN16 free
PIN6 X PIN17 innershield
PIN7 Y
PIN8 Z
PIN9 RA
PIN 10 RE
PIN 11 SA
Abb. 6.2j (Signal assignment for the motor feedback plug)
Information!
The list of the connections in the motor feedback circuit is shown in the
corresponding CNC diagram.
ELEKTRONIK.CNC.BA.V2.USA 6-13
6.2 AC motors
Motor feedback unit, small (Art. No. 218154)
Abb. 1.2k (Motor feedback unit, small)
Legend:
1 Plug
2 Stator
3 Rotor clamping device
4 Cable
Pin assignment for plug )(
Absolute magnetic generator signal for determining the position of the rotor re-
lative to the stator in the motor.
Tab. 6.2d (Pin assignment for plug)
6-14 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Signal assignment for cable
Feedback of the speed and the direction of rotation
Tab. 6.2e (Signal assignment for cable)
The signals from and are combined at the plug and fed together, without signal
processing, by mea
ns of a shielded cable to the AMFEED card (plug X53)on the
drive module.
ELEKTRONIK.CNC.BA.V2.USA 6-15
6.2 AC motors
Arrangement of the motor feedback unit in the motor
Fig. 6.2l (Arrangement of the motor feedback unit in the motor)
6-16 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Pin assignment for motor feedback plug
) (
PIN 1 +15Volt
PIN 2 0Volt GND
PIN 3 U
PIN 4 V
PIN 5 W
PIN 6 free
PIN 7 free
PIN 8 free
PIN 9 RA
PIN 10 RE
PIN 11 SA
PIN 12 SE
PIN 13 TA
PIN 14 TE
PIN 15 free
PIN 16 free
PIN 17 Inner shield
Fig. 6.2m (Pin assignment for motor feedback plug)
Information!
The list of connections in the motor feedback circuit is shown in the
corresponding CNC diagram.
ELEKTRONIK.CNC.BA.V2.USA 6-17
6.2 AC motors
Incremental encoder
The encoder (incremental encoder) performs the function of delivering a specific
number of electric pulses per distance covered. This information (pulses) tells a
superior system (POSCON) how far and in which direction the drive is moved.
The encoder is mechanically connected to the motor shaft, without compensating
coupling. The output (electrical connection) is transmitted directly to the superior
control (Poscon) without additional signal processing.
The encoder has an RS422 interface which is led toa) (protection
plug ( type
IP65).
The channels And a B and h t e zero markas well as the associated “invers
e” signals
are used. The signal voltagevaries between ±3 volt.
Fig. 6.2n (Incremental encoder)
Legend:
1 Clamping devicefor the connection between encoder and motor
2 Plug with RS422 interface
3 Bolt for clamping theencoder to the motor shaft.
6-18 ELEKTRONIK.CNC.BA.V2.USA
6.2 AC motors
Pin assignment for encoder plug
The pin assignmentis the same forall encoders and axes.
PIN 12 Encodersupply +10V bis+30V
PIN 10 Encodersupply 0VoltGND
PIN 5 Channel A
PIN 6 Channel A inverse
PIN 8 Channel B
PIN 1 Channel B inverse
PIN 3 Zeromark
PIN 4 Zero mark inverse
PIN 7 free
Fig. 1.2o (Encoder plug)
Information!
The list of connections in the encoder circuit is shown in the
corresponding CNC diagram.
ELEKTRONIK.CNC.BA.V2.USA 6-19
For your notes
6-20 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Drive supply module
7.1 The supply module ............................................................... 7-2
7.1.1 Power unit of supply module
7.1.2 Control unit
ELEKTRONIK.CNC.BA.V2.USA 7-1
7.1 The supply module
7.1 The supply module...
...generates and monit orsthe intermediate circuit voltageof the drive module
Furthermore, ni the event of an excessively high intermediate circuit voltage(ne-
gative acceleration of a drive), the supply module destroys this voltage via a pulse
resistance ( ).
The module is designed for 50 amp continuous current and is protected from
any overload by means of two temperature sensors ) and (().
The intermediate circuit voltagehas buscapabilities(). Thus, the drivemodules
can be arranged on the left as well as on the right side of the supply module.
We make a distinction between two different supply modules. At present,
exclusively version 1 is used.
Standard version
Intermediate circuit voltage Version 1
320 VDC intermediate circuit voltage (supply 3 x 230 VAC ± 10%)
Special version
Intermediate circuit voltage Version 2
560 VDC intermediate circuit voltage (supply 3 x 400 VAC ± 10%)
Fig. 7.1a (Supply module standard version)
7-2 ELEKTRONIK.CNC.BA.V2.USA
7.1 The supply module
7.1.1 Power unit of supply module
The rectifier modules ) with
( 80°C temperature sensor ), circuit
( capacitors
), (
an IGBT transistor (), a pulse resistance ) with
( 100°C temperature sensor ) (
and the intermediate circuit monit oring electronicsare located on the VMBASE
power unit.
Fig. 7.1b (Power unit of supply module)
Legend:
1 Cooling fan
2 Intermediate circuit capacitors
3 Monitoring and control electronics
4 Voltage supply bus
5 Rectifier modules
6 Rectifier plate temperature sensor
7 Pulse resistance
8 IGBT transistor
9 Pulse resistancetemperature sensor
ELEKTRONIK.CNC.BA.V2.USA 7-3
7.1 The supply module
7.1.2 Control unit
The VMDRIVE control unit contains the electronics supply, the intermediate
circuit monitor, the temperature monitor and the IGBT control.
The status of the power module in shown in a simple manner with the aid of the
light emitting diodes (LED).
Fig. 7.1c (Control unit VMDRIV)
7-4 ELEKTRONIK.CNC.BA.V2.USA
7.1 The supply module
emitting diodes
H 1 Red Excess temperature pulse resistance
The pulse resistanceis overloaded. The fan (1 Fig. 4.1a) may not
be operating or the ventilation slots may be soiled.
H 2 Green Supply module is ready for operation (voltage module OK)
H 3 Red Excess temperature rectifier module
The rectifiers are overloaded. The supply module may be soiled.
H4 Green Voltage supply (240 volt AC) for the internal electronic supply
(terminal X2) is in order.
H5 Yellow Pulse resistance is switched on.
H6 Yellow The intermediate circuit voltage was reduced. The terminals X4,
5+6 are cativated.
Fuse
The fuse F1 (T1A250V) protects the electronic supply on the supply module.
ELEKTRONIK.CNC.BA.V2.USA 7-5
7.1 The supply module
Plug X4
Terminals 1 + 2 Intermediate circuit in order (ZWOK), norma lly open contact;
if the intermediate circuit is not in order, the contact dropsoff
immediately.
Terminals 3 + 4 Normally closed contact. Same function as the terminals X4,
1+2. However, it closes if theintermediate circuit is not in order.
Terminals 5 + 6 Intermediate circuit reduction (ZWRED)
If terminal 5 is connected to 6, the power in the intermediate circuit is reduced
to about 10%, i.e. the power of the intermediate circuit is dissipated via the pulse
resistance.
The terminals can be activated by the safety control if the supply voltage of the
supply module was reduced or the supply module is completely disconnected from
the main power.
Information!
When the full supply voltage is applied, the intermediate circuit reduction
(ZWRED) may not be switched on. Otherwise, the supply module would
be destroyed.
7-6 ELEKTRONIK.CNC.BA.V2.USA
7.1 The supply module
Terminals X2 220 volt AC are connected to the terminals X2. The
voltage is used for operating the control logic unit on the
supply module.
Plugs X1 and X3 The two plugs are used for making the connection to the
power unit of the supply module.
Fig. 7.1d (Block diagram Voltagemodul)
ELEKTRONIK.CNC.BA.V2.USA 7-7
For your notes
7-8 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Drive module
8.1 AC drive module ................................................................. 8-2
8.1.1 Power unit
8.1.2 Power control unit
8.2 AMCONT .............................................................................. 8-8
8.2.1 Logic control unit
8.2.2 LEDs, plugs and switches
8.3 AMADAP ........................................................................... 8-12
8.3.1 Test points and potentiometers
8.4 AMFEED ............................................................................. 8-16
8.4.1 Test monitors, switches and plugs
8.5 AMCOMM ..........
8.5.1 Switches, .........
plugs ..........
and LEDs.............................................8-1 8
8.6 Overview of LED`s and switches on the drive module8-20
ELEKTRONIK.CNC.BA.V2.USA 8-1
8.1AC drive module
AC drive module
The AMAC is a drive modulewith analogue or digital interface for controlling
conti nuously energized synchronous mot
ors wit h 3-phase currents.
The governor permits complete 4-quadrant operation, i.e. driving and braking in
both directions of rotation, there being no interruption at the transition between
the quadrants.
The rotor-oriented regulation transforms the q
uantities of state measured in the
(stationary) stator system, such as current, speed and rotor position, into a
coordinate system rotating with the rotor. This results in a governor structure
similar to the direct current machine. Current of any phase structure for better
motor utilization for improving the torque ripple is therefore possible without
problems.
The hardware of the drive module is mounted on two main boards. The power
and control unit are thus not only electrically isolated but also spatially separated.
Drive modules with 25, 50, 100 and 200 amp output power are available for the
various axes.
Attention!
Replacement of individual
permissible. The cardsmust
drive module or components
be regardedofasa an
card is not element. If
integral
a drive module is thought to be faulty, it must be replaced as a whole.
Replacement of printed circuit boards between different drive modules is
not advisable.
Fig. 8.1a (Block diagram AC drive module)
8-2 ELEKTRONIK.CNC.BA.V2.USA
8.1AC drive module
Fig. 8.1b (Cards in the drive module)
Fig. 8.1bb (Cables on the drive module)
ELEKTRONIK.CNC.BA.V2.USA 8-3
8.1AC drive module
8.1.1 Power unit
The AMBASE powe r unit consists of a largeheat sink).( This removes the waste
heat of the three IGBT power half-bridges(). The temperature of the heat sink
is monitored by means of a temperature sensor ). (
Depending on the required motor power, different IGBT modules (25, 50, 100
and 200 amp) are used. They differ in the maximum current which they can
switch.
The terminals for the motor
) (are also located on the power unit.
Fig. 8.1c (Power unit)
Legend:
1 Heat sink
2 Heat sink temperature sensor
3 IGBT power half-bridges
4 Motor terminals
8-4 ELEKTRONIK.CNC.BA.V2.USA
8.1AC drive module
8.1.2 Power control unit
The AMDRIVE powe r control unit is screwed directly to the AMBASE. Together
they form a unit. The power control unit contains the control logic of the IGBT
power half-bridges on the AMBASE.
A fuse () for the power circuit is located on the AMDRIVE. This fuse protects
the IGBT power half-bridges and the voltage supply module (VM) from any
short-circuit.
The plug X12)( provides a connection to the next card (AMCONT) by means
of a flat cable.
Furthermore, two compensation current transformers
) are present
( on the powe
r
control unit. These two transformers measure the motor phase current U and V.
Fig. 8.1d (Power control unit)
Legend:
1 Plug X12
2 Compensation current transformer
3 Fuse
ELEKTRONIK.CNC.BA.V2.USA 8-5
8.1 AC drive module
Overview of the connections on the power
Tab. 8.1a (Overview of the connections on the power unit)
Information!
Plug X12
T he pin assignment of plug X12is not described in more detail since only
internal signals of the drive module are applied to the plug.
Fig. 8.1e (Block diagram AMBASE)
8-6 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 8-7
8.2 AMCONT
8.2 AMCONT
8.2.1 Logic control unit
The AMCONT logic control unit is the main board of the drive module. On
this board, all information is processed by means of a microprocessor and the
respective actions are initiated.
After application of the supply voltage, an automatic system reset is performed
and all elements are checked for their operability. If everything is in order, the drive
module is enabled.
A watchdog timer additionally monitors forcorrect program sequenceand blocks
the power unit actuation in the event of any program error.
The AMCONT includes the following functions:
• Voltage supply to thelogic unit for the total electronics
• Field orientation
• Phase current regulation
• Pulse width modulation
• Monitoring of the electronicsvoltages for overvolt ageand undervoltage
• Monitoring of the intermediate circuit for overvoltage and undervoltage
• Temperature monitoring of the heat sink
• Setting and storage of the operating parameters
•• Hardwa
Backingreupreset
thebutton
e
lectronic supply
• Output of safety signals
• Input for enabling thedrivesSteuerteil
8-8 ELEKTRONIK.CNC.BA.V2.USA
8.2 AMCONT
Fig. 8.2a (AMCONT)
ELEKTRONIK.CNC.BA.V2.USA 8-9
8.2 AMCONT
8.2.2 LEDs, plugs and switches
Light emitting diodes
H1 (green) Electronic supply +15 V
The +15 volt supply for the logic unit of the drive module is in order.
H2 (green) Electronics supply -15 V
The -15 volt supply for the logic unit of the drive module is in order.
H3 (green) Electronics supply +5 V
The +5 V supply for the logic unit of the drive moduleis in order.
H 4 (red) Watchdog
The watchdog monitors for correct program sequence. If the program is not
worked through in the required time (CPU is blocked, etc.), the watchdog switches
off the power output stage.
Attention!
T he watchdog monitors only the program sequence. A hardw are fault, for
example a faulty power half-bridge, a faulty motor, a faulty motor feedback
unit, etc., cannot be detected.
H5 (yellow)
The drive module is ready for operation.
The software (of the drive module) has enabled the drive module.
H6 (red)
Not yet implemented.
Fuse
The fuse F1 protectsthe electronicssupply (logic) of the drive module.
Technical data of the fuse F1:
Rated current: 250 mA
Responsetime: slow-blow
Rated voltage: 250 V
Dimensions: 5 mm diameter, 20 mm long
Designation: T250 mA/250 volt
8-10 ELEKTRONIK.CNC.BA.V2.USA
8.2 AMCONT
Button S1
In the event of a fault, the drivemodule can beinitialized by means of this button.
The button has the same effect as switching the drive module off and on again.
Electronic supply
At plug X31 230 V, +15%/-10%
Terminal 1 L (Phase)
Terminal 2 N (Neutral)
Terminal 3 PE (Ground)
Safety interface X38
Terminal 1 Driveenable 24 VDC +/-20%
Terminal 2 Driveenable0 VDC
Terminals 3 + 4 Drivenot ready (normally closed contact 230 V/6 A)
Terminals 5 + 6 Drivenot ready (normally open contact 240 V/6 A)
Fig. 8.2b
Information!
The pin assignment of the plugs X32 to X37 is not described in more detail
since only internal signals of the drive module are applied at these plugs.
HEX switches S2 and S3
These two switches configurethe drivemodule to the required cha
racteristicsfor
optimally controlling the associated axis.
The settings00 to FE are available for configuration of the axis. The suitable setting
for each machine is s
hown in the CNC diagram of the respective machine.
The setting FF is used for manual configuration of the drive module.
ELEKTRONIK.CNC.BA.V2.USA 8-11
8.3 AMADAP
8.3 AMADAP
The drive module adapter AMADAP is a digital configurable governor assembly
and serves for adapting the axis-specific data, uch
s asthe governor parameters, and
current and speed values, to a standard ± 10 V setpoint interface.
The potentiometers for setting the offset voltageand adjusting the tacho are also
on the AMADAP.
In addition, variousanaloguemonitors(test points) arealso pres
ent.
Fig. 8.3a (AMADAP)
8.3.1 Test points and potentiometers
Potentiometers
P1 Setting the offset
With forward and backward movement of the axes, the same voltage must be
measured on the plug X43, terminals 3 + 4 (setpoint input).
P2 Tacho adjustment
With forward and backward movement of the axes, the same voltage must be set
on the plug X43, terminals 3 + 4 (setpoint input) on all axes.
8-12 ELEKTRONIK.CNC.BA.V2.USA
8.3 AMADAP
Jumpers
J1 = 1-3 External setpoint speed ±10 V (standard)
J1 = 2-4 External setpoint torque ±10 V
J1 = 3-5 Internal setpoint speed
J1 = 4-6 Internal setpoint torque
Plugs
Plug X43
Terminal 1 Actual tacho value
Terminal 2 Tacho signal GND
Terminal 3 Setpoint value +
Terminal 4 Setpoint value -
Terminal 5 Setpoint valueGND
Terminal 6 Auxiliary voltage +15 V
Terminal 7 Auxiliary voltage -15 V
Information!
Only terminals 3 + 4 (setpoint value) may be used for operating our
systems.
Plug X41
The pin assignment of plug X41 is not described in more detail since only internal
signals of the drive module are applied at this plug.
Test points
TP1 = Actual speed
TP2 = Actual current
TP3 = Signal GND
Test referencepoint for test points TP1 and TP2
ELEKTRONIK.CNC.BA.V2.USA 8-13
8.3 AMADAP
Fig. 8.3b (Block diagram AMADAP)
8-14 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 8-15
8.4 AMFEED
8.4 AMFEED
The motor feedback interfaceAMFEEDgenerates the pha
se current referencevalues
and the actual speed and is tuned to the Bystronic motor feedback unit.
Depending on the rated motor speed and the number of poles and the method of
commutation, variousconfigured versions are used.
We make a distinction between the following versions:
Tab. 8.4a (Motor feedback variants)
Information!
T he version code suitable for the axis
is shown on the CN C diagram of the
corresponding machine.
Fig. 8.4a (AMFEED card)
8-16 ELEKTRONIK.CNC.BA.V2.USA
8.4 AMFEED
8.4.1 Test monitors, switches and plugs
Test monitors
T P1
Actual speed 10 V corresponds to the rated speed
T P2
Signal GND test referencepoint for test point TP1.
Switches
The direction of rotation of the motor (viewed from theshaft end with positive
setpoint value) can be changed with switch S1:
• CW Clockwise
• CCW Counterclockwise
Information!
The switch changes the direction of rotation of the motor and of the motor
feedback unit.
Plug
Tab. 8.4b (Plug X53 Interface to motor feedback unit)
Plug X52
The pin assignment of the plug X52 is not described in more detail since only
internal signals of the drive module are applied at this plug.
ELEKTRONIK.CNC.BA.V2.USA 8-17
8.5 AMCOMM
8.5 AMCOMM
The communication interfaceAMCOMM includes an electrically isolated serial
RS232 interface. The drive module can be configured and can be monitored during
operation by means of a terminal program.
The interfaceis not usually used. If used at all, it is used only for commissioning.
The variouslight emitting diodes make it possible to determine the status of the
drive module.
Attention!
A setup switch is also available. This switch makes it possible to limit the
power of the drives to about 10% . I t is strongly recommended to use this
switch for manipulations on the machine (adjusting the pinch rollers,
setting the reference, etc.). By using the switch, accidents can be avoided in
the event of an incorrect manipulation.
Fig. 8.5a (Electronic card AMCOMM)
8-18 ELEKTRONIK.CNC.BA.V2.USA
8.5 AMCOMM
8.5.1 Switches, plugs and LEDs
Tab.8.5a (Plug X62, serial interface)
Configuration of the interface9600 bps/8 data bits/1 stop bit/no parity
Plug X61
The pin assignment of plug X61 is not described in more detail since only internal
signals of the supply module are applied at this plug.
Light emitting diodes
H1 (red) Excess temperature drive module
Temperature at heat sink is higher than 80°C
H2 (red) Overvoltage intermediate circuit
H3 (yellow) Undervoltage intermediate circuit
H4 (yellow) Speed zero
The axis is stationary.
H5 (red) Speed error
• There is no setpoint value but the axis moves.
• There is a setpoint value but the axis does not move.
• There is asetpoint value but feedback of the motor feedback unit does not
correspond to the expected value.
H6 (red) Maximum speed exceeded
The information sent back by the motor feedback unit is outside the permissible
tolerance limits.
H7 (red) Effective current exceeded
The effective current was exceeded for too long a time.
ELEKTRONIK.CNC.BA.V2.USA 8-19
8.6 Overview of LED`s and switches on the drive module
8.6 Overview of LED`s and switches on the drive module
LED’s:
H1 = Electronics supply +15 V
H2 = Electronics supply -15 V
H3 = Electronics supply +5 V
H4 = Watchdog
H5 = Drive module ready to operate
H6 = Not used
Switches S2&S3
Information!
Settings 00 to FE are available for axis parametrizing. The correct setting
for each machine is detailed in the CNC diagram for the machine in
question. The setting FF is used for the manual parametrizing of the
drives.
S1 = Reset key
the drive module can beinitialised after a fault.
F1 = FuseT250 mA / 250 V
X31 = 240 VAC supply
X38 = Drivemoduleenable and error signalling contacts
8-20 ELEKTRONIK.CNC.BA.V2.USA
8.6 Overview of LED`s and switches on the drive module
Fig. 8.6a (AMCONT)
ELEKTRONIK.CNC.BA.V2.USA 8-21
8.6 Overview of LED`s and switches on the drive module
LED‘s:
H1 = Overtemperature AMBASE (heat sinks)
H2 = Overvoltage intermediate circuit
H3 = Undervoltage intermediate circuit
H4 = Speed zero
H5 = Speed error
H6 = Maximum speed exceeded
H7 = Effectivecurrent too high
Switches:
AMCOMM (10 %)
Motor power to approx. 10%
AMFEED (CW/CCW)
Switch for turning motor rotation direction
Potentiometers:
P1 = Drivemodule offset
P2 = Tacho adaptation adjustment
Jumpers:
AMADAP
J1 = 1-3 External speed setpoint value ±10 V
Measuring monitors:
AMADAP
TP1 = Speed actual value
TP2 = Current actual value
TP3 = Signal GND fo r TP1 and TP2
AMFEED
TP1 = Speed actual value
TP2 = Signal GND
Plugs:
X62 = Parametrizing interface drive module
X43 = Setpoint in put
X53 = Plug motor feedback signal
8-22 ELEKTRONIK.CNC.BA.V2.USA
8.6 Overview of LED`s and switches on the drive module
Fig. 8.6b (Overview of LED`s and switches)
ELEKTRONIK.CNC.BA.V2.USA 8-23
For your notes
8-24 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Pressure controller
9.1 The pressure controller with Prescon 2 board ................ 9-2
9.1.1 Indicators and setting elements
9.1.2 Plugs
9.1.3 Tuning of control loops (PRESCON2)
9.2 The pressure controller with Prescon 3 board ............... 9-8
9.2.1 Indicators and setting elements
9.2.2 Plugs
9.2.3 Tuning of control loops (PRESCON3)
ELEKTRONIK.CNC.BA.V2.USA 9-1
9.1 The pressure controller with Prescon 2 board
9.1 The pressure controller with Prescon 2 board
The pressure controller performs the function of continuously electronically
controlling the cutting pres
sure or the breaking pres
sure. It contains the necessary
electronicsfor regulation and control of two completely independent pneumatic
outputs (cutting tool and breaking tool,edge deleting tool).
The pressure values of the CNC are transmitted in digital form to the pressure
Serial Synchronous Interface/ controller via an SSI interface. In the pressure controller, the transmitted
RS485) information is conve rted into analogue values. A synchronized current sourcethen
controls the solenoid of the proportional valve on the cutting and/or breaking
tool. A transducer on the cutting and/or breaking tool measures the pressure and
feedsthe result in the form of a current(4-20 mA)back to the pressure controller.
If an error occurs and the required pressure cannot be reached, the pres sure
controller indicates this via the SSI interface to the CNC, from where it is
transmitted to the Panel PC and displayed there. This function is not available in
all CNC software versions(ROM/RAMx).
9.1.1 Indicators and setting elements
Light emitting diodes
H 1 = green 5 V TTL supply OK
H2
H3
=
=
green
green Electronics supply
Electronicssuppl y -15+15
V V
H4 = yellow Output stage control loop 1 switched on (cutti ng tool)
H5 = red Error in control loop 1 (cutting tool)
H6 = yellow Output stage control loop 2 switched on (breaking tool, edge
deleting tool ...)
H 7 = red Error in control loop 2 (breaking tool,edge deleting tool . .)
Potentiometers
P1 = Adjustment of proportional valve 1 (cutting tool)
P2 = Adjustment of proportional valve2 (breaking tool, edge deleting
tool...)
Test points
T P1 = Test point for adjusting proportional valve 1 (cutting tool)
T P2 = Test point for adjusting proportional valve2 (breaking tool, edge
deleting tool ...)
TPGN = Test reference point for TP1 and TP2 GND
9-2 ELEKTRONIK.CNC.BA.V2.USA
9.1 The pressure controller with Prescon 2 board
Fig. 9.1a (PRESCON2)
ELEKTRONIK.CNC.BA.V2.USA 9-3
9.1The pressure controller with Prescon 2 board
9.1.2 Plugs
Tab. 9.1a (X1 Electronics supply input)
Tab. 9.1b (X2 SSI interface)
Tab. 9.1c (X3 Connection for the pressure cells on the tools)
9-4 ELEKTRONIK.CNC.BA.V2.USA
9.1 9.1 The pressure controller with Prescon 2 board
Tab. 9.1d (X4 Connection for the proportional valves)
Fuses
F1 = Fuse of the 14 VAC supply 1 AT (1 amp 250 volt slow-blow),
analogue part.
F2 = Fuse of the 14 VAC supply 1 AT (1 amp 250 volt slow-blow),
analogue part.
F3 = Fuse of the 23 VAC supply 4 AT (4 amp 250 volt slow-blow), output
stages (proportional valves)
ELEKTRONIK.CNC.BA.V2.USA 9-5
9.1 The pressure controller with Prescon 2 board
9.1.3 Tuning of control loops (PRESCON2)
Preparation of the system for tuning
• The pressure controller must be under voltage.
• LEDs H1, H2 and H3 must light up.
• No default pressure value must be present in the CNC. It is also pos
sible to
uncouple plug X2.The LEDs H4 and H6 may not light up.
• The propor tional valve must be at atmospheric pressure.
Adjustment of cutting tool (control loop 1)
Connect volt meter in 2 V range to test point TBGN and to terminal X3.3. The
measured voltage should be approx. 880 mV.
If the voltage deviates more than ±20 mV from 880 mV,
• the pressure transduce r is not correctly connected or si faulty or
• the input circuit of the pressure controller is faulty or
• the output stage of the pressure controller is faulty.
The tester is now disconnected from terminal X3.3 and connected to TP1. By
means of potentiometer P1, the voltage is set 10 mV lower than the voltage
measured beforehand at terminal X3.3.
Adjustment of breaking tool (control loop 2)
Connect voltvoltage
measured meter inshould
2 V range
be to test point
approx. 880TBGN
mV. and to terminal X3.4. The
If the voltage deviates more than ±20 mV from 880 mV,
• the pressure transduce r is not correctly connected or si faulty or
• the input circuit of the pressure controller is faulty or
• the output stage of the pressure controller is faulty.
The tester is now disconnected from terminal X3.4 and connected to TP2. By
means of potentiometer P2, the voltage is set 10 mV lower than the voltage
measured beforehand at terminal X3.4.
9-6 ELEKTRONIK.CNC.BA.V2.USA
9.1The pressure controller with Prescon 2 board
Abb. 9.1b (Block diagram of Prescon2)
ELEKTRONIK.CNC.BA.V2.USA 9-7
9.2 The pressure controller with Prescon 3 board
9.2 The pressure controller with Prescon 3 board
The pressure controller performs the function of continuously electronically
controlling the cutting pres
sure or the breaking pres
sure. It contains the necessary
electronicsfor regulation and control of two completely independent pneumatic
outputs (cutting tool and breaking tool,edge deleting tool).
The pressure values of the CNC are transmitted in digital form to the pressure
controller via an SSI interface. In the pressure controller, the transmitted
information is conve rted into analogue values. A synchronized current sourcethen
controls the solenoid of the proportional valve on the cutting and/or breaking
tool. A transducer on the cutting and/or breaking tool measures the pressure and
feedsthe result in the form of a current(4-20 mA)back to the pressure controller.
If an error occurs and the required pressure cannot be reached, the pres sure
controller indicates this via the SSI interface to the CNC, from where it is
transmitted to the Panel PC and displayed there. This function is not available in
all CNC software versions(ROM/RAMx).
It is possible to disable each pneumatic output via a jumper (description of the
jumpers see below).
9.2.1 Indicators and setting elements
Light
H 1 =emitting
green diodes
5 V TTL supply OK
H 2 = green Supply of output stage and of analogue part OK
H 3 = green Communication CNC Þ controller OK
H 4 = yellow Output stage control loop 1 switched on (cutti ng tool)
H 5 = red Error in control loop 1 (cutting tool)
H 6 = yellow Output stage control loop 2 switched on (breaking tool)
H 7 = red Error in control loop 2 (breaking tool)
Potentiometers
P1 = Adjustment of the proportional valvefor cutting pressure
P2 = Adjustment of proportional valve2 (breaking pressure, edge deleting
tool)
Test points
T P1 = Test point for adjusting the proportional valve for cutting pressure
T P2 = Test point for adjusting the proportional valve of the breaking tool
GN D = Test reference point for TP1 and TP2
9-8 ELEKTRONIK.CNC.BA.V2.USA
9.2 The pressure controller with Prescon 3 board
Jumpers:
J2 = Jumper installed, pneumatic output 1 disabled *)
J3 = Jumper installed, pneumatic output 2 disabled *)
*) If the pneumatic output is disabled, the solenoid of the proporti o
nal valve is switched off and the CNC will not receive any status and
error information from the pressure controller.
Abb.9.2a (PRESCON3)
ELEKTRONIK.CNC.BA.V2.USA 9-9
9.2 The pressure controller with Prescon 3 board
9.2.2 Plugs
Tab. 9.2a (X1 Electronics supply input)
Tab. 9.2b (X2 SSI interface)
Tab. 9.2c (X3 Connection for the pressure cells on the tools)
9-10 ELEKTRONIK.CNC.BA.V2.USA
9.2 The pressure controller with Prescon 3 board
Tab. 9.2d (X4 Connection for the proportional valves)
Fuses
F1 = Fuse of the 14 VAC supply 1 AT (1 amp 250 volt slow-blow),
analogue part.
F2 = Fuse of the 14 VAC supply 1 AT (1 amp 250 volt slow-blow),
analogue part.
F3 = Fuse of the23 VAC supply 4 AT (4 amp 250 volt slow-blow), output
stages (proportional valves)
ELEKTRONIK.CNC.BA.V2.USA 9-11
9.2 The pressure controller with Prescon 3 board
9.2.3 Adjustment of the control loops (PRESCON3)
Preparations for adjustment
• The pressure controller must be under vol tage.
• Light emitting diodes H1 and H2 must light up.
• No default pres sure value must be present in the CN control. It is also
possible to uncouple plug X2. The ght li emitting diodes H4, H5, H6 and
H7 may not light up.
• The propor tional valve must be at atmospheric pressure.
Information!
If one of the light emitting diodes H5 or H7 lights up, the following points
should be checked:
• Is the pressure transducer correctly connected?
• Is the pressure transducer faulty?
• Is the input circuit of the pressure controller faulty?
• Is the output stage of the pressure controller faulty?
Adjustment of cutting tool (control loop 1)
• Set the volt meter in the 2 V range and
• connect the COM output of the volt meter to test point GND.
• Connect the V input of the volt meter to TP1.
• Adjust the voltage 0 V by means of potentiometer P1.
Adjustment of breaking tool (control loop 2)
• Set the volt meter in the 2 V range and
• connect the COM output of the volt meter to test point GND.
• Connect the V input of the volt meter to TP2.
• Adjust the voltage to 0 V by means of potentiometer P2.
9-12 ELEKTRONIK.CNC.BA.V2.USA
9.2 The pressure controller with Prescon 3 board
Abb. 9.2b (Block diagram of PRESCON3)
ELEKTRONIK.CNC.BA.V2.USA 9-13
For your notes
9-14 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Positioning module UNIPOS
10.1 Technical Data.................................................................. 10-2
10.1.1 Introduction
10.1.2 Characteristics
10.1.3 UNIPOS front view
10.2 Inputs and outputs ......................................................... 10-4
10.2.1 List of inputs and outputs
10.2.2 Supply
10.2.3 Axis switches
10.2.4 Encoder
10.2.5 Speed selection
10.3 Parallel command interface ........................................... 10-7
10.3.1 Inputs
10.3.2 Outputs
10.4 CAN command interface .............................................. 10-10
10.4.1 Input
10.4.2 Output
10.5 Light emitting diodes and switches .............................. 10-12
10.5.1 Light emitting diodes
10.5.2 Reset switch
10.5.3 DIP switch
10.6 Parameters ..................................................................... 10-14
ELEKTRONIK.CNC.BA.V2.USA 10-1
10.1 Technical Data
10.1 Technical Data
10.1.1 Introduction
The UNIPOS is a universal decentral one-axis positioning control with advantages
with regard to uncomplicated realization of movements with the aid of servo drives
and simple commissioning.
The functionality comprises position-controlled positioning of a servo axis.
Manual driving, approaching of reference points, vane driving and positioning
are available.
The commissioning and diagnostics software tool UNIPOS-IDT permits opti-
mal adaptation to the machine as well as fast diagnosis on site.
The data structure envisages the management of parame
ters, position valuesand
monitoring values.
The UNIPOS is actuated via a separate command interface. For simple
applications, actuation can beeffected via parallel I/O signals. For more extensive
applications(e.g. teach-in), networking via CAN busis possible.
10.1.2 Characteristics
Travel range,internal 15,000,000increments
TravelrangeCAN 1,048,575increments
Maximumspeed 10-655,350increments/s
Travelspeed 0.392-100%ofmaximumspeed
Accelerationdistance 1- 32767increments
Accelerationprofile lin, log, exp, sin2or n/M table
Hardwareswitches Limitation+,-,slow,vane
Encoderscanningrate 10MHz
Encoder multiplication factor 1/2/3/4
Position controller resolution 0.5 increment / 1 increment
Position controller amplification 0.6/1.2/2.4/4.8/9.7/19.5/39.2/78.4
mV/increment
Requiredvalue +/-10V
10-2 ELEKTRONIK.CNC.BA.V2.USA
10.1 Technical Data
10.1.3 UNIPOS front view
Abb. 10.1a (UNIPOS front view)
Legend:
1 Parallel outputs
2 CAN businterface, stepping motor plug *), reset switch
3 Supply
4 Axis switch
5 Encoder
6 Required value
7 Parallel inputs
8 Light emitting diodes
*) Not yet supported
ELEKTRONIK.CNC.BA.V2.USA 10-3
10.2 Inputs and outputs
10.2 Inputs and outputs
10.2.1 List of inputs and outputs
Suppy
X1.1 24VDC
X1.2 0V
Axis switc
X2.1
X2.2 Switch limitation -+
Switch limitation
X2.3 Switch slow
X2.4 Switch vane
X2.5 Switch 0 V
Enco er input
X3.1 Output channel A
X3.2 Output channel/A
X3.3 Output channel B
X3.4 Output channel/B
X3.5 Output channel 0
X3.6 Output channel/0
X3.7 Supply
X3.8 Ground
Para e input
X5.1 Manual driving
X5.2 Approach reference point
X5.3 Position
X5.4 Forwards/Reverse
X5.5 Required speed value (1)
X5.6 Required speed value (2)
X5.7 Required speed value (4)
X5.8 Required speed value (8)
X5.9 Enable/Stop
X5.10 Execute/Hold
X5.11 Set actual value
X5.12 Pos. required value/Pos. actual value
X5.13 Required position value (1)
X5.14 Required position value (2)
X5.15 Required position value (4)
X5.16 Required position value (8)
X5.17 -
X5.18 0 V (common)
10-4 ELEKTRONIK.CNC.BA.V2.USA
10.2 Inputs and outputs
Require vaue ou tput
X4.1 Required value
X4.2 0V
X4.3 Screen
Para e outputs
X6.1 Drive running
X6.2 End ramp
X6.3 End vane
X6.4
X6.5 End limitation
Switch limitation +
X6.6 Switch limitation -
X6.7 Switch slow
X6.8 Switch vane
X6.9 Ready
X6.10 -
X6.11 -
X6.12 Required value/Ranges
X6.13 Range 1/Required value (1)
X6.14 Range 2/Required value (2)
X6.15 Range 3/Required value (4)
X6.16 Range 4/Required value (8)
X6.17 +24 VDC (common)
X6.18 0V
10.2.2 Supply
The UNIPOS is supplied with 24 VDC, unstabilized, via terminal X1.
24VDC X1.1
0V X1.2
10.2.3 Axis switches
The axis switches are connected to terminal X2.
The switches used may be of any type with a supply voltage of 24 VDC and
positively switching outputs.
Switch limitation + X2.1
Switch limitation - X2.2
Switchslow X2.3
Switchvane X2.4
Switch0V X2.5
ELEKTRONIK.CNC.BA.V2.USA 10-5
10.2 Inputs and outputs
10.2.4 Encoder
An incremental encoder is connected to terminal X3, as a distance measuring
system. All incremental encoders with a supply voltage of 10 - 30 V and RS422
output driver can be used.
The maximum line length should not exceed 100 m.
For effective noise suppression in the entire system, encoder lines should be screened
and should be locally isolated from power lines and interference-generating devices.
With simple screening, the screen is connected at one end to the encoder housing.
Although the screening of the entire system is thusinterrupted, earth loopsare
reliably avoided in this way.
Output channel A X3.1
Output channel/A X3.2
Output channel B X3.3
Output channel/B X3.4
Output channel 0 X3.5
Output channel/0 X3.6
Supply X3.7
Ground X3.8
10.2.5 Required speed value
The required speed value of +-10 V is output via a 12 bit D/A converter to terminal
X4.
Required value X4.1
Ground X4.2
Screen X4.3
The cable length should not exceed 5 m. The screen is connected at one end to
the UNIPOS.
The servo amplifier used must have differential inputs.
10-6 ELEKTRONIK.CNC.BA.V2.USA
10.3 Parallel command interface
10.3 Parallel command interface
The parallel signal exchangewith the UNIPOS is via terminals X5.
10.3.1 Inputs
The input signals must be present as positively switched 24 VDC voltage values.
The supply is external.
- X5.17
Inputs 0 V (common) X5.18
Function selection
The first four inputs define the function
Manualdriving X5.1
Approaching reference points X5.2
Positioning X5.3
Forwards/Reverse X5.4
The following input combinationsare permitted:
Function/Input X5.1 X5.2 X5.3 X5.4
Manualtravelforwards 1 0 0 1
Manualtravelbackwards 1 0 0 0
Approachreferencepointforwards 0 1 0 1
Approachreferencepointbackwards 0 1 0 0
Incrementalpositioningforwards 0 0 1 1
Incrementalpositioningbackwards 0 0 1 0
Absolutepositioning 0 0 1 -
Vanetravelforwards* 0 1 1 1
Vanetravelbackwards* 0 1 1 0
Vanetravelabsolute * 0 1 1 -
*) Not yet supported
ELEKTRONIK.CNC.BA.V2.USA 10-7
10.3 Parallel command interface
Speed selection
The maximum travel speed is stipulated with inputs 5-8 (16 configurable speeds).
Required speed value (1) X5.5
Required speed value (2) X5.6
Required speed value (4) X5.7
Required speed value (8) X5.8
Drive commands
Inputs 9-12 are the actual drive commands.
Setting input 9 activates theposition controller and enables theUNIPOS to execute
drive commands.
When input 9 is reset, the position controller is blocked, required value 0 V is
output and any ongoing drive command is immediately stopped.
When input 10 is set, the preselected drive command is executed. On premature
resetting of input 10, the drive command is terminated with a hold ramp.
Input 11 permits “setting of a floating actual value”. With the positive flank of
this signal, the actual value register is set to the selected requi
red position value.
With input 12, it is possible to switch between required position value output
and actual position value output.
Enable/Stop X5.9
Execute/Hold X5.10
Setactualvalue X5.11
Required position value/Actual position value X5.12
Selection of required position value
The required pos
ition value is selected via inputs 13-16 (16 configurable required
position values, either absolute or incremental (in steps)
Required position value (1) X5.13
Required position value (2) X5.14
Required position value (4) X5.15
Required position value (8) X5.16
10-8 ELEKTRONIK.CNC.BA.V2.USA
10.3 Parallel command interface
10.3.2 Outputs
The output signals are positively switched. The current load per output may not
exceed 0.3 A. The supply is external.
+24 VDC (common) X6.17
V0 X6.18
Position status
The first four outputs show the position status
Driverunning X6.1
Endramp X6.2
Endvane X6.3
End limitation X6.4
Switch status
The output signals 5-8 show the switch status
Switch limitation+ X6.5
Switchlimitation- X6.6
Switchslow X6.7
Switchvane X6.8
Module status
The outputs 9-11 show the module status
Ready X6.9
- X6.10
- X6.11
- X6.12
Actual position value
If input 12 is not set, the configured actual value ranges 1-4 are output at outputs
13-16 (cam gear function). If input 12 is set, the currently selected required position
value is output at outputs 13-16.
Range 1 or required position value (1) X6.13
Range 2 or required position value (2) X6.14
Range 3 or required position value (4) X6.15
Range 4 or required position value (8) X6.16
ELEKTRONIK.CNC.BA.V2.USA 10-9
10.4 CAN command interface
10.4 CAN command interface
The UNIPOS can be controlled via SELECAN by mounting the intermediate
module DIOCAN.
10.4.1 Input
Bit 0 Required position value (1)
Bit 1 Required position value (2)
Bit 2 Required position value (4)
Bit 3 Required position value (8)
Bit 4 Required position value(16)
Bit 5 Required position value(32)
Bit 6 Required position value(64)
Bit 7 Required position value(128)
Bit 8 Required position value(256)
Bit 9 Required position value(512)
Bit 10 Required position value(1024)
Bit 11 Required position value(2048)
Bit 12 Required position value(4096)
Bit 13 Required position value(8192)
Bit 14 Required position value(16384)
Bit 15 Required position value(32768)
Bit 16
Bit 17 Required
Required position value(65536)
position value (131072)
Bit 18 Required position value (262144)
Bit 19 Required position value (524288)
Bit 20 Enable/Stop
Bit 21 Execute/Hold
Bit 22 Set actual value
Bit 23 Required position value/Actual position value
Bit 24 Manual driving
Bit 25 Approach reference point
Bit 26 Position
Bit 27 Forwards/Reverse
Bit 28 Speed selection (1)
Bit 29 Speed selection (2)
Bit 30 Speed selection (4)
Bit 31 Speed selection (8)
All inputs of the parallel interface are blocked in this mode!
10-10 ELEKTRONIK.CNC.BA.V2.USA
10.4 CAN command interface
10.4.2 Output
Bit 0 Actual position value (1)
Bit 1 Actual position value (2)
Bit 2 Actual position value (4)
Bit 3 Actual position value (8)
Bit 4 Actual position value (16)
Bit 5 Actual position value (32)
Bit 6 Actual position value (64)
Bit 7 Actual position value (128)
Bit 8 Actual position value (256)
Bit 9 Actual position value (512)
Bit 10 Actual position value (1024)
Bit 11 Actual position value (2048)
Bit 12 Actual position value (4096)
Bit 13 Actual position value (8192)
Bit 14 Actual position value (16384)
Bit 15 Actual position value (32768)
Bit 16 Actual position value (65536)
Bit 17 Actual position value (131072)
Bit 18 Actual position value (262144)
Bit 19 Actual position value (524288)
Bit 20 Actual position value (1048576)
Bit
Bit 21
22 Actual
Actual position
position value
value (2097152)
(4194304)
Bit 23 Actual position value (8388608)
Bit 24 Driverunning
Bit 25 End ramp
Bit 26 End vane
Bit 27 End limitation
Bit 28 Switch limitation +
Bit 29 Switch limitation -
Bit 30 Switch slow
Bit 31 Switch vane
All outputs of the parallel command interfaceremain active!
ELEKTRONIK.CNC.BA.V2.USA 10-11
10.5 Light emitting diodes and switches
10.5 Light emitting diodes and switches
10.5.1 Light emitting diodes
Four light emitting diodes are present on the front panel:
• WDDOG
The watchdog timer is operated only in the line mode. In the local mode,
the LED is lit up continuously.
If the LED lights up in the line mode, a hardware error is present.
• UL0M
The LED indicates two states:
The position controller is in overflow
The encoder passes through the zero markon approaching the reference
position
• RUN
The RUN LED lights up if the module is in the line mode. At each start
command, the LED goes out briefly.
• ERR
The
LED ERROR
lights up:LED
Errorindicates two error
in the encoder cases:
signals
LED flashes: Encoder supply faulty
If the FLASH EPROM is empty (first start) and the DIP switch isat line mode,
the ERR and RUN LEDs flash in a continuous loop.
In this case, the DIP switch must be switched off and a reset performed.
The light emitting diodes ERR and RUN are in principle valid only in the line
mode.
10.5.2 Reset switch
The reset switch is located at the bottom of the module, behind the plugs.
After a reset, the UNIPOS copies all parameters again from the FLASH to the
RAM and sets the modewhich is preset on the DIP switches.
10-12 ELEKTRONIK.CNC.BA.V2.USA
10.5 Light emitting diodes and switches
10.5.3 DIP switch
The DIP switch is located under the metal cover at the top of the UNIPOS. At
present, only DIP switch 1 isused.
ON : UNI POS starts up in line mode
OFF: UNIPOS starts up in local mode
ELEKTRONIK.CNC.BA.V2.USA 10-13
10.6 Parameters
10.6 Parameters
The parameters are set via the serial terminal interface under the metal cover at
the top of the module. For this purpose, the special UNIPOS installation and
diagnosticssoftware tools UNIPOS IDT are required.
The following parameters can be set with it:
•Command interface
•Amplification
•
Absolute driving
• Vane driving mode
• 4 ranges
• Maximum driving frequency
• Zero mark
• Motor output
• Encoder direction
• Encoder multiplication factor
• 16 required position values
• 16 required speed values
• Acceleration profile
Further information can be found in the documentation on the UNIPOS IDT
software (available from the software department).
10-14 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 10-15
For your notes
10-16 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Adjustment instructions
11.1 Adjustment of Poscon XYZ, KSM and VSM .................... 11-2
11.2 Adjusting the drive modules ............................................. 11-6
11.3 Adjustment of pressure controller ................................... 11-10
11.3.1 Adjustment of pressure controller with Prescon2 board
11.3.2 Adjustment of pressure controller with Prescon3 board
11.4 Adjustment of POSCON PSM ......................................... 11-18
11.5 Adjustment of drive module PSM .................................. 11-22
ELEKTRONIK.CNC.BA.V2.USA 11-1
11.1 Poscon XYZ, KSM and VSM
11.1 Adjustment of Poscon XYZ, KSM and VSM
Proceed as follows:
•Shut down Windows 95 and switch off the CN control.
•Set the setup switch
) in
( all drive modules, on the AMCOMM board at
the back of the CNC cabinet to 10%.
Fig. 11.1a (10% switch on AMCOMM card)
• Switch off motor protection switch Q3 at the front in the CNC cabinet.
• Disconnect required value cable (white and brown)
) from( terminals 3 and
4 on all drive modules (AMADAP).
Fig. 11.1b (Required value cable on AMADAP card)
Information!
T his is the cable which brings the RE QU IR ED VALU E (+/- 10 VD C) from
the POSCON to the drive module.
11-2 ELEKTRONIK.CNC.BA.V2.USA
11.1 Poscon XYZ, KSM and VSM
Attention!
On no account may the two cables come into contact with one another
(short-circuit). Otherwise, the POSCON cards might be destroyed!
• Connect volt meter in the 20 VDC range to the required value cable of the
POSCON card to be adjusted.
Fig. 11.1c (Volt meter at required value cable)
• Switch on CN control.
• Movethe axis belonging to the POSCON (required value cable) very slowly,
millimetre by millimetre, in onedirection.
• During this it is possible to observe how the voltage on the volt meter
display
negativeincreases
. As soon(see Figure
as the redbelow).
LED The voltagemay bepositive as well as
() on the POSCON lights up, stop
moving.
Fig. 11.1d (Diagram showing the voltage)
• This value is about +10 VDC or -10 VDC.
• This value must be noted (e.g. 9.985 V).
• The axis is now moved in the other direction. The voltage on the volt meter
decreases slowly and increases again with the opposite sign (different
polarity).
• As soon asthe maximum value is reached again, the red LED)( on the
POSCON lights up again; stop moving.
• This value too must be noted (e.g. 10.075 V).
.
ELEKTRONIK.CNC.BA.V2.USA 11-3
11.1 Poscon XYZ, KSM and VSM
• With potentiometer P2 on the POSCON card (), the voltage can now be
adjusted (see Figure below) so that it has absolutely the same magnitude both
in the minus direction and in the plus direction (e.g. +9.998 V and -9.998
V). In other words, the symmetry of the setpoint voltage on the POSCON
card is adjusted with potentiometer P2.
Fig. 11.1e (POSCON board)
Information!
SW1 = Switch 1
LED = Light emitting diode 1 (red)
LED2 = Light emitting diode 2 (green)
P2 = Potentiometer for symmetry adjustment of Poscon
• This adjustment should be carried out in the same way for all axes.
• Shut down Windows 95 and switch off the CN control.
• Switch on motor protection switch Q3 at the
front in the CNC cabinet.
• Set the setup switch) on
( AMCOMM back to
100%.
• Reconnect all required value cables (white and
brown) to terminals 3 and 4 on the AMADAP again.
11-4 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 11-5
11.2 Drive modules XYZ, KSM and VSM
11.2 Adjusting the drive modules
• Shut down Windows 95 and switch off the CN control.
• Connect the volt meter in the 20 VDC range, for the axis to be adjusted, to
terminals 3 and 4 on the AMADAP board (parallel to the white and brown
wire) on the drive module to beadjusted.
Fig. 11.2a (Volt meter at AMADAP)
• Switch on the CN control. Logging into the MMC program is not
neces
sary.
• Start the “HAND” menu (“HAND” key on CNC keyboard).
• Start the “ADJUST” menu (key “S7” on CNC keyboard).
• Press key [WZ1] or [WZ2] (WZ1 is for the cutting tool, WZ2 is for the
grinding or breaking tool).
• By pressing the manual control keys (X, Y or Tool), move the axis to be
adjusted forwards and backwards; during the travel, the voltage is set to the
same value in the plus and minus travel direction by means of potentiometer
P1 () (see Figure 10.2b).
11-6 ELEKTRONIK.CNC.BA.V2.USA
11.2 Drive modules XYZ, KSM and VSM
• By pres
sing the manual control keys, travel with the axis in one direction;
during the travel, the voltage is set to 1.0 V on potentiometer ) (see
P2 (
Figure below).
Fig. 11.2b (Drive module, AMADAP board)
• This adjustment should be carried out in the same way for the X and Y axes.
• The adjustment procedure forthe auxiliary axes (cutting, grinding and
breaking tool) is identical to the X and Y axes. However, the voltage must be
set as follows:
Cuttingtool = 2.5V
Edgedeletingtool = 2.5 V
Breakingtool = 2.5V
ELEKTRONIK.CNC.BA.V2.USA 11-7
For your notes
11-8 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 11-9
11.3 Adjustment of pressure controller
11.3 Adjustment of pressure controller
11.3.1 Adjustment of pressure controller with Prescon2 board
Preparations for the adjustment
•The pressure controller must be under voltage.
•Light emitting diodes H1, H2 and H3 must light up.
•Uncouple plug X2).( The light emitting diodes H4 and H6 may not li ght
up.
• The proportional valve must be at atmospheric pressure.
Adjustment of cutting tool (control loop 1)
•Set the volt meter in the 2 V range and
•connect the COM output of the volt meter to test point TBGN ().
•Measure the voltagewith the V output at terminal X3.3).
(
•This should be approx. 880 mV, ± 20 mV.
•The voltage is now measured with the V output of the volt meter at TP1
(). This must be 10 mV lower than that measured at terminal).X3.3 (
Example:
Voltage at terminal X3.3 = 874 mV
Voltage at test point TP1 = 864 mV
•If this is not the case, the voltage is adjusted on potentiometer
). P1 (
Adjustment of breaking tool (control loop 2)
•Set the volt meter in the 2 V range and
•connect the COM output of the volt meter to test point TBGN ().
•Measure the voltagewith the V output at terminal X3.4().
•This should be approx. 880 mV, ± 20 mV.
•The voltage is now measured with the V output of the volt meter at TP2
(). This must be 10 mV lower than that measured at terminal).X3.4 (
Example:
Voltage at terminal X3.4 = 874 mV
Voltage at test point TP2 = 864 mV
•If this is not the case, the voltage is adjusted on potentiometer
). P2 (
11-10 ELEKTRONIK.CNC.BA.V2.USA
11.3 Adjustment of pressure controller
Information!
If the voltage deviates by more than ± 20 mV, this may be due to the
following causes:
• The pressure transducer is not correctly connected.
• T he pressuretransducer is fault
y.
• The input circuit of the pressure controller is faulty.
• The output stage of the pressure controller is faulty.
Fig. 11.3a (Pressure controller, PRESCON2 board)
ELEKTRONIK.CNC.BA.V2.USA 11-11
For your notes
11-12 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 11-13
11.3 Adjustment of pressure controller
11.3.2 Adjustment of pressure controller with Prescon3 board
Preparations for the adjustment
•The pressure controller must be under voltage.
•Light emitting diodes H1 and H2 must light up.
•Uncouple plug X2).( The light emitting diodes H5 and H7 may not li ght
up.
•The proportional valve must be at atmospheric pressure.
Information!
If one of the light emitting diodes H5 or H7 lights up, this may be due to
the following causes:
• T he pressure transducer is not correctly connected.
• T he pressure transducer is faulty.
• T he input circuit of thepressure controller is faulty.
• T he output stage ofthe pressure controller is faulty.
Adjustment of cutting tool (control loop 1)
•Set the volt meter in the 2 V range and
•connect the COM output of the volt meter to test point GND ().
•Connect the V input of the volt meter to TP1). (
•Set the voltage to 0 V by means of potentiometer ). P1 (
Adjustment of breaking tool (control loop 2)
•Set the volt meter in the 2 V range and
•connect the COM output of the volt meter to test point GND ().
•Connect the V input of the volt meter to TP2). (
•Set the voltage to 0 V by means of potentiometer ). P2 (
11-14 ELEKTRONIK.CNC.BA.V2.USA
11.3 Adjustment of pressure controller
Fig. 11.3b (Pressure controller, PRESCON3 board)
ELEKTRONIK.CNC.BA.V2.USA 11-15
For your notes
11-16 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 11-17
11.4 POSCON PSM
11.4 Adjustment of POSCON PSM
Proceed as follows:
•Shut down Windows 95 and switch off the CN control.
•Set the setup switch
) in
( all drive modules, on the AMCOMM board at
the back of the CNC cabinet, to 10%.
Fig. 11.4a (10% switch on AMCOMM card)
• Switch off motor protection switch Q3 at the front in the CNC cabinet.
• Disconnect required value cable (brown and white)
) from( terminals 3 and
4 in all drive modules (AMADAP).
Information!
T his is the cable which brings the REQU IR ED VALU E (+/- 10 VD C) from
the POSCON to the drive module.
Attention!
On no account may the two cables come into contact with one another
(short-circuit). Otherwise, the POSCON cards might be destroyed!
11-18 ELEKTRONIK.CNC.BA.V2.USA
11.4 POSCON PSM
• Connect volt meter in the 20 VDC range to the required value cable of the
POSCON card to be adjusted.
Fig. 11.4c (Volt meter at required value cable)
• Switch on CN control.
• Turn the axis belonging to the Poscon, at the motor coupling, very slowly,
millimetre by millimetre, in onedirection.
• During this it is possible to observe how the voltage on the volt meter
display increases (see Figure below). The voltagemay bepositive as well as
negative. As soon as the red LED () on the POSCON lights up, stop
turning.
Fig. 11.4d (Diagram showing the voltage)
• This value is about +10 V or -10 V.
• This value must be noted (e.g. 9.985 V).
• The axis is now moved in the other direction. The voltage on the volt meter
decreases slowly and increases again with the opposite sign (different
polarity).
ELEKTRONIK.CNC.BA.V2.USA 11-19
11.4 Poscon PSM
• As soon as the maximum value has been reached a gain, the red LED
) (on
the POSCON lights up again; stop turning.
• This value, too, must be noted (e.g. 10.075 V).
• The voltage can now be adjusted with potentiometer ) (see
2 Figure
( 10.4e)
so that it has absolutely the same magnitudeboth in the minusand in the
plus direction (e.g. +9.998 V and -9.998 V). In other words, the symmetry
of the required volt age on the POSCON card is set with potentiometer P2.
Fig. 11.4e (POSCON board)
Information!
SW1 = Switch1
LED1 = Light emitting diode 1 (red)
LED2 = Light emitting diode 2 (green)
P2 = Potentiometer for symmetry adjustment of POSCON
• Carry out this adjustment for the linear and polar axis in the same way.
• Shut down Windows 95 and switch off the CN control.
• Switch on motor protection switch Q3 at the front in the CNC cabinet.
• Set the setup switch (1) on AMCOMM back to
100%.
• Reconnect all required value cables (white and
brown)to terminals 3 and 4 on the AMADAP.
11-20 ELEKTRONIK.CNC.BA.V2.USA
For your notes
ELEKTRONIK.CNC.BA.V2.USA 11-21
11.5 Drive module PSM
11.5 Adjustment of drive module PSM
• Shut down Windows 95 and switch off the CN control.
• Connect the volt meter in the 20 VDC range, for the axis to be adjusted, to
terminals 3 and 4 on the AMADAP board (parallel to the white and brown
wire) on the drive module.
Fig. 11.5a (Volt meter on AMADAP)
• Switch on the CN control. Log into MMC
• User: EXPERT
• Password: EXPERT
• Start the “SETUP” menu (“SETUP” key on CNC keyboard)
• Set the parameter “HAND FEED” to 5000 mm/min
• Start the “HAND” menu (“HAND” key on CNC keyboard)
• Start the “ADJUST” menu (key “S7” on CNC keyboard)
• Start the “MAIN DRIVES” menu (key “S1” on CNC keyboard)
• By pressing the manual control keys (Rot, Lin), move forwards and
backwards with the axis to be adjusted; during the travel, the OFFSET
voltage is set to the same value in the plus and minus direction by means of
potentiometer P1 () (see adjacent Figure).
11-22 ELEKTRONIK.CNC.BA.V2.USA
11.5 Drive module PSM
• By pressing themanual control keys, travel with the axis in onedirection;
during the travel, set the tacho value to 1.0 V on potentiometer ) (see
P2 (
Figure below).
Fig. 11.5b (Drive module, AMADAP board)
• This adjustment should bemade in the same way for the polar and linear
drive.
ELEKTRONIK.CNC.BA.V2.USA 11-23
For your notes
11-24 ELEKTRONIK.CNC.BA.V2.USA
Contents of Chapter
Appendix
12.1 Customer Service information ......................................... 12-2
12.1.1 Bystronic Maschinen AG
12.1.2 Bystronic Inc.
12.1.3 Bystronic Asia
12.2 List of Figures ................................................................... 12-4
12.3 List of Tables .................................................................... 12-8
12.4 Index ............................................................................... 12-10
1
12.1 Customer Service information
12.1 Customer Service information
You will help usand yourself if you have the following n
i formation ready before
making the call:
Company name
Place
Contact person
Direct dialling number
Year of construction) (
Order number()
Machine type()
Exact description of the problem (what exactly does not function - answers
obtained on working through the “Troubleshooting scheme”).
The responsible engineer should havethe following docume
nts to hand:
•Technical docume ntation
•Circuit diagram
Fig. 12.1a (The identification plate is mounted on every machine)
2
12.1 Customer Service information
12.1.1 Bystronic Maschinen AG
Bystronic Maschinen AG
Industriestrasse 5
CH-4922 Bützb erg
Telephone +4162-958 77 77
Telefax +4162-958 77 00
E-Mail [email protected]
http://www.bystronic.ch
12.1.2 Bystronic Inc.
Bystronic Inc.
30 Commerce Drive,
Hauppauge, NY, 11788
Phone +1516 231 12 12
Facsimile +1516 231 10 40
email [email protected]
12.1.3 Bystronic Asia
Bystronic Asia
61 Alexandra
#06-11 HarbourTerrace
Link
Singapore 119936
Phone +65 278 66 78
Facsimile +65 272 59 78
email [email protected]
3
12.2 List of Figures
12.2 List of Figures
Introduction
Fig. V.1a Organization of thepages in these operating instructions
Chapter 1
Fig. 1.1a Block diagram of cutting machineXYZ97/98
Fig. 1.1b Block diagram of cutting machineXYZF97/98
Fig. 1.1c Block diagram of cutting machineXYZF97/98R
Fig. 1.1d Block diagram of cutting machineXYZF97/98DS
Fig. 1.1e Block diagram of cutting machine PSM-XYZF98
Fig. 1.1f Block diagram of shapecutting machine KSM 97/98
Fig. 1.1g Block diagram of shape cutting and breaking machine KSBM97/
98
Fig. 1.1h Block diagram of multipurpose cutting machineVSM97/98
Fig. 1.1i Block diagram of polar grindingmachinePSM97/98 Stand Alone
Fig. 1.1j Block diagram of polar grinding machinePSM97/98 Compact
Fig. 1.1k Block diagram of polar drilling machinePBM97/98
Chapter 2
Fig. 2.1a Electronicsrack
Fig. 2.1b Rack supply 2
Fig. 2.1c Block diagram of rack supply 2
Fig.
Fig. 2.2a
2.2b CPU
CPU 386SX
386SX
Fig. 2.2c Block diagram of CPU 386SX
Fig. 2.3a ROM/ RAM2
Fig. 2.3b Block diagram of ROM/ RAM2
Fig. 2.4a CUTCON2
Fig. 2.4b Block diagram of CUTCON2
Fig. 2.5a IM PGEN
Fig. 2.5b Block diagram of IM PGEN
Fig. 2.6a Voltage curve for drive on POSCON
Fig. 2.6b POSCON
Fig. 2.6c POSCON wrap connections
Fig. 2.6d Block diagram of POSCON
Fig. 2.7a SERCOM2
Fig. 2.7b Block diagram of SERCOM2
Fig. 2.7c SERPORT adapter card
Fig. 2.7d SER232 adapter card
Fig. 2.7e SER422 adapter card
Fig. 2.7f SERCUL adapter card
Fig. 2.8a DIOCOM
Fig. 2.8b Block diagram of DIOCOM
Fig. 2.8c DI OPAR interfacecard
Fig. 2.8d DI OSSI i nterfacecard
Fig. 2.8e DIOCAN interfacecard
4
12.2 List of Figures
Fig. 2.9a POSCAD
Fig. 2.9b Block diagram of POSCAD
Chapter 3
Fig. 3.1a Front view of Berger stepping motor rack
Fig. 3.1b Back of Berger stepping motor rack
Fig. 3.2a Stepping motor card D900
Chapter 4
Fig. 4.1a TERMI F
Fig. 4.2a PARAN
Fig. 4.3a Speed limit monitor SLIM
Fig. 4.3b Block diagram of speed limit monitor SLIM
Fig. 4.4a Module busS3
Fig. 4.5a I/O m odule SSI
Fig. 4.5b I/O m odule SSI
Chapter 5
Fig. 5.1a Front view of panel PC
Fig. 5.1b Block diagram of Panel PC
Fig. 5.1c Serial interface card PCOLA
Fig. 5.1d I/O addresson PCTIF
Fig.
Fig. 5.1e
5.1f Keyboard interface
Voltage and PCTIF
temperature monitor PTCON
Chapter 6
Fig. 6.1a Block diagram of drivesystem
Fig. 6.2a AC synchronousmotor beam drive
Fig. 6.2b Signal diagram for AC synchronous motor beam drive
Fig. 6.2c AC synchronousmotor carriage drive
Fig. 6.2d Signal diagram of AC synchronousmotor carriage drive
Fig. 6.2e AC synchronousmotor rotary drive
Fig. 6.2f Signal diagram of AC synchronousmotor rotary drive
Fig. 6.2g Pin assignment for motor connection plug
Fig. 6.2h Motor feedback unit, large
Fig. 6.2i Arrangement of large motor feedback unit in motor
Fig. 6.2j Pin assignment of motor feedback plug
Fig. 6.2k Motor feedback unit, small
Fig. 6.2l Arrangement of small motor feedback unit in motor
Fig. 6.2m Pin assignment of motor feedback plug
Fig. 6.2n Incremental encoder
Fig. 6.2o Pin assignment of incremental encoder plug
5
12.2 List of Figures
Chapter 7
Fig. 7.1a Supply module, standard version
Fig. 7.1b Power pack of supply module
Fig. 7.1c VMD RIV control unit
Fig. 7.1d Block diagram of supply module
Chapter 8
Fig. 8.1a Block diagram of AC drive module
Fig. 8.1b Schematic diagram of thecardsin thedrivemodule
Fig. 8.1bb Schematic diagram of the cable laying in the drivemodule
Fig. 8.1c Power pack in drive module
Fig. 8.1d Power control unit i n drive module
Fig. 8.1e Block diagram of AMBASE
Fig. 8.2a AMCONT logic control
Fig. 8.2b Schematic diagram of reset switch in drivemodule
Fig. 8.3a Drive module adapter AMADAP
Fig. 8.3b Block diagram of AMADAP
Fig. 8.4a Motor feedback interface AMFEED
Fig. 8.5a Communication interface AMCOMM
Fig. 8.6a Overview of light emitting diodes and switches in drivemodule
AMCONT
Fig. 8.6b Overview of light emitting diodes and switches in drivemodule
AMCOMM/AMADAP/AMFEED
Chapter 9
Fig. 9.1a Pressurecontroller PRESCON2
Fig. 9.1b Block diagram of PRESCON2
Fig. 9.2a Pressurecontroller PRESCON3
Fig. 9.2b Block diagram of PRESCON3
Chapter 10
Fig. 10.1a Front view of UNI POS
Chapter 11
Fig. 11.1a 10% switch at drive module
Fig. 11.1b Required value cable on drivemoduleAMADAP card
Fig. 11.1c Volt meter at required value cable
Fig. 11.1d Schematic diagram of voltage
Fig. 11.1e POSCON
Fig. 11.2a Volt meter at AMADAP
Fig. 11.2b Drive module, AMADAP card
Fig. 11.3a Pressurecontroller PRESCON2
Fig. 11.3b Pressurecontroller PRESCON3
Fig. 11.4a 10% switch in drive module
Fig. 11.4b Required value cable at drivemoduleAMADAP card
Fig. 11.4c Volt meter at required value cable
6
12.2 List of Figures
Fig. 11.4d Schematic diagram of the voltage
Fig. 11.4e POSCON
Fig. 11.5a Volt meter at AMADAP
Fig. 11.5b Drive module, AMADAP card
7
12.3 List of Tables
12.3 List of Tables
Chapter 2
Tab. 2.5a IM PGEN switch positions
Tab. 2.5b IMPGEN switch positions, overview accordingto machine type
Tab. 2.6a Switch positions SW1 POSCON, overview accordingto machine
type
Tab. 2.6b Wire Wrap Configuration POSCON, overview according to
machine type
Tab. 2.7a Interrupt SW1 SERCOM2, overview according to machine type
Tab. 2.7b Switch positions of bidirectional interface SERCUL
Tab. 2.8a Interrupt SW1 DI OCOM slot STD
Interrupt SW1 DIOCOM slot STE
Tab. 2.8b DI OCAN switch position
Tab. 2.9a Switch positionsfor encoder input POSCAD
Tab. 2.9b Switch positions for encoder input POSCAD, overview according
to machine type
Tab. 2.9c POSCAD configuration
Chapter 3
Tab. 3.2a Dip switch settings on Berger card D900
Tab. 3.2b Rotary switch for motor pha se current on Berger card D900
Chapter
Tab. 4.3a 4 Speed setting on speed limit monitor SLIM
Chapter 5
Tab. 5.1a IRQ and I/O addresses in Panel PC
Tab. 5.1b Settingsfor interrupt keyboard interface PCTIF
Chapter 6
Tab. 6.2a Pin assignment for motor connection plug
Tab. 6.2b Signal assignment for largemotor feedback plug
Tab. 6.2c Signal assignment for largemotor feedback cable
Tab. 6.2d Signal assignment for small motor feedback plug
Tab. 6.2e Signal assignment for small motor feedback cable
Chapter 8
Tab. 8.1a Power pack connections on AC drivemodule
Tab. 8.4a Motor feedback variants on AMFEED
Tab. 8.4b Plug X53, interface to motor feedback unit
Tab. 8.5a Plug X62, serial port
Chapter 9
Tab. 9.1a X1 PRESCON2 electronicssupply input
Tab. 9.1b X2 SSI interface PRESCON2
8
12.3 List of Tables
Tab. 9.1c X3 Connection for thetransduceron on the toolsPRESCON2
Tab. 9.1d X4 Connection for theproportional valves PRESCON2
Tab. 9.2a X1 PRESCON3 electronicssupply input
Tab. 9.2b X2 SSI interface PRESCON3
Tab. 9.2c X3 Connection for the transducer on thetoolsPRESCON3
Tab. 9.2d X4 Connection for theproportional valves PRESCON3
Chapter 10
Tab. 10.2a List of the UNIPOS inputsand outputs
Tab. 10.3a Parallel command interface input combinations
9
12.4 Index
A
Adjustment of drive modules PSM 11-22 Block diag
ram of XYZF97/
98 1-3
Adjustment ofcontrol loops(PRESCON2) 9-6 Block diagram of XYZF97/98DS 1-5
Adjustmentof control loops(PRESCON3) 9-12 Block diagram of XYZF97/98R 1-4
Adjustment of Poscon PS M 11-18 Block diag
ram of XYZF97/
98 1-2
Adjustment of Poscon XYZ, KSM and VSM 11-2
Adjustment instructions 11-1 C
Adjustment of drive modules PSM 11-22 CAN command interface 10-10
Adjustment of Poscon PSM 11-18 CNC rack 2-2
Adjustment of Poscon XYZ, KSM and VSM 11-2 CPU 386SX 2-8
Drive modules, adjust 11-6 CUTCON2 2-14
Pressure controller, adjust 11-10
with Prescon2 board 11-10 D
with Prescon3 11-14 DIOCAN. SeeDI OCOM
AC drivesystem 6-2 DIOCOM 2-36
AC motors6-4 DIOPAR.SeeDIOCOM
AC installation synchronous motor 6-4 DIOSSI.SeeDIOCOM
AC standard synchronous motor
6-6 Pressure controller 9-1
Incremental encoder 6-18 with Prescon 2 board 9-2
Motor feedback unit 6-11 Adjustment of the control loops (PRESCON2) 9-6
Drive module 8-1 I ndicatorsand setting elements 9-2
AMADAP 8-12 Plugs9-4
AMCOMM 8-18 with Prescon 3 board 9-8
Switches, plugsand light emitting diodes 8-19 Adjustment of the control loops(PRESCON3) 9-12
AMCONT 8-8 I ndicatorsand setting elements 9-8
Light emitting diodes, plugsand switches 8-10 Plugs9-10
Control unit 8-8 Pressure controller, adjust 11-10
AMFEED 8-16
Test monitors, switches and plugs8-17 E
Drive module AC 8-2 Electronicsrack 2-1
Power control unit 8-5 CNC rack 2-2
Power pack 8-4 RACK SUPPLY 2 2-4
Light emitting diodesand switches in drivemodule 8-20 CPU 2-8
Drive modules, adjust 11-6 CPU 386SX 2-8
CPU jumper 2-10
B CPU light emitting diodes 2-9
Back panel.See CNC rack CPU switches 2-10
Block diagrams 1-1 CUTCON2 2-14
Block diagram of KSBM97/98 1-8 DIOCOM 2-36
Block diagram of KSM97/98 1-7 Interface boardsfor DIOCOM 2-40
Block diagram of PBM98 1-12 IMPGEN 2-18
Block diagram of PSM-XYZF98 1-6 I mpgen switches 2-18
Block diagram of PSM97/98 (Stand Alone) 1-10 POSCAD 2-44
Block diagram of PSM97/98 Compa ct 1-11 POSCAD switches 2-44
Block diagram of VSM97/98 1-9 POSCON 2-22
10
ROM/RAM2 2-12 Outputs10-9
ROM/RAM2 jumpers 2-12 Parame
ters 10-14
SERCOM2 2-28 Technical Data 10-2
Adapter cardsfor SERCOM 2 2-32 Front view of UN IPOS 10-3
I R
I/O module SSI 4-12 ROM/RAM2 2-12
IMPGEN 2-18
Increme
ntal encoder 6-18 S
Stepping motor cards D900 3-4
J Stepping motor rack 3-1
Jumpers and switches on Panel PC 5-6 Page organization V-3
Ser232.See SERCOM2
L Ser422.SeeSERCOM2
Light emitting diodes and switches in drivemodule 8-20 SERCOM2 2-28
SERCUL.SeeSERCOM2
P SEROPT.
SeeSERCOM2
Panel PC 5-1 SSI module busS3 4-10
Bystronic interfacecards inPPC 5-6 Speed limit monitor SLIM 4-6
Jumpers and switches 5-6
Switch S1 I/O address 5-8 T
Overview of the interrupts and I/O addresses in the PPC
TERMIF
5-4 4-2
PARAN 4-4
Peripheralcards 4-1 V
I/O module SSI 4-12 Supply module 7-2
Li ght emitting diodes SSI 4-12 Power pack for supplymodule 7-3
Plugs in module SSI 4-14 Control unit 7-4
PARAN 4-4
SSI module bus S3 4-10
Speed limit monitor SLIM 4-6
TERMIF 4-2
Plugsin TERMIF 4-3
POSCAD 2-44
POSCON 2-22
Positioning module UN
IPOS 10-1
CAN command interface 10-10
I nput 10-10
Output 10-11
Inputs and outputs 10-4
Axis swi tch 10-5
Supply 10-5
Encode
r 10-6
Li st of i nputsand outputs10-4
Light emitting diodes and switches 10-12
D I P swi tch 10-13
Li ght emitting diodes 10-12
Parallel command interface 10-7
11
For your notes
12
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