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The NUM 1000 Family CNC - NUM Drive Maintenance Manual provides comprehensive information on the hardware and software components of the NUM 1000 CNC systems, including system overview, power supplies, processors, memory, and various input/output cards. It emphasizes that the programming examples are for guidance only and must be adapted for industrial applications. Additionally, the document includes a detailed table of contents and a record of revisions, indicating its creation date in July 1998.

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0% found this document useful (0 votes)

8 views

Num

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NUM 1000 FAMILY

CNC - NUM DRIVE

MAINTENANCE
MANUAL
0101938979/0

07-98 en-938979/0
Despite the care taken in the preparation of this document, NUM cannot guarantee the accuracy of the information it contains and cannot be held
responsible for any errors therein, nor for any damage which might result from the use or application of the document.

The physical, technical and functional characteristics of the hardware and software products and the services described in this document are subject
to modification and cannot under any circumstances be regarded as contractual.

The programming examples described in this manual are intended for guidance only. They must be specially adapted before they can be used in
programs with an industrial application, according to the automated system used and the safety levels required.

© Copyright NUM 1998.

All rights reserved. No part of this manual may be copied or reproduced in any form or by any means whatsoever, including photographic or magnetic
processes. The transcription on an electronic machine of all or part of the contents is forbidden.

© Copyright NUM 1998 software NUM 1000 family.

This software is the property of NUM. Each memorized copy of this software sold confers upon the purchaser a non-exclusive licence strictly limited
to the use of the said copy. No copy or other form of duplication of this product is authorized.

2 en-938979/0
Table of Contents

Table of Contents

Part 1: CNC
1 General 1-1
1.1 Main Rack 1-3
1.2 Differences Between Versions 1-5
1.3 Panels 1-9
1.4 Additional Components 1 - 11
2 System Overview 2-1
3 Power Supplies 3-1
3.1 Rack Power Supply 3-3
3.2 Panel Power Supply 3-6
3.3 Keyboard Power Supply 3-7
4 Processors 4-1
4.1 CNC Processor 4-3
4.2 Machine (PLC) Processor 4-7
4.3 Graphic Processor 4 - 14
4.4 UCSII Monoprocessor 4 - 18
4.5 PCNC Processor 4 - 23
4.6 1020/1040 Motherboard 4 - 39
5 Memory 5-1
5.1 Memory Card 5-3
6 Axis card 6-1
6.1 Encoder Feedback Theory 6-3
6.2 Analogue Axis Card 6-4
6.3 QVN Axis Card 6 - 11
7 Input/Output Cards 7-1
7.1 I/O Card Display and Troubleshooting 7-3
7.2 32-Input Card 7-5
7.3 32-Output Card 7-7
7.4 32-Input/24-Output Card (with Sub.D
connectors) 7 - 10
7.5 32-24 I/O Card (with high density
connectors) 7 - 14
7.6 64-48 I/O Card (with high density
connectors) 7 - 15
7.7 32-Input Interface Panel 7 - 16
7.8 24-Output Relay Panel 7 - 17
8 IT/Serial Line Card 8-1
9 Analogue Input/Output Card 9-1
10 Remote Input/Output Modules 10 - 1
10.1 Introduction 10 - 3
10.2 Diagnostics and Maintenance 10 - 5
10.3 Replacement 10 - 7

en-938979/0 3
11 Racks 11 - 1
11.1 Rack Addressing 11 - 3
11.2 EEPROM Chips 11 - 3
11.3 Temperature Sensor 11 - 3
11.4 Power Connections 11 - 4
11.5 Replacing a Rack 11 - 4
12 Machine Panel 12 - 1
12.1 Connections 12 - 3
12.2 Fibre-Optic Power Settings 12 - 5
12.3 Address Settings 12 - 5
12.4 Troubleshooting 12 - 6
12.5 Replacing a Machine Panel 12 - 6
13 Software 13 - 1
13.1 Selecting the CNC Serial Port 13 - 3
13.2 CNC Software Backup Methods 13 - 6
13.3 NUMCOM 13 - 8
13.4 Part Programme (Zone 0) Backup/Restore 13 - 9
13.5 Part Programme Backup/Restore in
Zone 1, 2 or 3 13 - 11
13.6 Tool Offset Backup/Restore 13 - 13
13.7 Parameter File Backup/Restore 13 - 14
13.8 PLC File Backup/Restore 13 - 16
13.9 Axis Calibration File Backup/Restore 13 - 18
14 PLC Diagnostics 14 - 1
14.1 Global Addresses CNC —> PLC 14 - 3
14.2 Global Addresses PLC —> CNC 14 - 9
14.3 CNC —> PLC Axis Group Addresses 14 - 18
14.4 PLC —> CNC Axis Group Addresses 14 - 22
14.5 Standard Internal Variables 14 - 24
14.6 Displaying the PLC Variables 14 - 25
14.7 Utility 7 - Ladder Programming 14 - 28
15 Machine Parameters 15 - 1
15.1 List of Parameters 15 - 3
15.2 Utility 5 - Machine Setup Data 15 - 6
15.3 Often Accessed Machine Parameters 15 - 8
16 PCNC 16 - 1
16.1 Using in the PC 16 - 3
16.2 OS/2 Window Session 16 - 8
16.3 Hard Drive Directory Structure 16 - 8
16.4 Making Utility Diskettes 16 - 9
16.5 Hard Drive Backup/Restore 16 - 9
16.6 OS/2 Text Editor 16 - 10
16.7 Mouse Enabling 16 - 10
16.8 Default System Files 16 - 11

4 en-938979/0
Table of Contents

17 Option Grid Settings 17 - 1

17.1 Viewing the Options 17 - 3
17.2 Setting the Options 17 - 6
18 Main Diagnostics 18 - 1
19 Initial Messages 19 - 1
20 Card Part Numbers 20 - 1
Appendix A - List of Errors A-1
A.1 Miscellaneous and Machine Errors A-3
A.2 Parametric Programming Errors A-5
A.3 Profile Geometry Programming (PGP)
Errors A-5
A.4 Miscellaneous errors A-6
A.5 Axis Overtravel Errors A-6
A.6 Structured Programming Errors A-7
A.7 Axis Faults A-7
A.8 Errors in Pocket Cycles A-8

Part 2: NUM DRIVE

21 Axis Motors 21 - 1
21.1 General 21 - 3
21.2 Characteristics and Performance 21 - 3
21.3 Sensors 21 - 9
21.4 Thermal Probes 21 - 11
21.5 Maintenance 21 - 11
21.6 Technical Characteristics of
Brushless Motors 21 - 12
21.7 Technical Characteristics of
BMS Motors 21 - 13
21.8 Technical Characteristics of
BMH Motors 21 - 15
22 Spindle Motors 22 - 1
22.1 General 22 - 3
22.2 Characteristics and Performance 22 - 3
22.3 Sensors 22 - 11
22.4 Thermal Probes 22 - 14
22.5 Maintenance 22 - 14
22.6 Electrical Characteristics of the
Spindle Motors Described in
the Catalogue 22 - 15
23 UAC Line 23 - 1
23.1 General 23 - 3
23.2 Rack 23 - 3
23.3 Power Connections 23 - 7

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24 PWS Power Supply Modules 24 - 1
24.1 Resistive Braking Power Supply Module 24 - 3
24.2 Regenerative Power Supply Module 24 - 10
25 UAC Servo-Drives 25 - 1
25.1 Technical Characteristics 25 - 3
25.2 Hardware Implementation 25 - 4
25.3 Maintenance - Alarms 25 - 14

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Record of Revisions

Record of Revisions

DOCUMENT REVISIONS

Date Revision Reason for Revision

07 - 98 0 Document creation

en-938979/0 7
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Part 1

CNC
General

1 General

1.1 Main Rack 1-3

1.2 Differences Between Versions 1-5 1
1.3 Panels 1-9
1.4 Additional Components 1 - 11

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1-2 en-938979/0
General

1.1 Main Rack

The main rack of NUM 1000 CNCs is available in two versions. 1

A yellow tag is affixed to each rack indicating the version and other very important information.

Identification Tag
This tag includes the following information (values given as illustration):
- Type : 1060M SI PCNC
- Affaire (Job number) : 12345600
- Ref. Client (User) : NUM SA
- Année (Year) : 1996

Serial/Part Number Tag

This tag includes the following information:
- No. de dossier (Part Number): 205202080
- No. de série (Serial Number): 70785

en-938979/0 1-3
Affaire Number
Whenever you need to contact NUM for service or parts information, you will be asked for the 8-digit Affaire Number,
used by NUM to keep track of all the systems sold throughout the world. All the pertinent information on 1060 systems
is available from Num.

Model Number Breakdown

1060M SI PCNC

Identifies any special versions:

PC: A PC compatible computer is used as MMI
Identifies the series: SI = Series I: 3 processors in rack
SII = Series II: 2 processors in rack
UCSII = Monoprocessor: 1 processor in rack
Identifies the version: M = Milling
T = Turning
G = Grinding
H = Gear hobbing
HG = Gear hobbing and grinding

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General

1.2 Differences Between Versions

The entire family of NUM 1000 CNCs is based on Motorola MC68020 microprocessors and associated chipsets. The 1
differences between series are a result of the number of processors in each series. The dialogue functionality (MMI)
is identical on all systems, which differ only by the hardware.
The main rack assembly is available in two sizes: 19" and 12". Series I generally uses a 19" rack and Series II and
UCSII a 12" rack, but this is not always the case. Always check the Affaire Number on the ID tag. The main components
are briefly described below. For more detailed information on the sizes and conditions of use, refer to Installation
Manuals 938816, 938938 and 938977.

Series I Systems
Series I systems include three processors:
- Graphic processor
- CNC processor
- Machine (PLC) processor.
The series I graphic processor can optionally be replaced by an Intel 486 PC processor.
Panel
Compact panel ∗

Graphic
processor or

Memory or

Optional keyboark
System Bus

CNC Serial link

processor

Speed reference
Axes Measurement
Origin switch

Special Inputs
Serial Bus

interfaces

Remote
Outputs inputs
Machine
processor
Serial bus/fibre
optic Remote
adapter outputs

Machine
Interrupts panel
Analogue inputs/outputs Machine
Serial link panel
extension (I/O)
∗ The use of the compact panel precludes the use of a machine panel.

en-938979/0 1-5
Series II Systems
Series II systems include two processors:
- CNC/graphic processor
- Machine (PLC) processor.
In a Series II system, all the processors are Motorola MC68020s.

Panel
Compact panel ∗

CNC/graphic
processor or

or
Memory
Optional keyboard
System Bus

Speed reference
Axes Measurement
Origin switch

Special Inputs
interfaces
Serial Bus

Outputs
Machine
processor

Serial bus/fibre
optic Machine
adapter panel

Machine
panel
extension (I/O)
Interrupts
Analogue inputs/outputs
Serial link

∗ The use of the compact panel precludes the use of a machine panel.

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General

UCSII Systems
Such systems general include only one processor unless the PCNC option is present. In a standard system, the single 1
processor performs all the functions:
- Graphic, CNC, PLC processor (Motorola MC68020).
Such systems can optionally be equipped with an Intel 486 PC card. The tasks are then divided as follows:
- Graphic/keyboard processor : Intel 486 PC
- CNC/machine (PLC) processor : Motorola MC68020

Panel
Compact panel ∗

Graphic
function or

U Memory Optional keyboard

C
S CNC
function RS 232 serial interface
II
PLC Interrupt
function
System Bus

Analogue inputs/outputs

Serial
Serial Bus

bus/fibre Machine
optic adapter panel

Machine
Inputs panel
extension (I/O)

Outputs

Speed reference
Axes Measurement
Origin switch

Dedicated
interfaces

∗ The use of the compact panel precludes the use of a machine panel.

en-938979/0 1-7
1020/1040 Systems
The architecture of 1020/1040 systems is comparable to that of UCSII systems. The integrated PC functionality is not
available on such systems. Unlike earlier 1020/1040 systems, they have a monolithic, not a modular, architecture.

Panel

Graphic
function
or

Memory

RS 232E serial interface

Communication
function
RS 232E / RS 422A / RS 485 serial interface

Speed reference
Axes Measurement
Origin switch

PLC
CNC
function
CPU

Memory

Status RAM User logic

I/O register Ladder logic networks
Discrete I/O and segments

I/O processor

Communication
function Modbus Plus Communication processor
(PCMCIA card)

1-8 en-938979/0
General

1.3 Panels
The panel includes a standard VGA CRT connected to the rear of the keyboard by a cable with a conventional Sub.D 1
connector which is fully VGA compatible. The following panels are available for the 1000 family of CNCs:

9" Monochrome (grey scale) or 10" Colour Panel

These two panels are the same size (483 x 220 mm) and are completely
interchangeable. They have a 50-key keyboard providing all the controls
necessary to control the machine.

14" Colour Panel

This panel is functionally completely interchangeable with the 9" or 10"
panel, but it is physically larger (483 x 399 mm). It has a complete
QWERTY keyboard. Most of the new 14" panels include an ALT key for
compatibility with PCNC systems. CAUTION: Panels which do not have
an ALT key cannot be used with PCNCs.

Compact Panel
The compact panel has a 483 x 220 mm 9" monochrome or 10" colour
CRT with, in addition to the CNC keys, programmable keys for control of
the machine. A PC type keyboard can be connected for settings or
maintenance.

en-938979/0 1-9
PC Panel
The PC panel is an industrial PC measuring 320 x 200 x 200 mm running DOS/Windows. It is connected to 1020/1040
systems via a conventional serial port or a high speed link requiring a special ISA card plus a PCMCIA card on the
1020/1040 system. The CNC is controlled via a special MMI application.

320 mm 8 holes diameter 4.5

10
5.5

15 minimum

5.5

9 9

320 mm

200 mm

Multiplexer Module
This module is not a panel as such, but is closely related to it. It is mounted
at the rear of a panel or externally and is used to connect and gate two
to four panels to a CNC or a panel to two to four CNCs.

1 - 10 en-938979/0
General

1.4 Additional Components

Machine Panel
1
The machine panel is connectable via a fibre-optic ring. It includes the
main machine control keys, programmable keys and handwheel, feed
rate and spindle speed override and mode locking functionalities plus an
emergency switch.

Extension Rack (NUM I/O)

This rack is actually a small (125 x 140 mm) input/output panel which is
connected to the fibre-optic ring. It can be installed on 1060 and
1040 CNCs and is available in three versions:
- 16 inputs at 24 VDC
- 16 inputs at 24 VDC, 16 outputs at 24 VDC, 0.5 A
- 8 inputs at 24 VDC, 8 relay outputs at 2 A.

Additional Racks

The extension racks are connected to the fibre-optic ring and can be fitted
with input/output cards. They can only be used with 1060 Series I type
CNCS. Two versions are available:
- Rack for a maximum of 2 cards (142 x 266 mm)
- Rack for a maximum of 12 cards (483 x 310.4 mm).
The maximum number of extension racks is limited to six per main rack.
Each extension rack has its own power supply which is also used for the
fibre-optic link.

en-938979/0 1 - 11
32-Input Interface Panel with Cable

24-Output Relay Panel with Cable

1 - 12 en-938979/0
System Overview

2 System Overview

The NUM 1060 CNC is of a modular design with a multislot main rack. The system consists of cards plugged into the
rack, each of which performs a specific function (see below for detailed operation of the cards). The 1020/1040 CNCs
are of a monolithic design with a motherboard into which are plugged daughterboards or optional cards (graphic, axis,
memory). This section gives a general functional description to allow a better understanding of the role of each card.
The CNCs of the 1000 family make extensive use of RAM memory. Roughly 90% of all the data are stored in battery
backed RAM memory. The remaining 10% are stored in EEPROM memory which is more permanent. The table below
2
lists the types of data, type of memory and location.
Data Storage type Location
Part programmes RAM Memory card
Tool offsets RAM Memory card
External parameters RAM Memory card
User-defined macros RAM Memory card
PLC Ladder programmes RAM Memory card
PLC assembler programmes RAM Memory card
PLC C programmes RAM Memory card
PLC stored variables RAM Memory card
Axis calibration RAM Memory card
Machine parameters EEPROM Rack backplane
CNC customisation EEPROM Rack backplane
Executive software EPROM Memory card – daughterboard
Bootstrap BIOS EPROM On each processor card

Power up Sequence (PCNC Only)

When power is first applied to the system, the PC must boot up just like any other PC. The PC has an on-board hard
drive which stores the OS/2 operating system and some special programmes to interface to the CNC through the
system bus. First OS/2 boots, then it loads the interface programmes. Once these programmes are running, the
normal 1060 boot sequence is started.
Each CNC processor starts independently from the others. They each perform the boot-up routines defined by the
on-board BIOS chips. Once each processor is running, it requests the CPU to load its private operating system into
its local RAM. Between 1 and 4 MB of RAM are allocated to the operating system of each processor.
Once all the cards have loaded their operating system, the CPU enables start-up of each processor in turn. Finally,
when all the processors are running, the system finishes its boot-up sequence and the CNC is ready to run.

Power up Sequence (Conventional Version)

When power is applied to the system, each processor is started independently of the others. They each perform the
boot-up routines defined by the on-board BIOS chips. Once each processor is running, it requests the CPU to load
its private operating system into its local RAM. Between 1 and 4 MB of RAM are allocated to the operating system
of each processor.
Once all the cards have loaded their operating system, the CPU enables start-up of each processor in turn. Finally,
when all the processors are running, the system finishes its boot-up sequence and the CNC is ready to run.

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Power Supplies

3 Power Supplies

3.1 Rack Power Supply 3-3

3.1.1 Voltage Level Indicators 3-4
3.1.2 PWR FAIL LED 3-4
3.1.3 RaZ (Reset) Button 3-4
3.1.4 Fibre-Optic Ports 3-5
3.2 Panel Power Supply 3-6
3.3 Keyboard Power Supply 3-7
3

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3-2 en-938979/0
Power Supplies

3.1 Rack Power Supply

The rack is powered by 220 VAC, 50/60 Hz. The power consumption depends on the number and types of cards in
the rack. Theoretically, it is equal to the sum of the power consumptions of each card. The total consumption is used
to calculate the required fuse ratings. For further information on this subject, refer to the Installation and
Commissioning Manual 938816.
The power cable is connected to the receptacle located in the upper left-hand corner of the rack. There is a small fuse
in the receptacle. If this fuse blows, the optional fans located in the top of the rack are stopped. If the fans are operating,
the input voltage is probably normal, but it should nevertheless be checked. Use a small screwdriver to remove the
fuse-holder from the receptacle.
3
1

Minimum fibre-optic
cable curve
radius: 50 mm

Tx
Rx
Tx Rx

4 3
1- Power cable
2- Receiver of following unit
3- Fibre-optic cable
4- Transmitter of previous unit

The power supply is available in two versions: 60 W and 130 W. The table below shows the main differences.

Power supply 60 W 130 W

Power consumption 90 W maximum 175 W maximum
+5V 10 A 25 A
+ 15 V 250 mA 500 mA
- 15 V 250 mA 500 mA
+ 24 V (bus) N/A 2A
+ 24 V (external) N/A 2A

en-938979/0 3-3
3.1.1 Voltage Level Indicators

The power supply card (see opposite) includes six LEDs, one for each
output (voltage engraved on the LED) plus one PWR FAIL LED.
The voltage level LEDs are normally lit. If one or more LED is unlit, this
could indicate a fault in the output or an excessive power draw by one of
the other cards.
To correctly diagnose a problem, first power down the system. Then
remove all the cards from the rack except the power supply card. Power
up the system and check the voltage level LEDs. If they are all lit, the fault
is probably on another card. However, if one of the LEDs remains unlit,
the fault is in the power supply, which must be replaced (see below for the
fibre-optic port switch settings).

3.1.2 PWR FAIL LED

This LED is lit in case of a fault in the input voltage. It remains lit until the
internal capacitors fall to 0 V.

3.1.3 RaZ (Reset) Button

! CAUTION
Pressing this button causes an emergency stop, leading
to complete rebooting of the system. It has the same
effect as turning the system off and back on.
+24VI +24VE

+15V -15V

+5V Pw Fail

Em
RaZ

F/O

24 VE
0 VE
Rec

Alim

3-4 en-938979/0
Power Supplies

3.1.4 Fibre-Optic Ports

Some versions of the power supply include two fibre-optic ports on the front, used to communicate with other racks,
remote input/output units or a machine panel. One port is the emitter port and the other is the receiver port.

Power supply card

3 2 1

The diagram shows the location of the switches used to set the power on the fibre-optic ports. The settings are shown
in the table below. They depend on the length of the fibre-optic cable. The wrong settings could lead to communication
errors between the PLC and its inputs/outputs.

Fibre-optic cable length Switch 3 Switch 2 Switch 1

L ≤ 15 m ON ON OFF
15 m ≤ 30 m ON OFF ON
L > 30 m OFF ON ON

en-938979/0 3-5
3.2 Panel Power Supply
The panel includes two separate parts, the CRT and the keyboard. The CRT has a built-in power supply connected
to the 220 VAC, 50/60 Hz mains by a cable which plugs into the side.

2
1 - Panel
2 - Trim pane
3 - Panel attaching screw and washer (4)

The CRT includes a few fuses, but they are located inside the CRT housing.

! CAUTION
It is not recommended to open the housing because of the very high voltage levels inside.

No Video – CRT Test

1. Power down the machine.
2. Unplug the video cable from the rear of the CRT.
3. Connect a standard PC VGA monitor to this connector.
4. Power up the system and check for video on the PC monitor.
5. If there is still no video, the CRT is probably not the cause of the trouble which should be investigated elsewhere.
If there is now video, replace the CRT.

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Power Supplies

3.3 Keyboard Power Supply

The keyboard power is supplied by the graphic card. The panel is connected to the main rack by a single cable
equipped at both ends with a 37-contact Sub.D connector. This cable is used for power supply, video and keyboard
signal transfers between the panel and the graphic card.

Keyboard Troubleshooting
1. If the keys on the keyboard are not functioning, power down the system.
2. Unplug the video cable from the graphic processor and the rear of the keyboard.
3. Test the continuity of each conductor in the cable, referring to the wiring diagram below and using an ohmmeter.
3
Also make sure there are no connections between any conductor and the connector casings.
4. If a short to the casing or a cut wire is detected, remove the two connectors and correct the problem.
5. If the cable test is OK, replace the keyboard.
6. If both the cable and keyboard are OK, then replace the graphic card, referring to the corresponding section (this
replacement is rather complicated).

Cable for standard graphic card (Motorola MC68020)

Red (white wire) Red Red (white wire)

7 7
Red earth Red earth
(black wire) 8 8 (black wire)
Green (white wire) Green Green (white wire)
27 27
Green earth Green earth
(black wire) 28 28 (black wire)
Blue
Blue (white wire) 10 10 Blue (white wire)
Blue earth Blue earth
(black wire) 11 11 (black wire)
H sync (white wire) White H sync (white wire)
30 30
H sync earth H sync earth
(black wire) 31 31 (black wire)
V syn (white wire) Black V syn (white wire)
13 13
V sync earth V sync earth
(black wire) 14 14 (black wire)
Blue (0.6)
Vcc 1 1 Vcc
Red (0.6)
Vcc 2 2 Vcc
White (0.6)
GND 20 20 GND
Black (0.6)
GND 21 21 GND
Red (0.22) Red (0.22)
TRANS 1 19 37 RECEP 1
White (0.22) White (0.22)
TRANS 2 18 36 RECEP 2
Black (0.22) Black (0.22)
RECEP 1 37 19 TRANS 1

36 Blue (0.22) Blue (0.22) 18

RECEP 2 TRANS 2

PROTECTIVE CONNEC- CONNEC- PROTECTIVE

EARTH TOR TOR EARTH
SHELL SHELL

en-938979/0 3-7
Cable for PCNC card (Intel 486)

Red
Red (white wire) Red (white wire)
7 7
RGround (black wire) RGround (black wire)
8 Green 8
Green (white wire) Green (white wire)
27 27
GGround (black wire) GGround (black wire)
28 Blue 28
Blue (white wire) Blue (white wire)
10 10
BGround (black wire) BGround (black wire)
11 White 11
HSync (white wire) HSync (white wire)
30 30
HSGround (black wiire) HSGround (black wire)
31 Black 31
VSync (white wire) VSync (white wire)
13 13
VSGround (black wire) VSGround (black wire)
14 Blue (0.6) 14
VDC VDC
1 Red (0.6) 1
VDC VDC
2 White (0.6) 2
GND GND
20 Black (0.6) 20
GND GND
21 21
Red (0.22) Red (0.22)
DATA DATA
17 White (0.22) White (0.22) 17
GND GND
Blue (0.22) Blue (0.22)
22 22
Black (0.22) Black (0.22)
CLOCK CLOCK
35 35

PROTECTIVE CON- CON- PROTECTIVE

EARTH NECTOR NECTOR EARTH
SHELL SHELL

3-8 en-938979/0
Processors

4 Processors

4.1 CNC Processor 4-3

4.1.1 Version Identification 4-3
4.1.2 LEDs 4-4
4.1.3 Ports 4-4
4.1.4 Card Location 4-5
4.1.5 Replacing the Card 4-6
4.2 Machine (PLC) Processor 4-7
4.2.1 Version Identification 4-7
4.2.2 LEDs 4-8
4.2.3 Ports 4-8
4.2.4 Card Location 4 - 11
4.2.5 Replacing the Card 4 - 13
4
4.3 Graphic Processor 4 - 14
4.3.1 Version Identification 4 - 14
4.3.2 LEDs 4 - 15
4.3.3 Daughterboards 4 - 15
4.3.4 Ports 4 - 16
4.3.5 Card Location 4 - 17
4.3.6 Replacing the Card 4 - 17
4.4 UCSII Monoprocessor 4 - 18
4.4.1 Version Identification 4 - 18
4.4.2 LEDs 4 - 19
4.4.3 Ports 4 - 19
4.4.4 Card Location 4 - 21
4.4.5 Replacing the Card 4 - 22
4.5 PCNC Processor 4 - 23
4.5.1 Version Identification 4 - 23
4.5.2 LEDs 4 - 24
4.5.3 Ports 4 - 24
4.5.4 Card Location 4 - 27
4.5.5 Pre-replacement Diagnostics 4 - 28
4.5.6 Replacing the Card Alone 4 - 29
4.5.7 Card and Hard Drive Replacement
Procedure 4 - 29
4.5.8 CMOS RAM Configuration Access 4 - 30
4.5.9 Replacing the Battery 4 - 32
4.5.10 Adding or Removing a DRAM Memory
Module 4 - 33
4.5.11 Diskette Drive 4 - 35
4.6 1020/1040 Motherboard 4 - 39
4.6.1 Version Identification 4 - 39
4.6.2 LEDs 4 - 40
4.6.3 Ports 4 - 40
4.6.4 Characteristics 4 - 43
4.6.5 Replacing the Card 4 - 44
4.6.6 Replacing the Battery 4 - 45
4.6.7 Adding an SRAM Module 4 - 46

en-938979/0 4-1
4-2 en-938979/0
Processors

Depending on the type, the system is equipped with one or more processors. Chapter 1 explains how to determine
the number of processors in a given system.
This section contains a detailed description of the cards, their functions, connectors, and diagnostic aids. It also
explains how to replace the processors if necessary.

4.1 CNC Processor

CNC processors exist only on 1060 Series I CNCs. The main functions of this processor are to compute
the machining paths and speeds, manage the part programmes and control the axes. This card can
communicate with all axis cards, other processor cards and the memory card via the system bus.
Halt The on-board processor is a Motorola MC68020. There is one BIOS EEPROM used for booting the
Def system. This BIOS chip may have to be kept if the card is replaced. The BIOS chips are generally the 4
same for all the processors in the system, but there are some exceptions. When replacing the card, make
sure that the BIOS chip on the new card does not have a lower index than the one on the card replaced.

4.1.1 Version Identification

There are many different versions of the CNC processor cards. The part number changes in case of major
modifications, such as the amount of available memory, but not for minor ones to a circuit, which may
change only the version letter.
The main differences between cards generally concern the amount of memory. In case of doubt, check
with the local NUM distributor that the card version is correct.
New cards are equipped with a small metal tag soldered near the top edge of the card. On this metal tag
is a white paper sticker giving the serial number and part number of the card. On older cards, the sticker
may be located on the card itself or on the edge connector at the rear of the card. Ignore the number
engraved on the card, which is not a part number!
D The sticker has numbers of the following types:
N
C
- 201775/C : Part number/version
- 12345/002 : Serial number/lot
As a general rule, a spare card can be used if it has exactly the same part number as the original card
and an equal or higher version letter.

P CNC processor card types

E
R 204201775 1 MB CNC processor card
I
P
H
204202771 4 MB CNC processor card
204203288 Referee CNC processor card
204203484 V2 CNC processor card

Proc CN

en-938979/0 4-3
! CAUTION
Never replace a card by a card with a different part number or a lower version
letter without first consulting NUM Technical Support.

4.1.2 LEDs
The front plate of this card includes two red LEDs, marked DEF and HALT. Under normal operating conditions, neither
LED is lit, except during start-up, when they may come on briefly.

HALT LED
If the HALT LED is lit steady, the processor has stopped generally due to a fault on the card. However, this is not an
absolute rule, and in some rare cases, the fault may be due to an outside cause.
Replace the card and reboot the system. If the system hangs on reboot or stops later with the same fault, reinstall the
original card, which was not the cause of the failure, and look elsewhere for the cause.

4.1.3 Ports
There are two communication ports available on the front plate.

DNC Port (9 contacts)

This port is a TTL interface which can be assigned to different functions by the OEM by software settings. More details
are given in the chapter on communications. A special adapter is available from NUM to configure this port differently,
for instance as an RS232 or RS485 port.

Adapter Part Number

TTL —> RS232 205201338
TTL —> RS485 205201339

4-4 en-938979/0
Processors

PERIPH Port (25 contacts)

This port is an RS232 interface which can be assigned to different functions by the OEM by software settings. More
details are given in the chapter on communications.

Pin Signal
2 TD - Transmitted data
3 RD - Received data
4 RTS - Ready to send
5 CTS - Clear to send
7 GND - Signal earth
8 DCD - Data carrier detection 4
20 DTR - Data terminal ready
25 + 12 V
Connector Protective earth
shell

4.1.4 Card Location

The actual slot where a given card is located depends on the system. The location of the cards in a 1060 SI system
is illustrated below.
Machine processor card
Graphic processor card

Inputs/outputs cards
CNC processor card

Power supply card

Memory card
Axis card
Axis card

Figure 1: 1060 Series I in a 19" rack

en-938979/0 4-5
The location of the cards in a 1060 SI PCNC system is illustrated below:

Slots for CNC cards

14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

To left of last
PC module

CNC card
PCMCIA

Machine processor

CNC processor

Power supply
Memory card

12 11 10 9 8 7 6 5

Slots for input/output cards

Figure 2: 1060 Series I PCNC in a 19" rack

4.1.5 Replacing the Card

Before beginning, make sure a replacement card is available.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
5. Make note of the direction of the notch on the BIOS chip.
6. If necessary, remove the BIOS EPROM from the original card with an IC removing tool.
7. If necessary, insert the original BIOS chip onto the socket on the replacement card, being very careful not to bends
the leads on the chip and to insert it in the right direction.
8. Install the card in the rack and moderately tighten the attaching screws.
9. Reinstall all the connections removed above.
10. Power up the machine, then the CNC.

4-6 en-938979/0
Processors

4.2 Machine (PLC) Processor

Machine processors are found on 1060 Series I and Series II systems. The main functions of this
processor are to process the PLC programmes and control the discrete inputs and outputs. This card
can communicate with all the other processor cards, the power supply (for the serial fibre-optic link) and
the memory card via the system bus.
Halt
Def
The on-board processor is a Motorola MC68020. There is one BIOS EEPROM used for booting the
system. This BIOS chip may have to be kept if the card is replaced. The BIOS chips are generally the
same for all the processors in the system, but there are some exceptions. When replacing the card, make
I sure that the BIOS chip on the new card does not have a lower index than the one on the card replaced.
T
.
E 4.2.1 Version Identification
X
T
There are many different versions of processor cards. The part number changes in case of major
4
modifications, such as the amount of available memory, but not for minor ones to a circuit, which may
change only the version letter.
C
A
N
The main differences between cards generally concern the amount of memory. In case of doubt, check
/ with the local NUM distributor that the card version is correct.
C
N New cards are equipped with a small metal tag soldered near the top edge of the card. On this metal tag
A
is a white paper sticker giving the serial number and part number of the card. On older cards, the sticker
RS 232
422/485 may be located on the card itself or on the edge connector at the rear of the card. Ignore the number
S
engraved on the card, which is not a part number!
E
R The sticker has numbers of the following types:
I
E - 203035/C : Part number/version
- 12345/002 : Serial number/lot
RS 232

As a general rule, a spare card can be used if it has exactly the same part number as the original card
and an equal or higher version letter.
S
E Machine processor card types
R
I 204201935 1 MB machine processor card
E
204203035 4 MB machine processor card
204203123 4 MB machine processor card

Proc Mach

! CAUTION
Never replace a card by a card with a different part number or a lower version letter without
first consulting NUM Technical Support.

en-938979/0 4-7
4.2.2 LEDs
The front plate of this card includes two red LEDs, marked DEF and HALT. Under normal operating conditions, neither
LED is lit, except during start-up, when they may come on briefly.

HALT LED
If the HALT LED is lit steady, the processor has stopped generally due to a fault on the card. However, the fault is not
necessarily on the card.
Replace the card and reboot the system. If the system hangs on reboot or stops later with the same fault, reinstall the
original card, which was not the cause of the failure, and look elsewhere for the cause.

4.2.3 Ports
There are four ports available on the front plate, two dedicated to I/O and two to communications.

IT/EXT Port
This port has 15 contacts. It allows connection of discrete I/O devices such as sensors requiring the use of fast
interrupts. The port has four fast interrupts which can be connected. It can be configured for 5 VDC or 24 VDC logic
levels by wiring of the contacts.

INPUT 0 : 5 V 1
INPUT 0 : 24 V 2
24 V 5V
COMMON 0 9

Protective earth
INPUT 1 : 5 V 10
INPUT 1 : 24 V 11
24 V 5V
COMMON 1 3
Protective earth
INPUT 2 : 5 V 4
INPUT 2 : 24 V 5
24 V 5V
COMMON 2 12

Protective earth
INPUT 3 : 5 V 13
INPUT 3 : 24 V 14
24 V 5V
COMMON 3 6

Protective earth
PROTECTIVE CONNEC-
TOR
EARTH SHELL

4-8 en-938979/0
Processors

CAN/CNA (ADC/DAC) Port

This port has 15 contacts. It allows connection of analogue I/O devices and a timer I/O (only on versions 204201935
and 204203035). For example, in configurations which do not include the NUM machine panel in a fibre-optic ring,
the feed rate and spindle speed override potentiometers are wired to this connector as analogue signals.

I/O Number and type Voltage level

Analogue inputs Four non-differential 8-bit inputs 0-10 V
Analogue outputs Two 12-bit outputs +10 V
External reference output One +10 V @ 100 mA
Timer One input, one output
4
Load
TIMER OUTPUT 2
- +
TIMER OUTPUT COMMON 9
24 V
TIMER POWER SUPPLY 10
INPUT ANA. 2 7
INPUT ANA. 0 8
ANA. GND 12
13
For wiring analogue inputs
EXTERNAL REF. OUTPUT
INPUT ANA. 3 14 Screening not compulsory
INPUT ANA. 1 15
OUTPUT ANA. 1 4 2 kΩ min.

ANA. GND 6
2 kΩ min.
OUTPUT ANA. 0 5

TIMER INPUT - +
COMMON 3
24 V
TIMER INPUT 11

PROTECTIVE CONNEC-
TOR
EARTH Protective earth
SHELL

Figure 3: Processor 204203035 with timer input/output

Blue Feed rate

INPUT ANA. X potentiometer
Red
1 kΩ
ANA. GND White
EXTERNAL REF.
OUTPUT White
Red
1 kΩ
INPUT ANA. Y Blue Spindle
potentiometer
PROTECTIVE CONNEC-
EARTH TOR
SHELL Screening not compulsory Protective earth

Figure 4: Typical analogue input wiring for feed rate and spindle speed override potentiometers

en-938979/0 4-9
There are at least two different pin configurations for this port. The pinouts are shown in the tables below.

PROCESSOR 204203035 PROCESSOR 204203123

Signal Pin Signal Pin
Timer output 2 Not connected 2
Timer output common 9 Not connected 9
Timer power supply 10 Not connected 10
Analogue input 2 7 Analogue input 2 7
Analogue input 0 8 Analogue input 0 8
Analogue earth 12 Analogue earth 12
External reference output 13 External reference output 13
Analogue input 3 14 Analogue input 3 14
Analogue input 1 15 Analogue input 1 15
Analogue earth 6 Analogue earth 6
Analogue output 1 5 Analogue input 1 5
Time input common 3 Not connected 3
Timer input 11 Not connected 11
Not connected 1 Not connected 1

SERIE Port (9 contacts)

There are two versions of this port, determined by the card part number. Older models provided only a TTL interface,
whilst newer ones also support RS232 E, RS422 A and RS485 interfaces. The choice is made by wiring of the
connector.

PROCESSOR 204203035 PROCESSOR 204203123

Signal Pin Signal Pin
TD TTL 2 TD 2
RD TTL 4 RD 3
RTS TTL 3 RTS 7
CTS TTL 6 CTS 8
DTR TTL 8 0V 5
DCD TTL 7 T (A)+ 9
DSR TTL 9 T(B)- 4
0V 5 R(A)+ 6
5V 1 R(B)- 1
There are two adapters available for the TTL compatible port, listed in the table below.

Adapter Part Number

TTL —> RS232 205201338
TTL —> RS485 205201339

4 - 10 en-938979/0
Processors

RS232 Port (25 contacts)

This port is an RS232 interface which can be assigned to different functions by the OEM by software settings. More
details are given in the chapter on communications.

4.2.4 Card Location

The actual slot where a given card is located depends on the system. The location of the cards in a 1060 SI system
is illustrated below. Machine processor card
Graphic processor card

Inputs/outputs cards
CNC processor card

Power supply card

Memory card
Axis card
Axis card

Figure 5: 1060 Series I in a 19" rack

en-938979/0 4 - 11
The location of the cards in a 1060 SII system is illustrated below.

Machine processor card

Graphic processor card
Inputs/outputs cards

CNC processor card

Power supply card

Memory card
Axis card
Axis card

Figure 6: 1060 Series II in a 19" rack

The location of the cards in a 1060 SI PCNC system is illustrated below:

Machine processor
CNC processor

Power supply
Memory card
PC module

Axis card
Axis card
PCMCIA

Input/output cards

Figure 7: 1060 Series I PCNC in a 19" rack

4 - 12 en-938979/0
Processors

4.2.5 Replacing the Card

en-938979/0 4 - 13
4.3 Graphic Processor
Graphic processors are found on 1060 Series I and Series II systems. The main functions depend on
the system where it is installed. In a Series II CNC, it computes the machining paths and speeds,
manages the part programmes and controls the axes. It also controls the keyboard and display, which
is all it does in a 1060 Series I system. It can communicate with all the axis cards, the other processor
Halt
Def
cards and the memory card via the system bus.
The on-board processor is a Motorola MC68020. There is one BIOS EEPROM used for booting the
system. This BIOS chip may have to be kept if the card is replaced. The BIOS chips are generally the
same for all the processors in the system, but there are some exceptions. When replacing the card, make
sure that the BIOS chip on the new card does not have a lower index than the one on the card replaced.

4.3.1 Version Identification

There are many different versions of graphic processor cards. The part number changes in case of major
modifications, such as the amount of available memory, but not for minor ones to a circuit, which may
change only the version letter.
The main differences between cards generally concern the amount of memory. In case of doubt, check
with the local NUM distributor that the card version is correct.
New cards are equipped with a small metal tag soldered near the top edge of the card. On this metal tag
is a white paper sticker giving the serial number and part number of the card. On older cards, the sticker
may be located on the card itself or on the edge connector at the rear of the card. Ignore the number
engraved on the card, which is not a part number!
The sticker has numbers of the following types:
- 203778/C : Part number/version
L
I - 12345/002 : Serial number/lot
A
I
S As a general rule, a spare card can be used if it has exactly the same part number as the original card
O
N
and an equal or higher version letter.
P
U Graphic processor card types
P
I
T 204202374 1 MB V2 graphic processor card
R
E
204202778 4 MB V2 graphic processor card
204203485 4 MB V3 graphic processor card

Proc Graph

! CAUTION
Never replace a card by a card with a different part number or a lower version letter without
first consulting NUM Technical Support.

4 - 14 en-938979/0
Processors

4.3.2 LEDs
The front plate of this card includes two red LEDs, marked DEF and HALT. Under normal operating conditions, neither
LED is lit, except during start-up, when they may come on briefly.

DEF LED
If the DEF LED is lit steady, the processor card is no longer operating. It may be a hardware or a software failure, but
the most frequent cause is a problem with the software or memory. It is then necessary to reboot the system.
Note: On the V3 graphic processor card (204203485), the Halt LED may flash at a very high rate and appear to be
lit dimly. This does not indicate a fault, but corresponds to normal microprocessor operating modes.

HALT LED
4
If the HALT LED is lit steady, the processor has stopped generally due to a fault on the card. However, the fault is not
necessarily on the card.
Replace the card and reboot the system. Do not forget to recover the BIOS EPROM from the original card. If the system
hangs on reboot or stops later with the same fault, reinstall the original card, which was not the cause of the failure,
and look elsewhere for the cause.

4.3.3 Daughterboards
Card 204203485 has two daughterboards which must not be moved. They are
- One 4 MB DRAM memory module
- One display control card (204202888).
These cards are almost always installed. If it should prove necessary to recover one of these cards on the card to be
replaced, take all due precautions against electrostatic discharge and be careful to install the daughterboards gently
on the new motherboard without forcing.

en-938979/0 4 - 15
4.3.4 Ports
There is one port available on the front plate of this card.

LIAISON PUPITRE Port (37 contacts)

This is the connector to the panel. All the video signals to the CRT are sent out through this port and all the keyboard
signals are input through it. This port is the only link between the panel and main rack.

Red (white wire) Red Red (white wire)

36 Blue (0.22) Blue (0.22) 18

RECEP 2 TRANS 2

PROTECTIVE CONNEC- CONNEC- PROTECTIVE

EARTH TOR TOR EARTH
SHELL SHELL

4 - 16 en-938979/0
Processors

4.3.5 Card Location

When this card is present, it is always located in slot 0.

Machine processor card

Graphic processor card
Inputs/outputs cards

CNC processor card

Power supply card

Memory card
Axis card
Axis card
4

Figure 8: 1060 Series I in a 19" rack

4.3.6 Replacing the Card

en-938979/0 4 - 17
4.4 UCSII Monoprocessor
In the monoprocessor version of the 1060 CNC, the processor card is always located immediately
to the left of the power supply. This Motorola MC68020 monoprocessor performs the CNC, PLC
and graphic functions. When this processor is present, the system does not have a memory card.
Halt
The executive firmware then resides on a daughterboard which plugs into this card. The memory
Def
includes several SRAM modules mounted in SIMM style instead of soldered RAM chips. The
graphic function is performed by a daughterboard. This module also includes a battery to back up
C the memory in case of a power failure.
O
M
M 4.4.1 Version Identification
1
There are many different versions of UCSII processor cards. The part number changes in case
of major modifications, such as the amount of available memory, but not for minor ones to a circuit,
which may change only the version letter.
C The main differences between cards generally concern the amount of memory. In case of doubt,
O check with the local NUM distributor that the card version is correct.
M
M New cards are equipped with a small metal tag soldered near the top edge of the card. On this
2
metal tag is a white paper sticker giving the serial number and part number of the card. On older
cards, the sticker may be located on the card itself or on the edge connector at the rear of the card.
Ignore the number engraved on the card, which is not a part number!
A
N The sticker has numbers of the following types:
E
/
A - 202886/C : Part number/version
L
S
O
- 12345/002 : Serial number/lot
G
UCSII processor card types (complete modules)
L
I
- 206202886 (128K/4MB module)
A - 206203542 (512K/4MB module)
I
S Daughterboards which can be installed
O - 204203329 EPROM daughterboard
N
- 204202888 GSP daughterboard (graphic control)
P - 204202897 1MB DRAM memory card
U - 204202892 4 MB DRAM memory card
P
I
- 204202898 128 KB SRAM memory card
T - 204202894 512 KB SRAM memory card
R - 204203390 2 MB SRAM memory card.
E
As a general rule, a spare card can be used if it has exactly the same part number as the original
card and an equal or higher version letter.
UC SII

! CAUTION
Never replace a card by a card with a different part number or a lower version letter without
first consulting NUM Technical Support.

4 - 18 en-938979/0
Processors

4.4.2 LEDs
The front plate of this card includes two red LEDs, marked DEF and HALT. Under normal operating conditions, neither
LED is lit, except during start-up, when they may come on briefly.

HALT LED
If the HALT LED is lit steady, the processor has stopped generally due to a fault on the card. However, the fault is not
necessarily on the card.
4
Replace the card and reboot the system. If the system hangs on reboot or stops later with the same fault, reinstall the
original card, which was not the cause of the failure, and look elsewhere for the cause.

4.4.3 Ports
There are two communication ports, one analogue I/O port and one panel interface port, on the front plate of the card.

COMM1 Port (9 contacts)

This port is an RS232 interface which can be assigned to different functions by the OEM by software settings. More
details are given in the chapter on communications.

Pin Signal
1 DCD - Data carrier detection
2 RD - Received data
3 TD - Transmitted data
4 DTR - Data terminal ready
5 GND - Signal earth
6 DSR - Data set ready
7 RTS - Ready to send
8 CTS - Clear to send
9 Not connected
Connector Protective earth
shell

en-938979/0 4 - 19
COMM2 Port (25 contacts)
This port is an RS232 interface which can be assigned to different functions by the OEM by software settings. More
details are given in the chapter on communications.

Pin Signal
2 TD - Transmitted data
3 RD - Received data
4 RTS - Ready to send
5 CTS - Clear to send
6 DSR - Data set ready
7 GND - Signal earth
8 DCD - Data carrier detection
20 DTR - Data terminal ready
Connector Protective earth
shell

E/S ANALOG (Analogue I/O) Port

This port has two analogue inputs, one analogue output and one fast interrupt input. The wiring diagram is given below.

INPUT ANA. BR 3
AGND 7 For wiring of analogue inputs
VCC 5 V 8
INPUT ANA. AV 4
IT 5 V 6
or
IT 24 V 1 IT Signal
COM IT 2 IT Common

Screen not compulsory CONNEC-

TOR
PROTECTIVE
SHELL
EARTH

S-A 5 Analogue output

AGND 9 Analogue common

CONNEC- CONNEC-
PROTECTIVE TOR PROTECTIVE
TOR
EARTH SHELL SHELL
EARTH

4 - 20 en-938979/0
Processors

LIAISON PUPITRE Port (37 contacts)

This is the connector to the panel. The wiring diagram is given below.

Red (white wire) Red Red (white wire)

7 7
Red earth Red earth
(black wire) 8 8 (black wire)
Green (white wire) Green Green (white wire)
27 27
Green earth Green earth
(black wire) 28 28 (black wire)
Blue
Blue (white wire) 10 10 Blue (white wire)
Blue earth Blue earth
(black wire) 11 11 (black wire)
H sync (white wire) White H sync (white wire)
30 30
H sync earth
(black wire)
V syn (white wire)
31
Black
31
H sync earth
(black wire)
V syn (white wire)
4
13 13
V sync earth V sync earth
(black wire) 14 14 (black wire)
Blue (0.6)
Vcc 1 1 Vcc
Red (0.6)
Vcc 2 2 Vcc
White (0.6)
GND 20 20 GND
Black (0.6)
GND 21 21 GND
Red (0.22) Red (0.22)
TRANS 1 19 37 RECEP 1
White (0.22) White (0.22)
TRANS 2 18 36 RECEP 2
Black (0.22) Black (0.22)
RECEP 1 37 19 TRANS 1

36 Blue (0.22) Blue (0.22) 18

RECEP 2 TRANS 2

PROTECTIVE CONNEC- CONNEC- PROTECTIVE

EARTH TOR TOR EARTH
SHELL SHELL

4.4.4 Card Location

This cart is located immediately to the left of the power supply as shown in the diagram below.
UC SII Central processing unit

Power supply
PC module

Axis card
PCMCIA

Input/
output
cards

en-938979/0 4 - 21
4.4.5 Replacing the Card

! CAUTION
All the data stored in the RAM will be lost if the batteries are removed from the card. Make
sure all the data have been backed up before attempting this procedure.

Before beginning, make sure a replacement card is available and make sure ALL the data have been backed up.
1. Back up all the software, referring to the relevant section.
2. Power down the CNC system and the machine.
3. Remove all the connections from the card.
4. Loosen the two card attaching screws, one at the top and one at the bottom.
5. Gently pull out the card to unplug it from the rack.
2
6. If the replacement card is not equipped with the EPROM
daughterboard or the graphic daughterboard, recover
them from the card replaced and install them on the
new card, being very careful to correctly position the
connectors. The memory cards are normally provided
except for the SRAM2 card which is optional. Check
that all the cards are present and are of the same type,
especially the SRAMSys card, which can be of two
different types, depending on the application (128KB or
512KB). If replacing a memory card, proceed with care
and avoid electrostatic discharges.

! CAUTION
A memory module may be the cause of the
card failure, so be very cautious about
reusing them.

7. Make sure the battery cable is connected to the new

card. This cable is normally not connected on
replacement cards to avoid discharging the battery.
8. Install the card in the rack and moderately tighten the
attaching screws.
9. Reinstall all the connections removed above.
1 3
10. Power up the machine, then the CNC.
11. Reload the software backed up in step 1. 1 - Battery connector
2 - Battery
3 - SRAM memory module location

4 - 22 en-938979/0
Processors

4.5 PCNC Processor

The PCNC processor is available as an option for 1060 Series I and Series II UCSII systems. Its
main function is to control the keyboard and display. It provides a very flexible man/machine
interface (MMI) for the OEM. This card can communicate with all the other processor cards and
the memory card via the system bus.
Déf. The on-board processor is either an Intel 486 SX or DX microprocessor. It is actually a self-
contained personal computer on a card with all the functionalities of a desktop PC, including an
C IDE hard disk drive, 8 or 16 MB or RAM, an IDE diskette drive, two RS232 serial ports and one
O
M parallel port. The OS/2 operating system is installed on the hard disk.
1
4.5.1 Version Identification 4
Several different versions of the PC processor card are available from NUM. The part number
C
O changes in case of major modifications, such as the amount of available memory, but not for minor
M ones to a circuit, which may change only the version letter.
2
The main differences between cards generally concern the amount of memory, the type of
processor (DX33, DX66, etc.), the capacity of the hard disk, the presence or absence of the Sub.D
connector for the diskette drive and the PCMCIA option. In case of doubt, check with the local NUM
distributor that the card version is correct.
L
P PC cards are equipped with a small metal tag soldered near the top edge of the card. On this metal
T tag is a white paper sticker giving the serial number and part number of the card. On older cards,
1 the sticker may be located on the card itself or on the edge connector at the rear of the card. Ignore
the number engraved on the card, which is not a part number!
The sticker has numbers of the following types:
L - 203115/C : Part number/version
I - 12345/002 : Serial number/lot
A
I Be very careful when noting down the references of this card. Each card has a number of
S
O
references, one giving the size of the hard disk, another the RAM size, a number for the card itself,
N and another identifying the version as SX or DX.

P As a general rule, a spare card can be used if it has exactly the same part number as the original
U card and an equal or higher version letter.
P
I
T
R
E

Proc. PC

! CAUTION
Never replace a card by a card with a different part number or a lower version letter without
first consulting NUM Technical Support.

en-938979/0 4 - 23
4.5.2 LEDs
The front plate of this card includes two red LEDs, marked DEF and HD. Under normal operating conditions, the DEF
LED is never lit.

HD LED
The HD LED indicates hard drive activity. It lights when the hard drive is accessed for read or write of data. It only
exists on newer versions of PC cards which use the Sub.D connector for connection of the diskette drive.

4.5.3 Ports
There are four ports available on the front plate of this card, including two RS232 ports, one parallel printer port and
one panel interface port.

COM1/COM2 Ports (9 contacts)

These are industry-standard RS232 ports like those on every personal computer.

4 - 24 en-938979/0
Processors

Parallel Printer Port (25 contacts)

This is an industry-standard parallel port like that on every personal computer. The " * " means active low signal.

Pin Signal
1 Strobe*
2 Data bit 0
3 Data bit 1
4 Data bit 2
5 Data bit 3
6 Data bit 4
7 Data bit 5 4
8 Data bit 6
9 Data bit 7
10 Ack*
11 Busy
12 Paper out
13 Select
14 Auto line feed*
15 Error
16 Initialise printer*
17 Select in*
18 Earth
19 Earth
20 Earth
21 Earth
22 Earth
23 Earth
24 Earth
25 Earth

en-938979/0 4 - 25
LIAISON PUPITRE Port (37 contacts)
This is the connector to the panel. All the video signals to the CRT are sent out through this port and all the keyboard
signals are input through it. This port is the only link between the panel and main rack.

Red (white wire) Red Red (white wire)

36 Blue (0.22) Blue (0.22) 18

RECEP 2 TRANS 2

PROTECTIVE CONNEC- CONNEC- PROTECTIVE

EARTH TOR TOR EARTH
SHELL SHELL

4 - 26 en-938979/0
Processors

4.5.4 Card Location

When this card is present, it is always located immediately to the left of the memory cards and other processor cards
in the main rack. The slot number therefore depends on the system configuration. There must be no free slots to the
right of this card.

Slots for CNC cards

14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
4

To left of last
PC module

CNC card
PCMCIA

Machine processor

CNC processor

Power supply
Memory card

12 11 10 9 8 7 6 5

Slots for input/output cards

en-938979/0 4 - 27
4.5.5 Pre-replacement Diagnostics
It is not easy to determine whether a failure is due to the hard drive or the card. In order for the CNC part to be able
to boot up, the PC must already be booted up under OS/2. If the PC does not boot, the CNC cannot boot. Some of
the most common problems encountered with the PC system are outlined below.

Symptom Possible cause Corrective action

PC starts to boot but hangs Hard drive failure Replace the hard drive
up during the process
Hard drive interface cable loose Check the ribbon cable connection
or cut from the board to the hard drive
OS/2 swap file too large Find and delete the swap file
on the hard drive
Hard drive corrupted Reformat and restore the drive
using the backup diskettes
PC refuse to boot Hard drive failure Replace the hard drive

Hard drive interface cable loose Check the ribbon cable connection
or cut from the board to the hard drive
Drive interface failure Replace the PC card
PC boots completely but hangs Incorrect executive version in the Replace the executive or the
when CNC starts to boot CNC or incorrect gr_pc.exe file gr_pc.exe file
on the hard drive
PC responds slowly to keyboard Too many applications open Close some application windows
input
PC locks up randomly after Application related errors when Reboot the system and correct the
boot is complete transferring data on the bus application programmes

On machines equipped with a diskette drive, the PC alone can be booted from the O/2 utility disks or a DOS bootable
diskette. Insert the first diskette in the drive and turn on the system. Follow the prompts until reboot is complete.
REMARK If there are no backup diskettes, contact the machine builder or make a set from
a similar machine, referring to the chapter on backups.
When the machine has been booted from diskette, there are several ways of accessing the hard drive, which are
outside the scope of this manual. Ask a knowledgeable technician who knows PCs to help with the diagnosis.

4 - 28 en-938979/0
Processors

4.5.6 Replacing the Card Alone

Before beginning, make sure a replacement card is available and make sure all the software has been backed up.
Refer to Chapter 13.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.

! CAUTION
There may be other cables connected to the card from inside the rack, so remove the card
very carefully, without pulling hard.
4
5. If there are other cables inside the rack connected to the card, it is probably the diskette drive connection. Take
careful note of the orientation of the connector on the card before removing it.
6. Place the card on a static control surface and disconnect the hard drive’s ribbon cable from the card, not the drive.
7. Remove the hard drive from the card by removing the screws which hold the rubber mounts on the card. Do not
disconnect the rubber mounts from the card unless access to the card screws is impossible.
8. Mount the original hard drive on the new PC card by proceeding strictly in reverse order.
9. Connect the hard drive ribbon cable to the card, making sure that the cable connector is firmly pushed onto the
pins (this is a common source of trouble).
10. Reconnect the diskette drive cable coming from inside the rack if so equipped.
11. Install the card in the rack and moderately tighten the attaching screws.
12. Reinstall all the connections removed above.
13. Power up the machine, then the CNC.
14. It may be necessary to configure the CMOS RAM to match the hard drive with the new card. Refer to the section
on PC CMOS configuration for more information.

4.5.7 Card and Hard Drive Replacement Procedure

Before beginning, make sure a replacement card is available with a working hard drive.

! CAUTION
The new card may not have the application programmes which were installed on the hard
drive by the OEM. They will then have to be reinstalled. Refer to the section on software
backup/restore procedures.

1. Power down the CNC system and the machine.

2. Remove all the connections from the card.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.

! CAUTION
There may be other cables connected to the card from inside the rack, so remove the card
very carefully, without pulling hard.

en-938979/0 4 - 29
5. If there are other cables inside the rack connected to the card, it is probably the diskette drive connection. Take
careful note of the orientation of the connector on the card before removing it.
6. Reconnect the diskette drive cable coming from inside the rack if so equipped.
7. Install the card in the rack and moderately tighten the attaching screws.
8. Reinstall all the connections removed above.
9. Power up the machine, then the CNC.
10. It may be necessary to configure the CMOS RAM to match the hard drive with the new card. Refer to the section
on PC CMOS configuration for more information.

4.5.8 CMOS RAM Configuration Access

The CMOS RAM is configured in the same way as on any personal computer. Only the command to access the utility
is different.

! CAUTION
Changing the CMOS configuration data could result in loss of functionality of the hard drive,
pointing devices, diskette drives, memory allocation, etc. Only trained technicians familiar
with PC configurations should attempt these changes.
To access the CMOS configuration routine, depress the CTRL+ALT+S keys simultaneously while the PC is booting
up from a power off state. Depress these keys at the end of the memory test and hold them depressed until the CMOS
setup page appears.
The CMOS configuration utility is used to specify the type of hard drive, diskette drive, CRT, and keyboard and to set
the date and time for the PC card. However, the only settings which should ever be adjusted are the hard drive settings
and the time/date settings if required. In particular, the diskette drive should never be enabled from here. It is controlled
via a software driver loaded in the config.sys file.
Since there are many types of hard drives currently available on the market, the settings for each drive are too
numerous to list herein. To find out the settings required for a given hard disk, either call NUM technical support or
the hard disk manufacturer. It is important to note that the CMOS RAM configuration does not allow custom drive
settings, but only a choice among predefined values on a list for each parameter. This means that it may not be possible
to exactly configure a given hard drive, if it does not match the available values.
A typical CMOS RAM setup screen is illustrated below. For instance, the hard disk size is set to 81 MB. It also contains
other parameters such as time, date, memory size, diskette drives (none selected, which is correct), hard drives, video
mode, keyboard, etc.
Page 2 shows the shadow RAMs, which are usually all disabled.

4 - 30 en-938979/0
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CMOS RAM configuration page

Pressing the ESC key on page 1 or 2 of the CMS setup screens displays the following menu.

To exit the CMOS configuration utility, follow the prompts on this menu or press ESC to return to the setup utility.
Pressing F4 - Save and exit causes the system to reboot automatically.

en-938979/0 4 - 31
4.5.9 Replacing the Battery

! CAUTION
The battery must be replaced within 15 minutes or the data in the CMOS RAM will be lost.
A special capacitor continues to supply the memory for that time.

4 1 2
1. Check and back up all the CMOS RAM data, then
power down the CNC system and the machine.
2. Remove all the connections from the card.
3. Loosen the two card attaching screws, one at the top
and one at the bottom.
4. Gently pull out the card to unplug it from the rack.

! CAUTION
There may be other cables connected to the
card from inside the rack, so remove the
card very carefully, without pulling hard.

5. If there are other cables inside the rack connected to

the card, it is probably the diskette drive connection.
Take careful note of the orientation of the connector on
the card before removing it.
6. Take careful note of the orientation of the battery
connector, then disconnect the old battery and remove
it from its housing.
7. Insert the new battery in its housing and connect it,
making sure the connector is in the right direction.
8. Install the card in the rack and moderately tighten the 3
attaching screws. 1- Battery connector
9. Reinstall all the connections removed above. 2- Battery
3- Slot for DRAM memory module
10. Power up the machine, then the CNC. 4- Edge connector for diskette drive
11. Check the CMOS RAM to see whether any data loss (PC version 1 module only)
occurred. If so reset to the original values.

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4.5.10 Adding or Removing a DRAM Memory Module

! CAUTION
These modules are extremely sensitive to static electricity. Take all the normal precautions,
such as wearing an antistatic wrist band, etc. before handling them.

1. Power down the CNC system and the machine. 4 1 2

2. Remove all the connections from the card.
3. Loosen the two card attaching screws, one at the top
and one at the bottom. 4
4. Gently pull out the card to unplug it from the rack.

! CAUTION
There may be other cables connected to the
card from inside the rack, so remove the
card very carefully, without pulling hard.

5. If there are other cables inside the rack connected to

the card, it is probably the diskette drive connection.
Take careful note of the orientation of the connector on
the card before removing it.
6. INSTALLATION: Push the module at a slant into the
connector with the polarising notch on the left. Then tilt
the model into upright position until it snaps into place.
7. REMOVAL: Carefully retract the two metal retaining
clips on either side of the module and tilt the module
downwards. When the module is clear of the clips, lift
it out.
3
8. Install the card in the rack and moderately tighten the
attaching screws. 1- Battery connector
2- Battery
9. Reinstall all the connections removed above. 3- Slot for DRAM memory module
10. Power up the machine, then the CNC. 4- Edge connector for diskette drive
(PC version 1 module only)
11. Check the CMOS RAM to see whether any data loss
occurred. If so reset to the original values.

en-938979/0 4 - 33
Notch

Figure 9: Installing DRAM memory modules on the PC processor

4 - 34 en-938979/0
Processors

4.5.11 Diskette Drive

The diskette drive must be connected and enabled before being able to use it. There are currently two versions of the
PC processor with different diskette drive connection schemes. On the older version, the drive is directly connected
to the processor card by a dual-in line connector. The newer version has a sub.D connector on the front for connection
of the drive.

Diskette Drive Connection on the Old Version of the Card

J7
36 35

2 1
Edge connector to
PC version 1 card
Wiring diagram for connection of a 3 1/2" diskette drive (type TEAC FD-235HF) to V1 PC module
Maximum length: 1 metre.

GND 1 1 GND
RPM/LC 2 2 RPM/LC
GND 3 3 GND
nc 4 4 nc
GND 5 5 GND
nc 6 6 nc
GND 7 7 GND
INDEX# 8 8 INDEX#
GND 9 9 GND
DRV0# 10 10 DRV0#
GND 11 11 GND
DRV1# 12 12 DRV1#
GND 13 13 GND
nc 14 14 nc
GND 15 15 GND
MTRON# 16 16 MTRON#
GND 17 17 GND
DIR 18 18 DIR
GND 19 19 GND
STEP# 20 20 STEP#
GND 21 21 GND
WDATA# 22 22 WDATA#
GND 23 23 GND
WGATE# 24 24 WGATE#
GND 25 25 GND
TRK0# 26 26 TRK0#
GND 27 27 GND
WRPRT# 28 28 WRPRT#
GND 29 29 GND
RDATA# 30 30 RDATA#
GND 31 31 GND
HDSEL 32 32 HDSEL
GND 33 33 GND
DSKCHG 34 34 DSKCHG
GND 35
VCC 36
2 GND
4 VCC

Protective
earth

en-938979/0 4 - 35
Diskette Drive Connection to Sub.D Connector
The pinout of the sub.D connector and drive is shown below.
Solder side
19
37

20
1
37-contact male
connector

Wiring diagram for connection of a 3 1/2" diskette drive (type TEAC FD-235HF) to V2 PC module
Maximum length: 1 metre.

GND 1 1 GND
RPM/LC 20 2 RPM/LC
GND 2 3 GND
nc 21 4 nc
GND 3 5 GND
nc 22 6 nc
GND 4 7 GND
INDEX# 23 8 INDEX#
GND 5 9 GND
DRV0# 24 10 DRV0#
GND 6 11 GND
DRV1# 25 12 DRV1#
GND 7 13 GND
nc 26 14 nc
GND 8 15 GND
MTRON# 27 16 MTRON#
GND 9 17 GND
DIR 28 18 DIR
GND 10 19 GND
STEP# 29 20 STEP#
GND 11 21 GND
WDATA# 30 22 WDATA#
GND 12 23 GND
WGATE# 31 24 WGATE#
GND 13 25 GND
TRK0# 32 26 TRK0#
GND 14 27 GND
WRPRT# 33 28 WRPRT#
GND 15 29 GND
RDATA# 34 30 RDATA#
GND 16 31 GND
HDSEL 35 32 HDSEL
GND 17 33 GND
DSKCHG 35 34 DSKCHG
GND 18
VCC 37 2 GND
GND 19 4 VCC
Protective
earth Protective
COVER
earth

4 - 36 en-938979/0
Processors

In addition, the newer version can also come equipped with a PCMCIA slot. In this case, an additional card is attached
to the PC card as shown below.
With this card combination, both cards must always be removed together, as they are
interconnected by cables and screws.

HD
Déf.

C
O
M
1
! CAUTION 4
C
Never attempt to remove one card without the other. They are
O attached together.
M
2

L
P
T
1

O
P
E
R
A F
T L
O O
R P
NE RETIRER LA CARTE QU' AVEC

WITHOUT THE PROC. PC CARD

DO NOT REMOVE THIS CARD

P
LA CARTE PROC. PC

P Y
A
N
E
L

PCMCIA Proc. PC
PC

en-938979/0 4 - 37
Enabling the Diskette Drive
The diskette drive is enabled by editing the config.sys file, which is located in the root directory on the hard drive. A
typical config.sys file from a PC processor is shown below, with the line to be changed in boldface type. See Chapter
13 for information on how to edit this file.

Sample config.sys file:

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4.6 1020/1040 Motherboard

This board is functionally very similar to the UCSII board. The difference resides in the absence of a rack. 1020
systems consist of a motherboard containing the customisation parameters usually stored in the rack, to which are
connected axis cards and I/O cards. This Motorola MC68020 monoprocessor performs the CNC, PLC and graphic
functions. The executive firmware resides on a daughterboard which plugs into this card. The memory includes
several SRAM modules mounted in SIMM style instead of soldered RAM chips. The graphic function is performed
by a daughterboard. This module also includes a battery to back up the memory in case of a power failure.

4.6.1 Version Identification

There are several different versions of 1020/1040 cards. The part number changes in case of major modifications,
such as the amount of available memory, but not for minor ones to a circuit, which may change only the version letter. 4
The main differences between cards generally concern the amount of memory. In case of doubt, check with the local
NUM distributor that the card version is correct.
New cards are equipped with a small metal tag soldered near the top edge of the card. On this metal tag is a white
paper sticker giving the serial number and part number of the card. On older cards, the sticker may be located on the
card itself or on the edge connector at the rear of the card. Ignore the number engraved on the card, which is not
a part number!
The sticker has numbers of the following types:
- 203310/C : Part number/version
- 12345/002 : Serial number/lot
1020/1040 processor card types (complete modules)
- 204203310
Daughterboards which can be installed
- 204203329 EPROM daughterboard
- 204202888 GSP daughterboard (graphic control)
- 204202897 1MB DRAM memory card
- 204202892 4 MB DRAM memory card
- 204202898 128 KB SRAM memory card
- 204202894 512 KB SRAM memory card
- 204203390 2 MB SRAM memory card.
As a general rule, a spare card can be used if it has exactly the same part number as the original card and an equal
or higher version letter.

! CAUTION
Never replace a card by a card with a different part number or a lower version letter without
first consulting NUM Technical Support.

en-938979/0 4 - 39
4.6.2 LEDs
The front plate of this card includes three LEDs marked PWR, FAIL and HALT. Under normal operating conditions,
only the PWR LED is lit, except during start-up, when the other two may come on briefly.

PWR LED
This LED is lit when the card is powered up. Power supply is from a 24 V source connected to an internal power supply
unit.

FAIL LED
If the FAIL LED is lit steady, the processor card is no longer operating. It may be a hardware or a software failure, but
the most frequent cause is a problem with the software or memory. It is then necessary to reboot the system.

L1, L2 and L3 LEDs

These three LEDs correspond to operational states of the card. Their on or off state does not give any information
useful for diagnostic.

4.6.3 Ports
There are two communication ports, one analogue I/O and interrupt port and one panel interface port on the front plate
of the card. There may also be optical ports if a fibre-optic link is provided.

COMM1 Port (9 contacts)

This port is an RS232 interface which can be assigned to different functions by the OEM by software settings. More
details are given in the chapter on communications.

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Processeurs

SERIAL Port (9 contacts)

This port is a multistandard RS232, RS422, RS485 interface which can be assigned to different functions by the OEM
by software settings. More details are given in the chapter on communications.

Pin Signal
1 R(B) - RS422-RS485 reception
2 RD - Received data
3 TD - Transmitted data
4 T(B) - RS422-RS485 transmission
5 GND - Signal earth
6 R(A) - RS422-RS485 reception 4
7 RTS - Ready to send
8 CTS - Clear to send
9 T(A) - RS422-RS485 transmission
Connector Protective earth
shell

E/S ANALOG (Analogue I/O) Port

This port has two analogue inputs, one analogue output and one fast interrupt input. The wiring diagram is given below.

Spindle speed potentiometer

INPUT ANA. BR
3
1 kΩ

AGND
7
EXTERNAL REF. Screen not compulsory PROTECTIVE EARTH
OUTPUT 8

1 kΩ
INPUT ANA. AV
4
Feed rate potentiometer
IT 5 V
6 or
IT 24 V IT signal
1
COM IT IT commun
2
CON- PROTECTIVE
NECTOR EARTH
SHELL

S-A Analogue output

5
AGND Analogue common
9
CON- PROTECTIVE
PROTECTIVE CON- NECTOR EARTH
EARTH NECTOR
Screen not compulsory SHELL
SHELL

en-938979/0 4 - 41
REMARK If the interference level is low, the analogue output cable with double shielding can
be replaced by a cable with single shielding connected at both ends to the
protective earth.
LIAISON PUPITRE Port (37 contacts)
This is the connector to the panel. The wiring diagram is given below.

Red Red (white wire)

Red (white wire)
7 7
Red earth (black wire) Red earth (black wire)
8 Green 8
Green (white wire) Green (white wire)
27 27
Green earth (black wire) Green earth (black wire)
28 Blue 28
Blue (white wire) Blue (white wire)
10 10
Blue earth (black wire) Blue earth (black wire)
11 White 11
Hsync (white wire) Hsync (white wire)
30 30
HS earth (black wire) HS earth (black wire)
31 Black 31
Vsync (white wire) Vsync (white wire)
13 13
VS earth (black wire) VS earth (black wire)
14 Blue (0,6) 14
Vcc Vcc
1 Red (0,6) 1
Vcc Vcc
2 White (0,6) 2
GND GND
20 Black (0,6) 20
GND GND
21 21
Red (0,22) Red (0,22)
TRANS 1 RECEP 1
19 White (0,22) White (0,22) 37
TRANS 2 RECEP 2
18 Black (0,22) Black (0,22) 36
RECEP 1 TRANS 1
37 19
Blue (0,22) Blue (0,22) TRANS 2
RECEP 2
36 18

PROTECTIVE CON- CON- PROTECTIVE

EARTH NECTOR NECTOR EARTH
SHELL SHELL

4 - 42 fr-938979/0
Processeurs

4.6.4 Characteristics

Power consumption 11 W maximum

Location CNC card slots 0 and 1

Halt Serial Lines

Def 2 RS232 serial lines
Maximum input voltage ± 30 V
C
V0L typical -9V
O
M V0H typical +9V
M Extreme loads 2000 pF, 5 kΩ (approximately 10 m of cable)
1
Data rate 9600, 19200 or 38400 bauds
4
Analogue Inputs
The inputs can be dedicated to connection of resistive potentiometers
C
O Typical potentiometer rating 1 kΩ
M Resolution 0.4 percent full scale value
M
2
Analogue Output
Output voltage - 10 / + 10 V
Minimum load 2 kΩ
A
N Maximum error 20 mV (offset + accuracy)
E
/
A Output amplifier AD712 (Analog Device)
L
S
O
G External Interrupt
L Maximum current rating 20 mA
I Minimum current required 10 mA
A
I
5 V input Logic "0" between 0 and 1 V
S
Logic "1" between 3.5 and 5.5 V
O 24 V input Logic "0" between 0 and 4.7 V
N Logic "1" between 18 and 27 V
IT duration Programmable: T1 = 0,5/250/500/2220/4440 µs
P
U Masking between 2 ITs Programmable: T2 = 1/500/1000/4000/8000 µs
P
I
T Interrupt timing diagram:
R
E

Rising edge active

t ≥ T1 t ≥ T2
UC SII
Falling edge active
IT masking

en-938979/0 4 - 43
4.6.5 Replacing the Card

! CAUTION
All the data stored in the RAM will be lost if the batteries are removed from the card. Make
sure all the data have been backed up before attempting this procedure.
Before beginning, make sure a replacement card is available and make sure ALL the software has been backed up.
1. Back up all the software, referring to the relevant section.
2. Power down the CNC system and the machine.
3. Remove all the connections from the CNC.
4. Remove the CNC.
5. Open the cover, remove the two screws securing the card retaining rail and remove the rail.
6. Carefully remove the axis cards.

,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,
7. Disconnect the internal connecting cables (battery, I/O,
power supply and fibre-optic link if any, being careful to Screw
note their location).

S OW DC
P R
P 4V
U E

Y
2

L
P
+

-
8. Loosen the three motherboard attaching screws and
remove the motherboard.
t
se
Re

9. If the replacement card is not equipped with the EPROM L1

f ail
De F
L3 r
Pw

daughterboard or the graphic daughterboard, recover

o
S m
e 1
r
i
R a
e l

them from the old card and install them on the new card, c I
t
/
A
n
E a
m

being very careful to correctly position the connectors.

The memory cards are normally provided except for the
SRAM2 card which is optional. Check that the cards
are present and are of the same type, especially the
,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,

SRAMSys card, which can be of two different types,

is
Ax

depending on the application (128KB or 512KB). If P

a
n
e
l

replacing a memory card, proceed with care and avoid

electrostatic discharges.
Bar
! CAUTION
Screw
A memory module may be the cause of the
card failure, so be very cautious about
reusing them.
10. Proceed in reverse order for installation.
11. Power up the machine, then the CNC.
12. Reload the software backed up in step 1.

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4.6.6 Replacing the Battery

! CAUTION

The battery must be replaced within 15 minutes or the data in the RAM will be lost.
A special capacitor continues to supply the SRAM modules for that time.

1 - Disconnect the battery 2 - Remove the old battery from its housing

3 - Snap the new battery into its housing 4 - Connect the battery, being careful that the
connector is facing in the right direction

en-938979/0 4 - 45
4.6.7 Adding an SRAM Module
1 - Push the module into the connector with the polarising notch on the left.
2 - Tilt the model into upright position until it snaps into place.

Notch

4 - 46 fr-938979/0
Memory

5 Memory

5.1 Memory Card 5-3

5.1.1 Executive Firmware 5-3
5.1.2 Batteries 5-4
5.1.3 Battery Jumpers 5-4
5.1.4 Replacing the Card 5-5

en-938979/0 5-1
5-2 en-938979/0
Memory

The memory card used depends on the type of system. Many different memory designs are available. Check the card
or contact NUM for the card part number.
This section discusses the individual card functions, ports and diagnostic aids. It also includes instructions on how
to replace a memory card if required.

5.1 Memory Card

The memory card is basically a passive card. It contains the following system data:

Data Memory type Location

Part programmes RAM Memory card
External parameters RAM Memory card
User-defined macros RAM Memory card
PLC Ladder
programmes
RAM Memory card
5
PLC assembler RAM Memory card
programmes
PLC C programmes RAM Memory card
PLC variables RAM Memory card
Axis calibration points RAM Memory card

This card communicates with all the processor cards via the system bus. All the data on this card are
backed up by battery except the executive firmware. The battery is soldered to the card so that the data
are not lost when the card is removed.

5.1.1 Executive Firmware

The executive firmware is stored on a set of EPROMs (sometimes referred to as REPROMs in other NUM
documents). On older versions, the EPROMs are directly plugged into sockets on the motherboard,
whereas on newer versions, they are mounted on a daughterboard.
The executive firmware contributes to defining the basic personality of the CNC: milling, turning, grinding,
etc. There are only a few different types of executive firmware, since the same programme performs all
the functions. There are however many successive releases of the executives, called Indexes, identified
by the letter following the part number.

EXECUTIVE FIRMWEAR PART NUMBERS

Function 1060 SI 1060 SII 1060 UCSII
Milling, turning, 202852 203070 203375
grinding,
Mém general purpose
1,5M/2M

en-938979/0 5-3
The EPROM sockets are numbered U1, U2, U3, U4 or U1, V1, W1, etc. These numbers are etched on the card. Always
note down the socket number on a chip before removing it to be able to reinstall it in the same socket. This is very
important to prevent problems.
If the memory card is equipped with a daughterboard. The daughterboard may easily be removed if needed. Be very
careful not to bend the leads when reinstalling it.

5.1.2 Batteries

! CAUTION
All the data stored in the RAM will be lost if the batteries are removed from the card. Make
sure all the data have been backed up before attempting this procedure.
The batteries are soldered in the lower right-hand corner of the memory card, near the bus connector. These batteries
are under a constant charge whenever the rack is on. When the rack is turned off, the batteries supply the RAM chips
to preserve the data they contain.
The batteries can be replaced, but only by a skilled technician with suitable tools. Replacement batteries can be
obtained from NUM technical support.

5.1.3 Battery Jumpers

! CAUTION
Removing these jumpers causes a total loss of all the data contained in the RAM.
The two small jumpers located near the batteries control charging and discharging. If the jumpers are removed, the
batteries are not kept charged and will not be able to maintain the RAMs supplied.
One jumper controls charging and one controls the RAM socket. Their orientation is critical. The jumpers must be
installed parallel to the bottom of the memory card. NEVER INSTALL THE JUMPERS PERPENDICULAR TO THE
BOTTOM OF THE CARD.
These jumpers can be used to completely erase the memory. Other information on this subject is given in the section
on the backup/restore procedure.

5-4 en-938979/0
Memory

5.1.4 Replacing the Card

! CAUTION
Always back up the complete contents of the memory card before replacing the card. The
following data are lost when replacing this card: part programmes, tool geometry offsets,
tool wear offsets, DAT datum shifts, protected memory zones 1, 2 and 3, all PLC program-
mes and external parameters E8xxxx.

Before beginning, make sure a replacement card is available.

1. Power down the CNC system and the machine.
2. Loosen the two card attaching screws, one at the top and one at the bottom.
3. Gently pull out the card to unplug it from the rack.
4. Perform one of the following operations on the card, depending on the version:
a) If the old card is equipped with a daughterboard, carefully remove the daughterboard from the old card and
5
place it on the new one.
b) If the old card is not equipped with a daughterboard, carefully remove the EPROM chips from the old card
and install them on the new one. Handle these chips very carefully, because the leads are very fragile.

! CAUTION
Use an approved IC extraction device and take all normal anti-static measures to prevent
damage to the chips.

5. Make sure the battery jumpers are correctly installed on the new card.
6. Install the card in the rack and moderately tighten the attaching screws.
7. Power up the machine, then the CNC.
8. Restore all the data backed up by the procedures described in the relevant section of this manual.
9. Leave the CNC on for at least 24 hours to allow the batteries to charge fully.

en-938979/0 5-5
5-6 en-938979/0
Axis cards

6 Axis card

6.1 Encoder Feedback Theory 6-3

6.1.1 Incremental Encoders 6-3
6.1.2 SSI Absolute Encoders 6-3
6.2 Analogue Axis Card 6-4
6.2.1 SSI Absolute + Incremental Axis Cable -
Sinusoidal Pulses 6-5
6.2.2 SSI Absolute + Incremental Axis Cable -
Square Pulses 6-6
6.2.3 Axis Addressing 6-7
6.2.4 Troubleshooting 6-9
6.2.5 Replacing the Card 6 - 10
6.3 QVN Axis Card 6 - 11
6.3.1 Axis Port Connections 6 - 11
6.3.2 Axis Addressing 6 - 13
6.3.3 Troubleshooting 6 - 14
6.3.4 Replacing an Axis Card 6 - 17
6.3.5 Fibre-Optic Power Settings 6 - 18

en-938979/0 6-1
6-2 en-938979/0
Axis cards

The CNCs of the 1000 family can be equipped with up to three different types of axis cards:
- Analogue axis card with incremental encoder capabilities
- Analogue axis card with SSI absolute and incremental encoder capabilities
- QVN (quad digital drive) axis card for DISC (Digital Integrated Servo Control) axes.

6.1 Encoder Feedback Theory

There are many different types of feedback devices available today, using several different types of connections and
signals. The NUM 1060 CNCs accept both incremental and absolute encoder feedback.

6.1.1 Incremental Encoders

An incremental encoder normally has three output Te
channels: A, B and Z (home pulse). These channels
are normally electrically phase shifted by 90 degrees in
relation to each other so that the device reading the
pulse train can determine the direction of travel. For
instance, movement is in the positive direction if A Channel A
a
leads B or in the negative direction if B leads A. The
timing diagram on the right shows the correct phase
relationships for a BEI H25 encoder.
Channel B
6
It should be noted that there are complementary (in-
verse) channels for each regular channel. These Pulses
inverse channels are mainly used for error detection.
On the NUM 1060, a software parameter setting is used Te: signal period of one of the channels
to configure error detection if both A and A’ or B and B’ a: time between two edges
or Z and Z’ go high at the same time, which should never
occur when the system is operating correctly.

Figure 10

6.1.2 SSI Absolute Encoders

These encoders supply their information through a serial synchronous interface (SSI). The send the axis card a code
which directly indicates the encoder’s position. The code can be only 12, 16 or 24 bits, depending on the type of
encoder. The code is not sent randomly, but in response to periodic polling of the axis card. However, because the
interface is serial, data transmission takes longer, which can be penalising for high precision applications. Some
machines are therefore equipped with combined SSI and incremental encoders. In such systems, the SSI encoder
determines the slide position at power up and the incremental encoder supplies the position data when in motion. This
gives the best of both worlds, the accuracy of the absolute encoder for position sensing and the speed of the
incremental encoder.

en-938979/0 6-3
6.2 Analogue Axis Card
This type of card can have two, three or four ports. However, the functionality is always the same,
regardless of the number of ports.
These cards communicate with all the processor cards of the system via the system bus. They use DSP
(digital signal processing) technology for the axis control algorithms.

1
These cards allow connection of +5 VDC TTL line driver encoders, linear scales or handwheels. They
can supply a + 10 V command to the servo-drives or spindle motors. Each port allows connection of all
the axis, feedback, addressing and homing signals. Wiring is described in detail in the following section.
These cards are not addressed. They can therefore be placed in any slot, provided it is to the left of the
memory card and any QVN (Quadruple Variateur Numérique = Quadruple Digital Drive) cards present
in the system and to the right of the first I/O or PC processor card.
The older versions of the axis card only supported incremental encoders, but the recent versions (series
2042030000) also support absolute encoders using the SSI protocol. It is necessary to check the card
2 part number, because no external visual clues identify the type of card.

Axes

6-4 en-938979/0
Axis cards

6.2.1 SSI Absolute + Incremental Axis Cable - Sinusoidal Pulses

CHANNEL A 6 Ua+ A+
CHANNEL A 5 Ua- A-
CHANNEL B 10 Ub+ B+
CHANNEL B 9 Ub- B-
0.5
5V 0V
0.5
0V
PROTECTIVE
EARTH

2
0.5 mm +5V
+5V 22
21
0.5 mm2 0V
0V
0 V RETURN
CHANNEL S 7 5 V RETURN
CHANNEL RCLK 17
CHANNEL RCLK 4
CHANNEL ECLK
CHANNEL ECLK
1
14
CLK
CLK
6
DATA CHANNEL 19 DATA
DATA CHANNEL 18 DATA
PROTECTIVE
CONNEC- EARTH
PROTECTIVE Screen not compulsory
TOR
EARTH SHELL

PROTECTIVE
EARTH
PCH SPEED REF 16 PCH DRIVE
PFD SPEED REF 15 PFD DRIVE

Wiring of the switch only with

semiabsolute axis encoder
SWITCH + Y 3
+ Switch contact

SWITCH 0 V 2 - 24 V RETURN
24 V
PROTECTIVE
EARTH
Physical address of the axis: contacts 11, 12, 13, 23, 24 and 25

In the wiring diagram above, the card ports are connected to an encoder, a servo-drive input and a switch contact.

en-938979/0 6-5
6.2.2 SSI Absolute + Incremental Axis Cable - Square Pulses

CHANNEL A 6 A+
CHANNEL A 5 A-
CHANNEL B 10 B+
CHANNEL B 9 B-
22
0.5 mm2 +5V
+5V
21 0.5 mm2 0V
0V
0 V RETURN
CHANNEL S 7 5 V RETURN
CHANNEL RCLK 17
CHANNEL RCLK 4
CHANNEL ECLK 1 CLK
CHANNEL ECLK 14 CLK
DATA CHANNEL 19 DATA
DATA CHANNEL 18 DATA
PROTECTIVE
EARTH
PROTECTIVE CONNEC-
EARTH TOR Screen not compulsory
SHELL
PROTECTIVE
EARTH
PCH SPEED REF 16 PCH DRIVE
PFD SPEED REF 15 PFD DRIVE

Wiring of the switch only with

semiabsolute axis encoder
SWITCH + Y 3
+ Switch contact

SWITCH 0 V 2 - 24 V RETURN
24 V
PROTECTIVE
EARTH
Physical address of the axis: contacts 11, 12, 13, 23, 24 and 25

In the wiring diagram above, the card ports are connected to an SSI encoder and an incremental encoder, a servo-
drive input and a switch contact.

6-6 en-938979/0
Axis cards

6.2.3 Axis Addressing

Since the analogue type axis cards are not addressed, the axis connected to a port is recognised by the wiring of the
port connector. The connections labelled Addr1 to Addr16 on the wiring diagrams of the previous pages correspond
to the pin weights in the address definitions. The table below shows all the possible combinations of jumpers and the
associated axes.

13 13 13 13 13 13 13 13
25 25 25 25 25 25 25 25
12 12 12 12 12 12 12 12
24 24 24 24 24 24 24 24
11 11 11 11 11 11 11 11
23 23 23 23 23 23 23 23

0 1 2 3 4 5 6 7
13 13 13 13 13 13 13 13
25 25 25 25 25 25 25 25
12 12 12 12 12 12 12 12
24 24 24 24 24 24 24 24
11 11 11 11 11 11 11 11
23 23 23 23 23 23 23 23 6
8 9 10 11 12 13 14 15
13 13 13 13 13 13 13 13
25 25 25 25 25 25 25 25
12 12 12 12 12 12 12 12
24 24 24 24 24 24 24 24
11 11 11 11 11 11 11 11
23 23 23 23 23 23 23 23

16 17 18 19 20 21 22 23
13 13 13 13 13 13 13 13
25 25 25 25 25 25 25 25
12 12 12 12 12 12 12 12
24 24 24 24 24 24 24 24
11 11 11 11 11 11 11 11
23 23 23 23 23 23 23 23

24 25 26 27 28 29 30 31

Figure 11: Analog axis address selections

en-938979/0 6-7
Although all the addresses are listed in the previous table, AXIS NAME ADDRESS
the table does not show the customary axis assignment. X 0
For instance, the X axis is usually at address 0, the Y axis
Y 1
at address 1, etc.
Z 2
The table opposite shows the address usually assigned
U 3
to each axis. However, this table is given only for
guidance, since each OEM can freely choose the address V 4
system best suited to his applications. W 5
Both analogue and DISC axes can coexist in a system. In A 6
this case, the addressing is usually somewhat different B 7
for several reasons. Refer to the section on DISC C 8
addressing for further information. X1 9
Y1 10
Z1 11
U1 12
V1 13
W1 14
A1 15
B1 16
C1 17
18
19
20
21
22
23
Spindle 1 24
Spindle 2 25
Spindle 3 26
Spindle 4 27
Handwheel 1 28
Handwheel 2 29
Handwheel 3 30
Handwheel 4 31

6-8 en-938979/0
Axis cards

6.2.4 Troubleshooting
Troubleshooting of analogue axis cards is relatively easy. Since the cards do not contain any data or programmes,
no special precautions are required when replacing them.

Symptom Possible Cause Corrective actions

Axis shakes (oscillates) Position loop (CNC) gain too high Check the following error and
adjust as required
Speed loop (drive) gain too high Check drive performance in open
loop mode using a battery box and
an oscilloscope. Adjust as required
Poor encoder signals Check the signals with an oscillo-
scope. Check encoder wiring and
shielding
Poor motor speed control Check motor speed feedback wires
and feedback sensor (probably a
tachometer or a resolver)
Axis drifts or gradually loses
its position
Faulty encoder signals Check encoder wiring and shielding 6
After power up, axis immediately Encoder wiring error Check for correct encoder phasing
runs at uncontrollable high speed and that the wires are correctly
connected
Broken encoder wires Check for broken encoder wires
Speed command wiring error Check speed command for correct
phasing
Axis gives excessive error Drive fault Check for any type of drive fault
indication: ERROR 4x on CNC which will cause the motor not
to run
Axis stuck or hard to move Move the axis by hand to check it
Axis speed too high or too low Check the following error and
adjust as required
Axis performance is poor Check drive and motor in open loop
mode using a battery box and an
oscilloscope

If unexplained errors are occurring and all the wiring checks above are OK, the problem could be in the axis port itself.
Always begin by checking the wiring, which is small gauge and tends to break under repeated motions. If the wiring
is OK, try to connect the cable to another port using the procedure given below.

en-938979/0 6-9
Checking an Axis Port
1. Power down the machine and the CNC.
2. Remove the cable from the suspected bad port.
3. Connect the cable to another analogue port. If there are no free ports, remove another cable from a good port
and swap the two cables.
4. After reattaching the cables, power up the machine and the CNC. Test the axis where the problem was found.
If the problem has disappeared, the port is probably faulty and the card should be replaced. However, if the
problem persists on this axis, the original port is OK and the cause of the problem is elsewhere.

6.2.5 Replacing the Card

6 - 10 en-938979/0
Axis cards

6.3 QVN Axis Card

The QVN axis card is primarily used to control the DISC servo-amplifiers. It is installed in the rack just
to the left of the memory card. It sends current commands to the servo-drives via the fibre-optic ring. Each
servo-drive reads its respective current command and sends the appropriate power to the motor. As the
motor turns, the special DISC encoders send speed and armature angle information back to the QVN card
C
A
via the 26-contact axis port. The QVN card computes and controls the speed and current (torque)
P commands then issues new commands to the DISC servo-amplifiers via the fibre-optic ring.
T
3 There are four sub.D connectors and two fibre-optic ports on the front plate. The card is capable of
controlling up to four DISC servo-amplifiers. The four axis ports are specially designed to receive special
motor encoder signals from a DISC motor, but they can also be wired as traditional encoder ports and
used for handwheels, spindle encoders or secondary feedback ports.
C
A The two fibre-optic ports are for connecting the card in a fibre-optic ring, which can include up to four daisy-
P
T chained DISC amplifiers. One port is an emitter and the other a receiver.
2

6.3.1 Axis Port Connections

It is important to understand how the DISC encoder operates, to be able to understand and diagnose the

C
signals. The DISC encoder has two output channels, one a traditional incremental encoder and the other
an absolute channel.
6
A
P
T The absolute channel is only absolute for one revolution. This channel is use to determine the current
1 motor armature angle so that the motor can be commutated at the right time. That is the sole function
of this channel.
The incremental channel serves two purposes. First, it supplies the speed information to the QVN card,
C and second, it can be used for position control if so configured by the OEM.
A
P
T
0

E
M
V I
A
R R
E
C

QVN

en-938979/0 6 - 11
Red
Vcc Z
19 +5V
Black
GND W
10 0V
Red
Vcc Y
2 +5V
Black
GND
1
Red
Vcc S
12 +5V
Black
GND X
11 0V
Red
Vcc T
13 Black +5V
GND V
14 Red 0V
Vcc U
17 Black +5V
GND G
16 0V
Pink
x_Z_p H
9 Grey Z
x_Z_n J
8 Z\
Yellow
x_B_p K
7 Green B
x_B_n L
6 B\
Brown
x_A_p M
26 A
White
x_A_n N
18 A\
Pink/Blue
x_abs2_p A
20 abs2
Grey/Blue
x_abs2_n B
21 abs2 \
Yellow/White
x_abs1_p C
22 abs1
Green/White
x_abs1_n D
23 abs1 \
Brown/Violet
x_abs0_p E
24 White/Violet abs0
x_abs0_n F
25 Violet abs0 \
X_CTP P
5 Blue
T_GND R
15
PROTECTIVE
EARTH
PROTECTIVE
EARTH ERGOT

Red/Grey +
XBUT_p Switch contact
4 Black/Grey
XBUT_n - 24 V RETURN
3 24 V
PROTECTIVE
EARTH

Figure 12: Typical wiring between a DISC encoder and QVN axis port

6 - 12 en-938979/0
Axis cards

QVN axis port pinout

Pin Signal
1 Earth
2 Vcc + 5 V
3 Home switch common 0V
4 Home switch signal +24 VDC
5 X_CTP
6 x_B_n
7 x_B_p
8 x_Z_n
9 x_Z_p
10 Earth
11 Earth
12 Vcc + 5 V
13 Vcc + 5 V
14 Earth 6
15 T_GND
16 Earth
17 Vcc + 5 V
18 x_A_n
19 Vcc + 5 V
20 x_abs2_p
21 x_abs2_n
22 x_abs1_p
23 x_abs1_n
24 x_abs0_p
25 x_abs0_n
26 x_A_p

6.3.2 Axis Addressing

! CAUTION
QVN axis addressing is specific to both the slot and port. The cables cannot be swapped
as on an analogue axis card.

Unlike the analogue axis cards discussed above, these cards do not use jumpers to define the axis address. Instead,
the axes are addressed by a machine parameter setting. The cards themselves do not have an address, but take that
of the slot where they are located. It can therefore be complicated to change an axis address, which requires
knowledge of the complete axis addressing scheme. Therefore, it is not covered herein. For more information on this
subject, refer to Parameter Manual 938818.

en-938979/0 6 - 13
6.3.3 Troubleshooting
There are two ways of troubleshooting the QVN card and DISC axes. The first method consists of checking for faults
on the special QVN page displayed on the NUM panel screen. On one of the main screens, pressing key F9 (PLC
I/O) displays a menu including option 4 - QVN CONTROLLED AXES. Choosing this option displays a screen similar
to the one shown below.
On this screen, it is sufficient to select a Fbk.
pos (feedback position), which is basically
an axis address. For instance, if the fault
appears to be on the X axis, enter the X axis
feedback address (7 in the example) to
display the second screen.

This screen is more detailed, listing all the

possible faults on the axis selected. It
includes two columns, labelled “1st flt” and
“Curr. flt”. If the fault has disappeared, an
asterisk is located opposite the fault in the
“1st flt” column. If the fault still present, there
is an asterisk in the “Curr. flt” column.
Depending on the nature and severity of the
fault, it can be reset either by pressing the
RESET key (key ..) on the front panel or by
a power down/power up sequence.
Relatively minor faults are acknowledged
by the first method and more severe ones by
the second.

The two softkeys labelled CARDS QDD and AXES QDD are used to display other screens.

6 - 14 en-938979/0
Axis cards

CARDS QDD This key selects the screen below to help determine the status of the QVN cards themselves.
AXES QDD This key selects the first of the two screens shown above, labelled “QDD CONTROLLED AXIS
INFORMATION”.
The first column lists the numbers of the
QVN cards. Card 0 is the first card to the left
of the memory cards, card 1 is to the left of
card 0 and so forth.
The second column indicates whether or
not the card is used.
The third column indicates whether or not
the card has been put on hold (servos
stopped).
The fourth column indicates whether or not
the card is operational.
The fifth column indicates whether a fault
occurred then disappeared.
The sixth column shows if there is currently 6
a fault on the card.

List of Possible Faults, Description and Probable Cause

FAULTS DETECTED BY THE POWER SUPPLY

FAULT DESCRIPTION PROBABLE CAUSE
Undervoltage The voltage level on the DC bus Mains voltage out of tolerance.
is below the minimum threshold Mains isolating switch open
Overvoltage The voltage level on the DC bus is Braking module faulty
above the maximum threshold Mains voltage out of tolerance
Earth fault The current is not balanced Earth leakage (motor phase, etc.)
between the two branches of the
DC bus
Resistor temperature The thermal switch of the braking Braking module faulty
resistor is open Resistor rating

en-938979/0 6 - 15
FAULTS DETECTED BY THE CURRENT AMPLIFIERS
FAULT DESCRIPTION PROBABLE CAUSE
Heat sink temperature The thermal switch on the heat RMS current > amplifier Ip
sink is open
Power control Detection of an axis drive
(auxiliary power supply monitor) auxiliary power supply failure

Short circuit Short circuit between motor The fault might be internal or
phases or on the DC bus external ato the module. Check the
motor power leads for shorts

Serial bus Transmission error on the serial Fibre-optic ring not connected
(fibre-optic) bus between the QVN or open circuited SBCE drivers
card and a servo-drive faulty
Overcurrent Overcurrent detected in the
axis drive

FAULTS DETECTED BY THE QVN CARDS

FAULT DESCRIPTION PROBABLE CAUSE
Complementarity Faulty complementary signals Encoder failure
on one of the encoder channels Encoder wiring problems
Overspeed Overspeed detected (the threshold Motor runaway
is set at 1.8x the max speed Wrong speed setting in P73
specified by parameter P73)
Overcurrent (overtorque) Current draw greater than 20.5 / 3 Motor blocked
times the peak current detected Mechanical problem on the axis
for too long (detection threshold =
peak current x 2s)
Feedback loss With sinusoidal feedback, Motor encoder fault
the electrical angle supplied by the Encoder cable fault
incremental channels for the rotor
position is no longer consistent
with the electrical angle supplied
by the absolute channels (the fault
detection threshold is between
5 and 35 electrical degrees)
Drive runaway The axis drive power transistor
control is locked

6 - 16 en-938979/0
Axis cards

FAULTS DETECTED BY AN ENCODER

FAULT DESCRIPTION PROBABLE CAUSE
Noisy signal Encoder signal is weak or noisy Encoder fault
Cable fault
Shielding problems
Absolute channel code A code which is never used was Encoder fault
detected on the absolute feedback Encoder cable fault
channels from the motor

FAULTS DETECTED BY A MOTOR

FAULT DESCRIPTION PROBABLE CAUSE
Motor temperature The internal thermal switch of RMS current in the motor > rated
the motor is open motor current
Mechanical axis problem

6.3.4 Replacing an Axis Card

6
Before beginning, make sure a replacement card is available.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card. Be especially careful to identify the transmitter and receiver fibre-optic
cables.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
5. Set the DIP optical power switches on the new card exactly as they were the one on the old card (see Sec. 6.3.5).
6. Install the new card in the rack and moderately tighten the attaching screws.
7. Reconnect any cables removed from the axis ports. Be careful to place the fibre-optic cables in the same
connectors as on the old card.
8. Power up the machine, then the CNC.

en-938979/0 6 - 17
6.3.5 Fibre-Optic Power Settings
Fibre optics uses light instead of electricity to transmit information. To correctly calibrate the light intensity, it is
necessary to set the optical power on the QVN card. This is done by setting a series of DIP switches located near the
fibre-optic ports.

1 2 3
ON

SW1

Distance Switch 1 Switch 2 Switch 3

0.2, 1 m ON OFF OFF
5, 10, 15 m OFF ON OFF
20, 30 m OFF OFF OFF

The distances are specified in metres because the cables supplied by NUM come only in the lengths specified in the
table. If the cable used is a different length, chose the closest length from the table. The table settings are for plastic
fibres, which are the kind used in NUM cables.

6 - 18 en-938979/0
Input/Output Cards

7 Input/Output Cards

7.1 I/O Card Display and Troubleshooting 7-3

7.1.1 Input/Output Display 7-4
7.2 32-Input Card 7-5
7.2.1 Input Wiring 7-6
7.2.2 Replacing the Card 7-7
7.3 32-Output Card 7-7
7.3.1 Output Wiring 7-8
7.3.2 Replacing the Card 7-9
7.4 32-Input/24-Output Card (with Sub.D connectors) 7 - 10
7.4.1 Input Wiring 7 - 11
7.4.2 Output Wiring 7 - 12
7.4.3 External Power Connector 7 - 13
7.4.4 Replacing the Card 7 - 13
7.5 32-24 I/O Card (with high density connectors) 7 - 14
7.5.1 Replacing the Card 7 - 14
7.6 64-48 I/O Card (with high density connectors) 7 - 15
7.6.1 Replacing the Card 7 - 15
7.7 32-Input Interface Panel 7 - 16
7.7.1 Replacing the Panel 7 - 16
7.8 24-Output Relay Panel 7 - 17
7.8.1 Replacing the Panel 7 - 17 7

en-938979/0 7-1
7-2 en-938979/0
Input/Output Cards

Five different types of I/O cards are available from NUM. They are listed in the table below. These cards can be used
in any combination. Some OEMs prefer to combine different cards, whilst others choose only one type.
Type Inputs Outputs Connection
32 I 32 inputs @ 24 VDC None Terminal strip on the card edge
32 O None 32 relay outputs Terminal strip on the card edge
32 I/24 O 32 inputs @ 24 VDC 24 outputs @ 24 VDC 2 sub.D connectors on front plate
32 I/24 O 32 inputs @ 24 VDC 24 outputs @ 24 VDC 2 high density connectors
64 I/48 O 64 inputs @ 24 VDC 48 outputs @ 24 VDC 2 high density connectors

7.1 I/O Card Display and Troubleshooting

The state of each input or output can be displayed on the CNC. Before going into the display procedure, it is important
to understand the structure of the I/O addresses.

Input and Output Addresses

%I r c xx . b
The extension defines the bit number, from 0 to 7
Byte on the I/O card, range from 0 to 7
I/O card slot number, range from 5 to B
Rack number, range 0 to 7 7
Identifies whether it is an input or an output
%I: input
%Q: output.
The rack numbering is a little tricky because the logical addresses are not the same as the physical addresses. Always
use the logical address, not the physical address, to display an input or output on the CRT or call it in a ladder
programme.

Device Logical rack Physical Physical

address rack address rack address
with fibre-optic without fibre-optic
ring ring
Main rack 0 7 0
Extension racks 1-7 0-6 N/A
Machine panels 0 0- 3 N/A

en-938979/0 7-3
Byte Determination
To determine byte number xx on an input or output card, it is necessary to know how many bytes there are on each
card. This is given by the table below.
For instance, to obtain output 31 of the output card located in slot 9 of the main rack, the address would be %Q0903.7.
Input number Output number Byte Number
0-7 0-7 00
8-15 8-15 01
16-23 16-23 02
24-31 24-31 03
32-39 32-39 04
40-47 40-47 05
48-55 N/A 06
56-63 N/A 07

7.1.1 Input/Output Display

1. Press key F9 (PLC I/O) at the bottom of the screen.
2. Type 2 or use the cursor control keys to select option 2, PLC Memory, then press ENTER.
3. The PLC Memory screen is displayed. It contains a small prompt labelled “Address” in the lower left-hand corner
for entry of an address. For instance, if you type %I0100.0 and press ENTER, the contents of the address specified
are displayed.

PLC MEMORY

%W24.0 $05 0 0 0 0 0 1 0 1
%W25.1 $F1 1 1 1 1 0 0 0 1
%W26.2 $43 0 1 0 0 0 0 1 1
%W125.B $25 +37
%W126.B $97 -23
%W127.W $F852 -30802
>%W128.L $0463E247 +73654855

4 3 2 1

1- Values of bit variables highlighted in the corresponding bytes

2- Decimal values of byte, word or long word variables
3- Hexadecimal values of byte, word or long word variables
4- Variables

7-4 en-938979/0
Input/Output Cards

When displaying bit values, the contents of the address are always displayed as 8 bits.
Example: Entry of addresses %I0B00.0 and %Q0A01.4 and corresponding displays:
%I0B00.0 $01 0 0 0 0 0 0 0 1
%Q0A01.4 $10 0 0 0 1 0 0 0 0
In this example, bits 0 and 4 are requested. Both bits are highlighted (reverse video) on the screen.

7.2 32-Input Card

The 32-input card has two 16-contact screw terminal strips on the front plate. There are 32 LEDs
at the top of the card which are lit when the corresponding inputs are high. These cards assume
the address of the slot in which they are placed.

Nominal input voltage +24 VDC

Maximum current rating 8 mA per input
Reverse voltage withstand capability 30 V continuous
Low input level (logic 0) 0-5 VDC (current < 1 mA)
COM 0
00.0 High input level (logic 1) 13.2-30 V (current > 4 mA)
00.1 Logic Positive
00.2
00.3
00.4
00.5
00.6
00.7 7
01.0
01.1
01.2
01.3
01.4
01.5
01.6
01.7
COM 1
COM 2
02.0
02.1
02.2
02.3
02.4
02.5
02.6
02.7

03.0
03.1
03.2
03.3
03.4
03.5
03.6
03.7
COM 3

32 E

en-938979/0 7-5
7.2.1 Input Wiring
The inputs are wired as shown below. They are grouped in four sets of 8 inputs. Each group has its own common
connection.
Old notation New notation
COM 0 COM 0 1
IN 0 I 00.0 2
IN 1 I 00.1 3
IN 2 I 00.2 4 -
24 VDC
IN 3 I 00.3 5 +
IN 4 I 00.4 6
IN 5 I 00.5 7
IN 6 I 00.6 8
IN 7 I 00.7 9
LOCK LOCK 10
IN 8 I 01.0 11
IN 9 I 01.1 12
IN A I 01.2 13
IN B I 01.3 14 +
IN C I 01.4 15 24 VDC
-
IN D I 01.5 16
IN E I 01.6 17
IN F I 01.7 18
COM 1 COM 1 19

COM 2 COM 2 1
IN 10 I 02.0 2
IN 11 I 02.1 3
IN 12 I 02.2 4 -
24 VDC
IN 13 I 02.3 5 +
IN 14 I 02.4 6
IN 15 I 02.5 7
IN 16 I 02.6 8
IN 17 I 02.7 9
LOCK LOCK 10
IN 18 I 03.0 11
IN 19 I 03.1 12
IN 1A I 03.2 13
IN 1B I 03.3 14 +
IN 1C I 03.4 15 24 VDC
-
IN 1D I 03.5 16
IN 1E I 03.6 17
IN 1F I 03.7 18
COM 3 COM 3 19

Trelec 18-contact
connectors
+ locking system
and polarising pins

7-6 en-938979/0
Input/Output Cards

7.2.2 Replacing the Card

These cards do not include any components that can be replaced by the user. In case of a fault, replace the card.
Before beginning, make sure a replacement card is available.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card. The terminal strips are ganged and attached by a single screw.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
5. Install the card in the rack and moderately tighten the attaching screws.
6. Reinstall all the connections removed above.
7. Power up the machine, then the CNC.

7.3 32-Output Card

The 32-output card has two 16-contact screw terminal strips on the front plate. This card uses reed
relays with fuse protection for the outputs. There are 32 LEDs at the top of the card which are lit
when the corresponding outputs are high. These cards assume the address of the slot in which
they are placed.

Operating voltages 24 VDC or 48 VDC

24 VAC to 230 VAC
00.0:WD Maximum current rating per output DC:
COM 0 0.8 A at 24 VDC
00.1
COM 1 0.5 A at 48 VDC 7
00.2 AC:
00.3
00.4 0.8 A at 24 VAC
00.5 (refer to Installation and 0.6 A at 48 VAC
00.6
Commissioning Manual 938816 0.5 A at 110 VAC
00.7 for more detailed information) 0.25 A at 230 VAC
01.0
01.1 Maximum current per group of 8 outputs 5A
01.2 Fuses Two: 250 V, 5 A
01.3
01.4 Suppression None (provide an external diode or RC circuit)
01.5
01.6
01.7
COM 2
02.0
02.1
02.2
02.3
02.4
02.5
02.6
02.7

03.0
03.1
03.2
03.3
03.4
03.5
03.6
03.7
COM 3

32 S

en-938979/0 7-7
7.3.1 Output Wiring
The outputs are wired as shown below. On the top connector, the first two outputs have their own separate common
connections. The 14 other outputs use common COM2. The bottom connector with 16 contacts uses common COM3
for its supply voltages.
The wiring diagram shows DC and AC voltages on a single card. But in actual practice, the card could be wired for
all DC or all AC or any other combination of the two.
Old notation New notation M
OUT 0 O 00.0 1
COM 0 COM 0 2
M
OUT 1 O 00.1 3
COM 1 COM 1 4
OUT 2 O 00.2 5 M
OUT 3 O 00.3 6

For use with AC voltage

OUT 4 O 00.4 7
OUT 5 O 00.5 8
OUT 6 O 00.6 9
LOCK LOCK 10
OUT 7 O 00.7 11
OUT 8 O 01.0 12 24 VAC
OUT 9 O 01.1 13 48 VAC
110 VAC
OUT A O 01.2 14 230 VAC
OUT B O 01.3 15
OUT C O 01.4 16
OUT D O 01.5 17
OUT E O 01.6 18
OUT F O 01.7 19

COM 2 COM 2 1
OUT 10 O 02.0 2 M
OUT 11 O 02.1 3
OUT 12 O 02.2 4
OUT 13 O 02.3 5
OUT 14 O 02.4 6
For use with DC voltage

OUT 15 O 02.5 7
OUT 16 O 02.6 8
OUT 17 O 02.7 9 -
24 VDC
LOCK LOCK 10 48 VDC +
OUT 18 O 03.0 11
OUT 19 O 03.1 12
OUT 1A O 03.2 13
OUT 1B O 03.3 14
OUT 1C O 03.4 15
OUT 1D O 03.5 16
OUT 1E O 03.6 17
OUT 1F O 03.7 18
COM 3 COM 3 19

Trelec 18-contact
connectors
+ locking system

7-8 en-938979/0
Input/Output Cards

7.3.2 Replacing the Card

With the exception of the fuses, these cards do not include any components that can be replaced by the user. Always
check the fuses first, before deciding the card is faulty. There are two fuses, one for each group of 16 outputs.
If after checking the fuses, the card is determined to be faulty, replace the complete card.
Before beginning, make sure a replacement card is available.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card. The terminal strips are ganged and attached by a single screw.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
5. Install the card in the rack and moderately tighten the attaching screws.
6. Reinstall all the connections removed above.
7. Power up the machine, then the CNC.

en-938979/0 7-9
7.4 32-Input/24-Output Card (with Sub.D connectors)
The 32-input/24-output card has two sub.D connectors on the front plate separated
by a two-contact power supply connector, which can be used for connection of an
external power supply. This type of card can be used with input and relayed output
interface panels to allow external wiring of the inputs and outputs, or the inputs and
outputs can be directly connected to the sub.D connectors. Like all input/output
cards, these cards assume the address of the slot where they are located.
Outputs
Inputs
32 inputs
O 00.0 to O 00.7 Input voltage 15-30 VDC
24 S
O 01.0 to O 01.7 Maximum current rating per input 30 mA
O 02.0 to O 02.7 Low input level (logic 0) 0-5 VDC
High input level (logic 1) 11-30 VDC
Logic Positive (sink)

Outputs
24 open-collector outputs 1 group of 16 and 1 group of 8
Output voltage 15-30 VDC (external power supply
required)
24 VEE Maximum current rating per output 30 mA to interface panel 250 mA to
0VE
another load 3 A for t < 10 µs
Overload protection Thermal with trip
Clipping and discharge diode
Inputs Reverse-biased parallel diode

I 00.0 to I 00.7
32 E I 01.0 to I 01.7
I 02.0 to I 02.7
I 03.0 to I 03.7

32 E / 24 S

7 - 10 en-938979/0
Input/Output Cards

7.4.1 Input Wiring

The inputs are wired as shown below

I 00.0 1
I 00.1 20
I 00.2 2
I 00.3 21
I 00.4 3
I 00.5 22
I 00.6 4
I 00.7 23
COMMON 5
I 01.0 24
I 01.1 6
I 01.2 25
I 01.3 7
I 01.4 26
I 01.5 8
I 01.6 27 + -
I 01.7 9
COMMON 28
24 VDC
I 02.0
I 02.1
29
11 7
I 02.2 30
I 02.3 12
I 02.4 31
I 02.5 13
I 02.6 32
I 02.7 14
COMMON 33
I 03.0 15
I 03.1 34
I 03.2 16
I 03.3 35
I 03.4 17
I 03.5 36
I 03.6 18
I 03.7 37
COMMON 19
24 VE 10

en-938979/0 7 - 11
7.4.2 Output Wiring
The outputs are wired as shown below.

24 VS.0 19
O 00.0 37
O 00.1 18
O 00.2 36
O 00.3 17
O 00.4 35
O 00.5 16
COMMON 34 +
O 00.6 33 24 VDC
-
COMMON 14
O 00.7 32
O 01.0 13
O 01.1 31
O 01.2 12
O 01.3 30
O 01.4 28
COMMON 9
O 01.5 8
O 01.6 5
O 01.7 7
O 02.0 4
O 02.1 25
O 02.2 24
O 02.3 20
O 02.4 21
O 02.5 22
O 02.6 23
O 02.7 1
24 VS.1 2 +
24 VDC -
COMMON 3

7 - 12 en-938979/0
Input/Output Cards

7.4.3 External Power Connector

The external power connector is wired as shown opposite. Connect an 0V
external power supply to this connector to supply the output levels and
24 V
input commons.

7.4.4 Replacing the Card

These cards do not include any components that can be replaced by the user. In case of a fault, replace the complete
card.
Before beginning, make sure a replacement card is available.
1. Power down the CNC system and the machine.
2. Remove all the connections from the card. The terminal strips are ganged and attached by a single screw.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
5. Install the card in the rack and moderately tighten the attaching screws.
6. Reinstall all the connections removed above.
7. Power up the machine, then the CNC.

en-938979/0 7 - 13
7.5 32-24 I/O Card (with high density connectors)
The 32-24 I/O card includes two high density connectors on the front plate. This type
of card must be used with input and relayed output interface panels to allow external
24.O
wiring. Like all input/output cards, these cards assume the address of the slot where
they are located.
The connections to the interface panels are made via cables supplied by NUM fitted
with connectors at both ends and available in lengths of 1 m and 2 m. Since these
cables are already terminated, the pinout is not given.
Outputs
Refer to the sections on interface panels for more information on the connectors..
O 00.0 to O 00.7
7.5.1 Replacing the Card
O 01.0 to O 01.7
O 02.0 to O 02.7 These cards do not include any components that can be replaced by the user. In case
of a fault, replace the complete card.
Before beginning, make sure a replacement card is available.
32.I 1. Power down the CNC system and the machine.
2. Remove all the connections from the card. The terminal strips are ganged and
attached by a single screw.
3. Loosen the two card attaching screws, one at the top and one at the bottom.
4. Gently pull out the card to unplug it from the rack.
Inputs 5. Install the card in the rack and moderately tighten the attaching screws.
6. Reinstall all the connections removed above.
I 00.0 to I 00.7 7. Power up the machine, then the CNC.
I 01.0 to I 01.7
I 02.0 to I 02.7
I 03.0 to I 03.7

32.I / 24.O

7 - 14 en-938979/0
Input/Output Cards

7.6 64-48 I/O Card (with high density connectors)

The 64-48 I/O card includes two high density connectors on the front plate. This type
of card must be used with input and relayed output interface panels to allow external
48.O
Outputs wiring. Like all input/output cards, these cards assume the address of the slot where
they are located.
O 03.0 to O 03.7 The connections to the interface panels are made via cables supplied by NUM fitted
O 04.0 to O 04.7 with connectors at both ends and available in lengths of 1 m and 2 m. Since these
O 05.0 to O 05.7 cables are already terminated, the pinout is not given.
Refer to the sections on interface panels for more information on the connectors.
O 00.0 to O 00.7 7.6.1 Replacing the Card
O 01.0 to O 01.7
O 02.0 to O 02.7 These cards do not include any components that can be replaced by the user. In case
of a fault, replace the complete card.
Before beginning, make sure a replacement card is available.
64.I Inputs 1. Power down the CNC system and the machine.
2. Remove all the connections from the card. The terminal strips are ganged and
I 04.0 to I 04.7 attached by a single screw.
I 05.0 to I 05.7 3. Loosen the two card attaching screws, one at the top and one at the bottom.
I 06.0 to I 06.7 4. Gently pull out the card to unplug it from the rack.
I 07.0 to I 07.7 5. Install the card in the rack and moderately tighten the attaching screws.
6. Reinstall all the connections removed above.
7
I 00.0 to I 00.7 7. Power up the machine, then the CNC.
I 01.0 to I 01.7
I 02.0 to I 02.7
I 03.0 to I 03.7

64.I / 48.O

en-938979/0 7 - 15
7.7 32-Input Interface Panel
The input interface panel facilitates field wiring of the machine. The panel is equipped with three rows of terminals.
The first row contains the inputs, the second the +24 VDC bus and the third the 0V bus.

24 VDC

Power supply wiring

MOD. INTERFACE 32 E
COM +AL

E1F
E00

3-wire PNP
Input wiring Input = Exx
type sensor
Power supply = Lxx
Common = Cxx

xx = input number (00 to 1F)

7.7.1 Replacing the Panel

No settings are required when replacing the interface panel. Refer to Installation and Commissioning Manual 938816
for further details.

7 - 16 en-938979/0
Input/Output Cards

7.8 24-Output Relay Panel

The output relay panel facilitates field wiring of the machine. The panel is equipped with two rows of terminals. The
first row contains the direct and complemented outputs and the second the power supply for each output. This panel
is equipped with relays which are switched by the output from the CNC. Each relay can have different voltages wired
across its terminals. The relays are designed to be readily removable for replacement.

MOD. RELAYAGE 24 S
X17 X18 X19
S00

S17
Output wiring

xx4 xx2
Complemented output/Sxx 7
Output Sxx
xx1 xx1
Common xx
xx = output number (00 to 17)

7.8.1 Replacing the Panel

When replacing a panel, there are three jumpers to be set: X17, X18 and X19, located near the top edge of the panel.
Make sure the jumpers are in exactly the same location on the new panel. Refer to Installation and Commissioning
Manual 938816 for further details.

en-938979/0 7 - 17
7 - 18 en-938979/0
IT/Serial Line Card

8 IT/Serial Line Card

The IT/serial line card is connected to the system bus. It processes external interrupts (four 5 V or 24 V inputs) and
four multiprotocol serial lines (RS232, RS422 and RS485). A maximum of two IT/serial line cards can be installed in
a given system.
Note: This card must be installed just after the CNC cards to operate correctly.
No special adjustments are required for replacing this card. However, the serial line settings may have to be adapted
to the protocol used.
The card part number is 204203370. A simplified version which only processes interrupt inputs is also available. Its
part number is 204202371.
The interrupt wiring is as follows

1 2
Solder

5
9

6 1

1 - 9-contact male Sub.D connector plug

8
2 - Four shielded twisted pair cables (cross-sectional area 0,22 mm2)

INPUT 0 : 5 V 1
INPUT 0 : 24 V 2
24 V 5V
Protective earth
INPUT 1 : 5 V 3
INPUT 1 : 24 V 4
24 V 5V
COMMON 5
Protective earth
INPUT 2 : 5 V 6
INPUT 2 : 24 V 7
24 V 5V
Protective earth
INPUT 3 : 5 V 8
INPUT 3 : 24 V 9
24 V 5V

Protective earth
PROTECTIVE CONNEC-
EARTH TOR
SHELL

en-938979/0 8-1
All the interrupt signals must be sent via shielded cables.
The serial interfaces are wired according to one of the following diagrams

RS232 Serial Interface Cable

This cable can be adapted to suit the peripheral device by not wiring the signals that are not going to be used and by
using an appropriate cinnector (see peripheral manual).

Solder side 1 2 3

13
25
8
15
5
9

6 1
9
1
14
1

9 contacts 15 contacts 25 contacts

1 - Male Sub.D connector plug:

- 25 contacts on machine processor, CNC processor and UC SII CPU
- 15 contacts on IT/serial line card
- 9 contacts on the V2 machine processor, V2 CNC processor and
UC SII CPU
2 - Shielded cable depending on the peripheral device (2 twisted pairs and
4 conductors for complete connection, minimum size 0.2 mm2)
3 - Connector plug depending on the peripheral device
15 contacts

25 contacts
9 contacts
Sub.D

Sub.D

TD 3 1 2 RD
GND 5 7 7 GND

RD 2 3 3 TD
RTS 7 12 4 CTS
CTS 8 5 5 RTS
DTR 4∗ 14 20 DSR
DSR 6∗ 6 6 DTR
DCD 1∗ 13 8 DCD

PROTECTIVE CONNECTOR CONNEC- PROTECTIVE

EARTH SHELL TOR EARTH
SHELL

∗ Contacts 1, 4 and 6 are not wired on 9-contact connectors of the V2 machine processor and V2 CNC processor.

8-2 en-938979/0
IT/Serial Line Card

RS422 Serial Interface and High-Speed Cable

1 2 3
Solder side

8
15
5
9

6 1
9
1

9 contacts 15 contacts

1 - Male Sub.D connector:

- 15 contacts on IT/serial line card and high-speed
line of V2 CNC processor
- 9 contacts on the V2 machine processor and
V2 CNC processor
2 - Shielding twisted 2-pairs and one isolated wire
3 - Sub.D connector plug depending on the application
15 contacts
9 contacts
Sub.D

Sub.D

T(A) + 9 2 R(A) + 8
T(B) - 4 9 R(B) -
R(A) + 6 4 T(A) +
R(B) - 1 11 T(B) -
0V 5 7 0V

PROTECTIVE CONNECTOR CONNEC- PROTECTIVE

EARTH SHELL TOR EARTH
SHELL

en-938979/0 8-3
RS485 Serial Interface Cable

1 2 3
Solder side

8
15
5
9

6 1
9
1

9 contacts 15 contacts

1 - Male Sub.D connector:

- 15 contacts on IT/serial line card
- 9 contacts on the V2 machine processor and V2 CNC processor
2 - Shielding twisted 2-pairs and one isolated wire
3 - Sub.D connector plug depending on the application
15 contacts
9 contacts
Sub.D

Sub.D

T(A) + 9 2 R(A) / T(A) +

T(B) - 4 9 R(B) / T(B) -
R(A) + 6 4
R(B) - 1 11
0V 5 7 0V

PROTECTIVE CONNECTOR CONNEC- PROTECTIVE

EARTH SHELL TOR EARTH
SHELL

8-4 en-938979/0
Analogue Input/Output Card

9 Analogue Input/Output Card

This card processes 8 analogue inputs and 8 analogue outputs at +/-10 V with a resolution of 12 bits. It can be
configured by the machine processor application for:
- 8 inputs or 1 input (faster conversion)
- Gain of 1 or gain of 10 for each input.
No special adjustments are required for replacing this card. This card must be installed just after the CNC cards to
operate correctly.
The card part number is 204202613.
The card must be connected using shielded cables. The cable wiring is shown in the diagram below:

E1- 1
REFERENCE
E1+ 2
EARTH 3
E2- 15
REFERENCE
E2+ 16
EARTH 14
E3- 4
REFERENCE
E3+ 5
EARTH 6
E4- 18
REFERENCE
E4+ 19
EARTH 17
E5- 7
REFERENCE
E5+ 8
EARTH 9
E6- 21
E6+ 22 REFERENCE
EARTH
E7-
20
10
9
E7+ 11 REFERENCE
EARTH 12
E8- 24
E8+ 25 REFERENCE
EARTH 23
EARTH CONNECTED 13
TO THE COVER

en-938979/0 9-1
9-2 en-938979/0
Remote Input/Output Modules

10 Remote Input/Output Modules

10.1 Introduction 10 - 3
10.1.1 General 10 - 3
10.1.2 Module Connection to the CNC 10 - 4
10.2 Diagnostics and Maintenance 10 - 5
10.2.1 Block Diagram of a Remote I/O Module 10 - 5
10.2.2 Power Supply Faults 10 - 6
10.2.3 Fibre-Optic Ring Fault 10 - 6
10.2.4 Address Fault 10 - 6
10.2.5 Input or Output Stage Fault 10 - 6
10.3 Replacement 10 - 7
10.3.1 Setting the Output Power 10 - 7
10.3.2 Programming 10 - 8
10.3.2.1 Module Addressing 10 - 8

en-938979/0 10 - 1
10 - 2 en-938979/0
Remote Input/Output Modules

10.1 Introduction
10.1.1 General
The remote input/output modules are designed to complete the line of input/output devices supplied by NUM. They
are wired to the SBC fibre-optic bus to allow the inputs and outputs to be located as close as possible to the sensors
and actuators.
The following types of modules are available:
- 24 VDC 16-input module
- 24 VDC 16-input/24 VDC 0.5 A 16-output module
- 8-input/2 A 8-output relay module, and
- 4-input/2-output analogue module.
These modules can be used with the following equipment:

CNC type Limitation Comments

NUM 1060 Series 1 Maximum 32 modules (*) Maximum 4x4I/2O analogue
modules
NUM PCNC 1060 Series 1 Maximum 32 modules (*) Maximum 4x4I/2O analogue
modules
NUM 1060 Series 2 Maximum 336 I/O Maximum 2 machine panels in
(2-processor CPU) (integrated I/O + remote I/O) addition
Maximum 2x4I/2O analogue
modules in addition
NUM 1060 Seires 2 Maximum 336 I/O Maximum 2 machine panels in
(UCSII CPU) (integrated I/O + remote I/O) addition
4I/2O analogue modules not
allowed
NUM PCNC 1060 Series 2 Maximum 336 I/O Maximum 2 machine panels in
(integrated I/O + remote I/O) addition
4I/2O analogue modules not
allowed
NUM 1050 Maximum 336 I/O Maximum 2 machine panels in
(integrated I/O + remote I/O) addition
Maximum 2x4I/2O analogue
modules in addition
NUM 1040 Maximum 256 I/O Maximum 2 machine panels
(integrated I/O + remote I/O) in addition
Maximum 2x4I/2O analogue
modules in addition
(*) With CNC software at index K and above (this number is limited to 16 for the CNC software at index J).

! CAUTION

The use of the 4-input/2-output analogue modules requires CNC software at

index MA or above.

en-938979/0 10 - 3
10.1.2 Module Connection to the CNC
The modules are inserted in the fibre-optic ring of the PLC serial bus.

Machine panel NUM 1040 NUM 1060

Reset

L2
L1 L3
Def Pwr
Fail

S C
R e o
e r m
c i
a 1
l

E I

or
m t
/
A
n
a

Fibre-optic bus

32 E 32 S 32 E 32 S 32 E 32 S Proc. PC Axes Axes Axes Axes Mem Proc Mach Proc CN Alim

Axis

P
a
n
e
l

Remote input/output modules

! CAUTION

The maximum distance between two units is 40 metres.

10 - 4 en-938979/0
Remote Input/Output Modules

10.2 Diagnostics and Maintenance

10.2.1 Block Diagram of a Remote I/O Module
The internal structure of a remote I/O module can be schematically represented by the three functional subassemblies
illustrated below.
Reception Fibre-optic ring Transmission

Address
R E

Module power
Communication
supply (M,UM)
interface

Sensor power Output power

supply (M,UE) Input stages Output stages supply (M,US)

LEDs

LED status during normal operation.

RDY
BA
BC

Communication LEDs
Green LED RDY: Ready
ON: Module ready for communication
OFF: Module faulty (initialisation impossible)
Green LED BA: Bus Activity
ON: The module is receiving frames
OFF: No frames
When the PLC is not in RUN mode, the BA LED is unlit.
Red LED BC: Bus Connection
ON: Fibre-optic cable cut or connection fault with the previous module
OFF: Connection OK

en-938979/0 10 - 5
Faults can be classified in the following categories:
- Power supply faults
- Fault on the fibre-optic ring
- Address fault
- Input or output stage fault.

10.2.2 Power Supply Faults

To operate correctly, a remote I/O module requires presence of 24 VDC power supply for:
- The internal module logic (M,UM)
- The sensors wired to the inputs
- The output stages.
The presence of each of these power supplies is indicated by a green LED.
Failure of the power supply of a module causes a break in the fibre-optic ring, a watchdog timeout and sets the general
link fault bit (DEFBUS %R97F.0).
Failure of the power supply of the sensors and/or the output stages is not detected or indicated by the PLC. It results
in malfunctioning of the automatic control system, since the state of the inputs and/or outputs is no longer
representative of reality.
REMARK To enhance safety and availability of the automatic control system, it is
recommended to wire these voltages to inputs that can be continuously monitored
by the PLC programme.
10.2.3 Fibre-Optic Ring Fault
A break in the fibre-optic ring causing a loss of data frames is immediately detected by the PLC, causes a watchdog
timeout and sets the general link fault bit (DEFBUS %R97F.0).
The fibre-optic ring continuity fault can be located as follows:
- Search for the module on which the red BC LED is lit
- On this module, check that:
- The reception fibre-optic cable (marked Rx) is correctly connected
- The fibre-optic cable connecting it to the previous module is not damaged.
- On the previous module, check that:
- It is correctly supplied
- The transmission fibre-optic cable (marked Tx) is correctly connected
- The output power setting switches are correctly set.

10.2.4 Address Fault

It is necessary to make sure that the addresses set on the remote I/O module effectively correspond to the addresses
of the I/O variables used in the PLC programme.
When two I/O modules have the same address, the general link fault bit (DEFBUS %R97F.0) is set and a watchdog
timeout occurs.

10.2.5 Input or Output Stage Fault

A fault on an input or output stage is not detected and results in malfunctioning of the automatic control system.
On the 16-input/16-output static I/O module, each shorted output is indicated by a red LED and a status word %Irc3C.W
(1 bit per group of 8 outputs).

10 - 6 en-938979/0
Remote Input/Output Modules

10.3 Replacement
The replacement of these modules does not present any problems as they are software-configured. However, the
fibre-optic cable power requires adjustment, and the address of the relevant module needs to be set by means of the
"Cable length" and "Address bus" switch units which must be positionned as on the former module.

10.3.1 Setting the Output Power

The modules includes three switches used to set the output power according to the length of the fibre-optic cable.

Rear view:

- 24 VDC 16-input module

- 24 VDC 16-input/24 VDC 0.5 A 16-output module
- 8-input/2 A 8-output relay module

TX Cable length Address Bus RX

Switches
1 2 3
OFF=0
ON=1

Rear view:

- 4-input/2-output analogue module

TX Cable length Address Bus RX

Switches
1 2 3
OFF=0
ON=1

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Switch setting Fibre-optic cable length (in metres)
Switch 1 Switch 2 Switch 3
ON OFF OFF 0 < length < 15 m
OFF ON OFF 15 <= length < 30 m
OFF OFF ON 30 <= length <= 40 m

10.3.2 Programming
The remote discrete I/O modules must be used with CNC software at index J or above.
The remote analogue I/O modules must be used with CNC software at index MA or above.

10.3.2.1 Module Addressing

As is the case for the racks used in the PLC serial bus ring, it is necessary to define a geographical address for each
remote I/O module used.
The module address is specified by assigning it a rack number and a card number. It is set on the 7 address bits, A0
to A6:
- A0 to A3: for the card number (0 to $F)
- A4 to A6: for the rack number (4 to 5).
Address bits A6 and A5 are internally set to high and low logic levels respectively. This means that the address field
is limited to a maximum of 32 modules with a base address equal to $40. The first module has address $40 (rack 4,
board 0) and the last has address $5F (rack 5, board F).
The module address is thus set on address bits A0 to A4 using the five address switches at the rear of the module.

Rear view:
- 24 VDC 16-input module
- 24 VDC 16-input/24 VDC 0.5 A 16-output module
- 8-input/2 A 8-output relay module

TX Cable length Address Bus RX

Switches
1 2 3 4 5
OFF=0
1 0 ON=1
A A A A A A A
Address bits
6 5 4 3 2 1 0

Rack No. Card No.

In the example above, the module address is $41.

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Remote Input/Output Modules

Rear view:
- 4-input/2-output analogue module

TX Cable length Address Bus RX

Switches
1 2 3 4 5

OFF=0
1 0 ON=1
A A A A A A A
Address bits
6 5 4 3 2 1 0

Rack No. Card No.

In the example above, the module address is $5E.

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Module Address Table

Switches Module address

Switch 1 Switch 2 Switch 3 Switch 4 Switch 5

OFF OFF OFF OFF OFF $40
OFF OFF OFF OFF ON $41
OFF OFF OFF ON OFF $42
OFF OFF OFF ON ON $43
OFF OFF ON OFF OFF $44
OFF OFF ON OFF ON $45
OFF OFF ON ON OFF $46
OFF OFF ON ON ON $47
OFF ON OFF OFF OFF $48
OFF ON OFF OFF ON $49
OFF ON OFF ON OFF $4A
OFF ON OFF ON ON $4B
OFF ON ON OFF OFF $4C
OFF ON ON OFF ON $4D
OFF ON ON ON OFF $4E
OFF ON ON ON ON $4F
ON OFF OFF OFF OFF $50
ON OFF OFF OFF ON $51
ON OFF OFF ON OFF $52
ON OFF OFF ON ON $53
ON OFF ON OFF OFF $54
ON OFF ON OFF ON $55
ON OFF ON ON OFF $56
ON OFF ON ON ON $57
ON ON OFF OFF OFF $58
ON ON OFF OFF ON $59
ON ON OFF ON OFF $5A
ON ON OFF ON ON $5B
ON ON ON OFF OFF $5C
ON ON ON OFF ON $5D
ON ON ON ON OFF $5E
ON ON ON ON ON $5F

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Racks

11 Racks

11.1 Rack Addressing 11 - 3

11.2 EEPROM Chips 11 - 3
11.3 Temperature Sensor 11 - 3
11.4 Power Connections 11 - 4
11.5 Replacing a Rack 11 - 4

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11 - 2 en-938979/0
Racks

The main rack is not just a passive device. It includes some active components connected to the backplane bus. It
is necessary to set the address of the main rack.

11.1 Rack Addressing Thumwheel Thumwheel

Racking numbering is a little tricky because the

rack address differs according as the fibre-optic 01
ring is present or absent. 2
The table below shows the correct addressing. It 54 3
should be noted that the logical addresses are
not the same as the physical addresses. Always
set the physical address, on the rack thumbwheel.
Main racks and 12-slot 2-slot extension rack
extension racks

Device Logical rack Physical rack Physical rack

address address with address without
fibre-optic ring fibre-optic ring
Main rack 0 7 0
Extension racks 1-7 0-6 N/A
Machine panels 0 0-3 N/A

11.2 EEPROM Chips

The EEPROM chip on the backplane contains the CNC customisation data, i.e. the settings of the machine parameters
and the options selected by the OEM. This chip is not removable! Always back up the data it contains before replacing
the rack.

! CAUTION
The rack contains essential data. Do not replace the rack without checking with NUM
technical support.

The data contained in the EEPROM can be partially recovered. The machine parameters can be backed up by a
maintenance technician, but not the customisation data. It is therefore necessary to obtain a new customisation for
11
the spare rack in order for the machine to operate correctly. Among these data are the Affaire Number, mentioned
in Chapter 1. The other information concerns the maximum number of axes and spindles, as well as the basic and
extra software options, the memory sizes, etc.

11.3 Temperature Sensor

There is a temperature sensor mounted in the fan housing just above the power supply. This sensor is designed to
detect overheating of the power supply. It is normally wired to a PLC input and monitored by the PLC. It is a simple
thermistor and can be checked by an ohmmeter if it seems faulty or is open. The sensor resistance increase with
temperature until it looks like an open circuit to the PLC input.

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11.4 Power Connections
The rack is powered by 220 VAC single phase. The power cable is connected to the receptacle located in the upper
left-hand corner of the rack, which is fitted with a small fuse. If the fuse blows, the fans located in the top of the rack
are stopped. In case of a problem, the power supply is probably not faulty if the fans are running, but the voltage should
be checked. Use a small screwdriver to pry the fuse-holder out of the receptacle. Refer to Section 3.1 for further details
on the power supply.

11.5 Replacing a Rack

Always check with NUM technical support before attempting to replace a rack. Also read Section 11.2, EEPROM
Chips, and back up the machine parameters.
1. Power down the machine and the CNC system
2. Unplug all the cables from the cards in the rack and from the rack itself, marking each cable with the name of the
connector it came from!
3. Unscrew the rack equipped with all its cards as a single unit.
4. Set the old rack next to the new rack on a workbench. Gently remove each card from the old rack and insert it
in the new one, starting with the power supply on the right-hand side and working leftward. Always hold the cards
by the edges and be careful not to touch the surface.
5. Install the new rack in the cabinet.
6. Reconnect all the cables disconnected in step 2. Use the marks made when disconnecting the cables to ensure
that each cable is reconnected to the right connector. This is a very critical step!
7. Power up the CNC but do not attempt to take the system out of Emergency Stop.
8 Follow the procedure for checking or entering a new customisation and restore the machine parameters, referring
to the appropriate sections.
9. Once the parameters have been loaded and customisation confirmed, the system is ready to operate.

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Machine Panel

12 Machine Panel

12.1 Connections 12 - 3
12.1.1 Machine Panel Extension 12 - 4
12.2 Fibre-Optic Power Settings 12 - 5
12.3 Address Settings 12 - 5
12.4 Troubleshooting 12 - 6
12.5 Replacing a Machine Panel 12 - 6

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12 - 2 en-938979/0
Machine Panel

This chapter covers diagnosis and replacement of the machine panel with fibre-optic ring.

X 1 10 100 1000 10000 ILL X

Y M01

Z Y+ 5+ Z+ Z

4 X- X+ 4+ 4-

5 Y- 5- Z-

CYCLE
START

CYCLE
STOP

12.1 Connections
The machine panel is powered by 24 VDC. It communicates with the CNC via a serial fibre-optic field bus. On the
diagram the fibre-optic cables are marked Tx for transmit and Rx for receive. If a handwheel is present, it is hardwired
to an analogue or QVN axis port. The E-STOP (emergency stop) button is hardwired to the machine E-STOP circuit
and the sub.D connector to one of the CNC’s communication ports.
All the output signals are sent back to the CNC via the fibre-optic ring except those from the handwheel, E-STOP button
and sub.D connector.
4 5
Customer
24 VDC safety
external chain
power supply
Minimum curve radius: 6
50 mm

Tx
Rx

Rx Tx
12
3 2 1 7

11 - Transmitter of the previous unit

2 - Fibre-optic cable
3 - Receiver of the next unit
4 - Power supply cable
5 - Handwheel cable
6 - Emergency stop cable (P/N XB2-BS542)
7 - Relay cable of a serial line:
- RS 232
- RS 422 or 485
Figure 13: Rear view of the machine panel
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12.1.1 Machine Panel Extension
Certain machine panels are fitted with an extension at the rear giving access to 32 inputs and 24 outputs. These inputs
and outputs can be used to connect additional pushbuttons and indicator lights to the operator panel.
The extension includes additional connections which it is necessary to be aware of. The inputs and outputs are
connected in the same way as on the 32-input/24-output panel with sub.D connector. Refer to the wiring diagram of
this connector.

Rear of the machine panel

Input
(pushbuttons)
1

External
power supply
24 VDC

External
power supply
24 VDC Outputs
(indicator
External 2
lights)
power supply
24 VDC

1 - 24-output cable with or without power supply

2 - Power cable (only when the general power supply is not
provided by the input or output cable
3 - 32-input cable with or without general power supply

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Machine Panel

12.2 Fibre-Optic Power Settings

The machine panel fibre-optic ring transmit power must be set according to the cable length.

3
2
ON

Fibre-optic cable length Switch 3 Switch 2 Switch 1

L ≤ 15 m ON OFF OFF
15 m ≤ 30 m OFF ON OFF
L > 30 m OFF OFF ON

12.3 Address Settings 12

Up to four machine panels can be connected to each fibre-optic ring. The address of each panel must be set on the
thumbwheel located next to the optical power switches. The thumbwheel has ten possible settings numbered from
0 to 9, but the only legal settings are 0 to 3. For instance, if there is only one machine panel, its address must be set
to 0. If there are two panels, the addresses must be 0 and 1 and so forth up to a total of four panels.

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12.4 Troubleshooting
There is very little troubleshooting to be done on a machine panel. If a panel is thought to be faulty, proceed as shown
in the table below.

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

An LED or pushbutton is Function inhibited by the PLC Check the PLC variables; refer to
inoperative I/O troubleshooting
Pushbutton or LED defective Replace the machine panel
No LEDs or pushbuttons Loss of 24 VDC input power Check the 24 VDC input to the
are operative panel
Loss of fibre-optic signals Broken fibre-optic cable, incorrect
power settings or defective panel
Wrong address Check the address set on the panel

12.5 Replacing a Machine Panel

Proceed as follows to replace the machine panel.
1. Power down the machine and the CNC.
2. Disconnect all the cables from the rear of the machine panel. Carefully note down on each fibre-optic cable the
port to which it is connected (sometimes the cables are not marked by the OEM).
REMARK The 24 VDC wires are connected to a special type of terminal rail, without screws.
The wires are inserted in holes with special clamping mechanisms. To release a
clamp, insert a small screwdriver in the slot directly above where the wire enters
the terminal.
3. Remove the four panel attaching screws and remove the panel.
4. Set the removed panel on a workbench next to the replacement panel and check that the power settings on the
two panels are the same.
5. Install the new panel and screw down the attaching screws.
6. Reconnect all the wires and fibre-optic cables, being careful to connect them correctly, especially the fibre-optic
cables, which it is very easy to connect to the wrong port.
7. Power up the machine, then the CNC. Test the new machine panel.

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Software

13 Software

13.1 Selecting the CNC Serial Port 13 - 3

13.1.1 Configuring the Serial Ports 13 - 4
13.1.2 Configuring the Port for the NUMCOM
Software 13 - 5
13.1.3 Selecting an Existing Configuration 13 - 5
13.2 CNC Software Backup Methods 13 - 6
13.3 NUMCOM 13 - 8
13.3.1 Communication Cable 13 - 8
13.4 Part Programme (Zone 0) Backup/Restore 13 - 9
13.4.1 Backup (Upload) One or
All Programme(s) 13 - 9
13.4.2 Restore (Download) One or
All Programmes 13 - 10
13.5 Part Programme Backup/Restore in Zone 1, 2 or 3 13 - 11
13.5.1 Backup (Upload) a Protected
Memory Zone 13 - 11
13.5.2 Restore (Download) a Protected
Memory Area 13 - 12
13.6 Tool Offset Backup/Restore 13 - 13
13.6.1 Backup Tool Offsets 13 - 13
13.6.2 Restore (Download) Tool Offsets 13 - 13
13.7 Parameter File Backup/Restore 13 - 14
13.7.1 Backup (Upload) Parameters 13 - 14
13.7.2 Restore (Download) Parameters 13 - 15
13.8 PLC File Backup/Restore 13 - 16
13.8.1 Backup (Upload) PLC Files 13 - 16
13.8.2 Restore (Download) PLC files 13 - 17
13.9 Axis Calibration File Backup/Restore 13 - 18
13.9.1 Backup (Upload) Calibration Data 13 - 18
13.9.2 Restore (Download) Calibration Data 13 - 19

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13 - 2 en-938979/0
Software

This chapter is devoted to the operation, backup/restore functions and diagnostic tools available to the maintenance
personnel through NUM software and the MMI.

13.1 Selecting the CNC Serial Port

Before beginning communications, it is necessary to check that the serial line parameters are correctly set for the
backup and restore functions. There are many ways of configuring the serial ports on the NUM 1060 CNCs. The OEM
has a choice of several possible types of connection and configuration schemes. Since the number of possible
combinations is large, this manual covers only the most common cases. For other cases, contact NUM customer
support or the OEM for assistance.
The table below shows the recommended primary and secondary port choices for each of the three CNC types. If the
primary port is available, select it. Otherwise, choose the secondary port.

PREFERRED SERIAL PORT CHOICES

and line (port) numbers
PORT 1060 UCSII 1060 SII 1060 SI
COMM1 Primary
(line 0)
COMM2 Secondary
(line 1)
SERIE (line 0) (line 0)
RS232C Primary Secondary
(line 1) (line 1)
DNC (line 2)
Periph Primary
(line 3)

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13.1.1 Configuring the Serial Ports
Each port is configured from the operator panel. Proceed as follows to access the configuration page:
1. Press softkey F11 (UTIL)
2. Select option 1, Serial Line Parameters, then press ENTER.
The SERIAL LINE PARAMETERS page is displayed.

SERIAL LINE PARAMETERS

Line number................................ Line 3

Standard................................... RS232
Input speed (Bds).......................... 9600
Output speed (Bds)......................... 9600
Number of start bits....................... 1
Number of data bits........................ 8
Number of stop bits........................ 1
Parity..................................... None
Protocol................................... None
Flow control............................... None
Logical name............................... HARDCOPY

Configuration 1/12 ACCEPT

Prev. Next
config config EXIT

Figure 14: Serial Line Parameters page

Each port can have multiple configurations. This aim is to allow different devices to be connected to the same port,
simply by changing the software configuration. There are a maximum of 12 different configurations for each port. The
12 parameters listed below must be set for each configuration. The possible choices are displayed in the softkeys at
the bottom of the screen.
Line Number Number of the line (port) to be configured. Use the Prev Line and Next Line keys
to change the setting of this field.
Standard Communication standard to be used on the port. Select RS232, RS485 or RS422 by
pressing the appropriate softkey
Input Speed (Bds) Reception speed in bauds: 600, 1200, 2400, 4800, 9600, 19200 or 38400
Output Speed (Bds) Transmission speed in bauds: 600, 1200, 2400, 4800, 9600, 19200 or 38400
Number of start bits 0 or 1
Number of data bits 5, 6, 7 or 8
Number of stop bits 0, 1, 1.5 or 2
Parity None, Even or Odd
Protocol None, DNC1, Kermit or CMP
Flow Control None, RTS/CTS or Xon/Xoff
Logical Name Hardcopy, Mess $5, Mess $6 or Other Name. The Other Name softkey allows entry
of a user-defined name. A name like Tape or Punch or PC could be appropriate, to
facilitate recognition of the port function
Configuration x/12 Accept to confirm the settings or Reject to abort the process.
After setting a configuration, exit from the pages by F11 (EXIT).

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Software

13.1.2 Configuring the Port for the NUMCOM Software

NUMCOM is a public domain programme relatively widespread among NUM CNC users. It runs under DOS. It is used
to upload and download files via a serial interface. Other applications, such as NUMPC, are available from the NUM
network.
In order for NUMCOM to operate correctly, set the port as follows:
Line Number Free choice; see Sec. 13.1.
Standard RS232
Input Speed (Bds) 9600
Output Speed (Bds) 9600
Number of start bits 1
Number of data bits 8
Number of stop bits 1
Parity None
Protocol None
Flow Control RTS/CTS
Logical Name Free choice, but COMM1 is recommended
Configuration x/12 Accept

13.1.3 Selecting an Existing Configuration

Before data upload from or download to the CNC, select a port using the left or right arrow keys. Refer to the screen
below:

CN UTILITY

> 0 ACCESS TO UTILITY PROGRAMMES

1 SERIAL LINE PARAMETERS
2 COLOR PALETTE CHANGES
3 MACHINE BACKUP
4 SET DATE AND TIME
5 BATTERY MANAGEMENT

LINE ( ) : COMM1

?❙

This message appears on each upload/download page, to allow selection of a configuration before beginning. 13

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13.2 CNC Software Backup Methods
Several software packages are available for editing, backing up and restoring system files. The table below shows
the possibilities available for each type of file.

Backup/Restore and Editing Method

File type NUMCOM PLCTool Terminal
emulation software
Backup/ Edit Backup/ Edit Backup/ Edit
restore restore restore
PLC X X X X X X
Parameters X X X X
Axis calibration X X X X X X
Interaxis calibration X
Part programmes
Protected memory X
areas
Tool offsets X X X X
Options X

NUMCOM NUMCOM is a DOS-based software package which runs on any personal computer.
It can be used to backup and restore all the CNC files, some in binary format and
others as ASCII text files. However, it does not include an editor. ASCII files can be
edited using a simple text editor, but not binary files.
PLCTool PLCTool is a Windows-based software package that runs on any personal computer
which has Windows 3.1 or above. It is the package used by OEMs to create PLC
software. Although primarily intended for design of the system, it also supports many
other file types including part programmes stored in the CNC. It includes full editing
capability for all file types supported.
Terminal Emulation Software This is any off-the-shelf communication software. Both PROCOMM and CROSSTALK
are known to function correctly. These packages can only be used to transfer ASCII
type files, but not binary files.

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Software

The following table indicates the format of the files to be transferred:

File format
File type NUMCOM PLCTool Terminal emulation
software
PLC Binary Binary
Parameters ASCII or binary ASCII ASCII
Axis calibration ASCII or binary ASCII ASCII
Interaxis calibration ASCII or binary
Part programmes ASCII or binary ASCII ASCII
Protected memory Binary
areas
Tool offsets ASCII or binary ASCII
Options Binary
As can be seen from the above two tables, only the NUMCOM software can be used to back up and restore all file types.
Below, only this package is therefore discussed. The use of PLCTool is described in manual 938359. For terminal
emulation software, refer to the manufacturer’s manual.

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13.3 NUMCOM
13.3.1 Communication Cable

25-contact male sub.D CNC connector 9-contact female sub.D PC connector

Shielding 1 Not connected
TD 2 2 RD
RD 3 3 TD
RTS 4 8 CTS
CTS 5 7 RTS
DSR 6 Not connected
Earth 7 5 Earth
Not connected 1,4,6,9 Connected together
Connected together 8,25 Not connected
The NUMCOM communication cable can also be used with PLCTool and other communication packages such as
PROCOMM and CROSSTALK.

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Software

13.4 Part Programme (Zone 0) Backup/Restore

Part programmes are generally stored in zone 0, called the working memory. It is probably the main part programme
storage area. The operator can access the part programmes stored here to edit or delete them. The part programmes
in zone 0 can be backed up in ASCII or binary format, but ASCII is recommended.

13.4.1 Backup (Upload) One or All Programme(s)

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Select RECEIVE ASCII FILE
3 Press MODE key twice
4 Press UNLOAD F5
5 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
6 Select menu option 2
and press ENTER
7 Press ENTER again Green In Cycle lamp lights
8 Type %% and press ENTER Files being sent on CNC and
to backup all the files in zone 0 files being received on PC

Type %xxxx and press ENTER

to back up a single file
(where xxxx is the programme
number)
9 Transfer automatically Green In Cycle lamp goes out
stops when finished
10 File automatically closes List of files on PC
when reception is complete.
The disk filename is the name
of the first programme sent

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13.4.2 Restore (Download) One or All Programmes
Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Select SEND ASCII FILE
3 Press MODE key twice
4 Select the correct line configu- The line name changes at
ration with the left or right the bottom of the screen
arrow keys (see Sec. 13.1)
5 Press LOAD F4
6 Select menu option 0 and
press ENTER
7 Press ENTER again Green In Cycle lamp lights
8 Select the file to be sent The files sent by the PC are
loaded in the CNC
9 Transfer automatically Green In Cycle lamp goes out
stops when finished

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Software

13.5 Part Programme Backup/Restore in Zone 1, 2 or 3

The memory of CNCs of the 1000 family is divided into four zones. As was seen in section 13.4, zone 0 is the working
memory where programmes can be edited and deleted at will. Zones 1, 2 and 3 are special protected memory areas
where the OEM and NUM may have stored critical machine macros or canned cycles. Programmes stored in these
zones may be protected by password to prevent them from being deleted or edited, thereby offering some security
to the OEM.
Programmes can only be stored in binary format in zones 1, 2 and 3. To back them up in ASCII format, they must be
transferred to zone 0 and backed up using the zone 0 techniques described in Sec. 13.4. Refer to the chapter on Utility
3, Resident Macros, for more information on these special memory zones.

13.5.1 Backup (Upload) a Protected Memory Zone

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance Utility Menu
press ENTER
5 Select menu option 3 and Resident Macros Menu
press ENTER
6 Select menu option 5 and Zone selection menu
press ENTER
7 Select menu option 1, 2 or 3 (&x%[%/*/..]) &x%_
and press ENTER This is a prompt,
where x=zone number.
The CNC is waiting for you to
finish the command with either
a % to send all the program-
mes encoded with this affaire
number, "*" to send all
programmes without encoding
or a programme number.
8 Select RECEIVE BINARY FILE List of files in current directory
9 Press F3 to cancel automatic
file closing
10 Press %, * or xxxx and ENTER UNLOAD
to start sending ? (Y,N)
11 Press Y and ENTER UNLOADING IN PROGRESS
on PC 13

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Step On the PC On the CNC You can see
12 When file transfer is complete,
the number of bytes displayed
on the PC stops increasing.
Press ESC to close the file.
Then enter a file name.
13 To verify the data, press Y and VERIFY
ENTER; otherwise press N and
ENTER ? (Y,N)
14 If you answered Y to VERIFY,
select SEND BINARY FILE.
15 Select the file to verify and VERSION: xx
IDENTIFICATION: xxxx
press ENTER AFFAIRE No.: xxxxxxxxx
BACKUP OK!
16 Press EXIT F11 Resident macros menu
17 Press CTRL+S Exit from utilities

13.5.2 Restore (Download) a Protected Memory Area

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

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Software

13.6 Tool Offset Backup/Restore

Tool offsets are stored in the RAM memory and can be backed up via the serial interface. The files are in ASCII format.

13.6.1 Backup Tool Offsets

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.
Step On the PC On the CNC You can see
1 Run the NUMCOM software
2 Select RECEIVE ASCII FILE
3 Press MODE key twice
4 Press UNLOAD F5
5 Select the correct line configu- The line name changes at the
ration with the left or right arrow bottom of the screen
keys (see Sec. 13.1)
6 Select menu option 1 and
press ENTER
7 Press ENTER again Green In Cycle lamp comes on
8 Transfer automatically Green In Cycle lamp goes out
stops when finished
9 File automatically closes when
reception is complete.
Enter a filename.

13.6.2 Restore (Download) Tool Offsets

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Select SEND ASCII FILE
3 Press MODE key twice
4 Select the correct line configu- The line name changes at the
ration with the left or right arrow bottom of the screen
keys (see Sec. 13.1)
5 Press LOAD F4
6 Select menu option 1 and press
ENTER
7 Press ENTER again Green In Cycle lamp comes on
8 Select the file to be sent The files sent by the PC are
loaded in the CNC
9 Transfer automatically stops Green In Cycle lamp goes out
when finished 13

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13.7 Parameter File Backup/Restore
The parameter files are stored in EEPROM and do not need to be backed up often. They should be backed up only
after changes have been made for maintenance purposes. These files can be in binary or ASCII format, but ASCII
format is recommended.

13.7.1 Backup (Upload) Parameters

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes
ration with the left or right arrow at the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance
press ENTER Utility menu
5 Select menu option 5 and Machine Setup Data menu
press ENTER
6 Select menu option 3 and
press ENTER
7. Select RECEIVE ASCII FILE List of files in current directory
8 Press Y and ENTER READY?
9 Press ENTER %xxxxxxx
10 When file transfer is complete, On the PC, the data being
the PC closes the file and transferred
assigns it the affaire number as
filename
11 Press EXIT F11 Resident macros menu
12 Press CTRL+S Exit from utilities

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Software

13.7.2 Restore (Download) Parameters

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

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13.8 PLC File Backup/Restore
The PLC files are stored in RAM memory and should be backed up only after changes have been made for
maintenance purposes. These files must be in binary format.

13.8.1 Backup (Upload) PLC Files

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance Utility menu
press ENTER
5 Select menu option 7 and PLC Utility menu
press ENTER
6 Press S and ENTER Load/unload utility menu
7 Select RECEIVE BINARY FILE List of files in current directory
8 Press F3 to cancel automatic
file closing
9 Press U and ENTER
10 Press Y and ENTER READY?
11 Press ENTER
12 When file transfer is complete, The number of bytes received
press ESC to close the file then stops being incremented when
enter a filename transfer is complete
13 Press EXIT F11 Resident macros menu
14 Press CTRL+S Exit from utilities

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Software

13.8.2 Restore (Download) PLC files

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.

Step On the PC On the CNC You can see

1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance Utility menu
press ENTER
5 Select menu option 7 and PLC Utility menu
press ENTER
6 Press S and ENTER Load/Unload utility menu
7 Press L and ENTER
8 Press Y and ENTER READY?
9 Select SEND ASCII FILE List of available files
10 Select the file to send and
press ENTER
11 When loading is finished, Load/Unload utility menu
the file closes
12 Press EXIT F11 Machine Setup Data menu
13 Press CTRL+S Exit from utilities

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13.9 Axis Calibration File Backup/Restore
The axis calibration files are stored in RAM memory and do not normally need to be backed up often. The axis
calibration files should be backed up only after changes have been made for maintenance purposes. These files may
be in binary or ASCII format, but ASCII format is recommended.

13.9.1 Backup (Upload) Calibration Data

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.
Step On the PC On the CNC You can see
1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance Utility menu
press ENTER
5 Select menu option 2 and Axis Calibration Data menu
press ENTER
6 Select menu option 2 and READY (Y/N)?
press ENTER
7 Select RECEIVE BINARY FILE List of files in current directory
8 Press Y and ENTER %xxxxxxx
9 Press ENTER
10 When file transfer is complete, The data being transferred,
the PC closes the file and on the PC
assigns it the affaire number
as filename
11 Press EXIT F11 Axis Calibration Data menu
12 Press CTRL+S Exit from utilities

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Software

13.9.2 Restore (Download) Calibration Data

Before anything else, connect the communication cable, boot the PC and make sure the CNC is operating.
Step On the PC On the CNC You can see
1 Run the NUMCOM software
2 Press UTIL F11 Operator Utility Menu
3 Select the correct line configu- The line name changes at
ration with the left or right arrow the bottom of the screen
keys (see Sec. 13.1)
4 Select menu option 0 and Maintenance Utility menu
press ENTER
5 Select menu option 2 and Axis Calibration Data menu
press ENTER
6 Select menu option 1 and READY?
press ENTER
7 Press Y and ENTER
8 Select SEND BINARY FILE List of available files
9 Select the file to send and
press ENTER
10 When loading is finished, Axis Calibration Data menu
the file closes
11 Press EXIT F11 Machine Setup Data menu
12 Press CTRL+S Exit from utilities

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14 PLC Diagnostics

14.1 Global Addresses CNC —> PLC 14 - 3

14.2 Global Addresses PLC —> CNC 14 - 9
14.3 CNC —> PLC Axis Group Addresses 14 - 18
14.4 PLC —> CNC Axis Group Addresses 14 - 22
14.5 Standard Internal Variables 14 - 24
14.6 Displaying the PLC Variables 14 - 25
14.6.1 Displaying PLC Internal or I/O Variables 14 - 25
14.6.2 Displaying the Ladder Programme 14 - 26
14.7 Utility 7 - Ladder Programming 14 - 28
14.7.1 PLC Operation 14 - 29
14.7.2 Monitor and %TS Time Profile 14 - 32
14.7.3 PLC File Management 14 - 33
14.7.4 I/O Configuration 14 - 34
14.7.5 Software Backup 14 - 35

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14 - 2 en-938979/0
PLC Diagnostics

In NUM 1060 CNCs, the PLC is an integral part of the system. It controls the auxiliary functions of the machine other
than the feedback systems. For instance, when an axis reaches its travel limit switch, the PLC must stop axis
movement by the CNC. Similarly, when the operator presses a button on the panel, e.g. Cycle Start, the PLC must
order the CNC to start the cycle. Transfers between the PLC and CNC are therefore essential. Such transfers take
place via the Exchange Area, which contains a predefined set of variables in the form of bits, bytes and words which
the CNC or PLC can read and/or write to communicate with each other.
This chapter describes the variables that are critical to operation of the machine. There are many other variables, not
covered herein. Refer to manual 938846, PLC Programming in Ladder Language, for a complete listing of the
exchange area addresses.

14.1 Global Addresses CNC —> PLC

Variable Mnemonic Description
%R0.W CARCLAV Receives the characters entered from the keyboard at a rate of %TS5,
i.e.onecharacter every 5 RTCs.
%R2.7 E_M01 Optional programme stop enabled
Image of field M01 of the NC status window. Indicates inclusion of optional
programme stops in a part programme. The state of this bit can be changed
bypressing the M01 key on the panel or reading C_M01 =1.
%R2.6 E_SLASH Block skip enabled
Image of the / field of the NC status window. Indicates inclusion of block skips in
a part programme. The state of the bit can be changed by pressing the / key on the
panel or reading C_SLASH =1.
%R2.5 E_INTERV Intervention state
After a cycle stop, the switch to INTERV occurs the first time the AXIS RECALL key
on the machine panel is pressed. Set by read of C_RAX = 1 by the NC. Reset by
read of C_RAX = 0 by the NC.
%R2.4 S_RECUL Backward/forward movement on path
Set for backward or forward CNC movement. Reset to cancel this state.
%R2.1 E_NMAUTO N/M AUTO functionality
Set to indicate that the N/M functionality (2/3, 3/5, etc.) is enabled.
%R3.7 E_OPER Programme stop
Indicates a programme stop caused by M00 or enabled M01. Set by M00 or M01.
Reset by the CYCLE key on the machine panel (C_CYCLE = 1)
%R3.6 E_DEFCN CNC fault
Image of the NC?? field in the CNC status window. Indicates a machine error or
a part programme error. The machine error number is contained in ERRMACH.
Set by occurrence of a machine error (E30-E33, E36, E40-E71) or a part
programming error. Reset by the RAZ key on the panel, C RAZ = 1.
%R3.4 E DGURG General emergency retract
Indicates execution of an emergency retract programme. Set by read of
C_DGURG = 1 by the NC if the emergency retraction programme is enabled. Reset
by detection of M00 or M02.
%R3.3 E_RAX General axis recall
In CYHLD mode and at the end of SEARCH, indicates axis recall is enabled. Set
by read of C_RAX = 1 by the NC. Reset by read of C_RAX = 0 by the NC. 14

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Variable Mnémonique Description
%R3.2 E_CYCLE Cycle in progress
Set by the CYCLE key on the machine panel (C CYCLE = 1). Reset by the RAZ
key on the panel, C_RAZ = 1 or at the end of execution of the programme (M02).
%R3.1 E_ARUS Cycle stop
Indicates the CYHLD state of the system (programme stopped during execution
and enabling of axis jogs). Set by the CYHLD key on the machine panel
(C_ARUS = 1). Reset by the CYCLE key on the machine panel (C_CYCLE = 0).
%R3.0 E_RAZ CNC reset in progress
Pulse bit with a duration of 100 ms indicating a system reset. While this pulse is
high, data from the automatic control function are ignored. Set by the RAZ key on
the panel, a reset request from the automatic control function (C_RAZ = 1), at the
end of execution of a part programme (M02) or when the NC is turned on. This
variable is reset after 100 ms
%R5.7 E_TRANSP Transparent mode
Gives access by the machine processor to the CNC operator panel for display of
data (data tables, etc.). Machining may be in progress. Set by enabling the
TRANSPARENT MODE screen page. Reset by clearing the TRANSPARENT
MODE screen page.
%R5.5 E_PPP Dripfeed mode ready
Indicates that the NC is ready to operate in drip feed mode or that the machining
ordered by the automatic control function will be carried out in drip feed mode. In
the second case PROGDEM must be initialised with -2 (0xFFFE). Set after
CHOICE OF CURRENT PROGRAM and keyboard entry of PPR or PPL followed
by ENTER. Reset after CHOICE OF CURRENT PROGRAM and keyboard entry
of -PPR or -PPL followed by ENTER.
%R5. 1 E_PROG Active programme
Indicates that a part programme is being executed in AUTO, SINGLE, MDI or
DRYRUN mode. Set by the first action on the CYCLE key on the machine panel
(C_CYCLE =1). Reset by detection of M00 (programme stop), M01 (optional stop),
M02 (end of programme); the reset key on the operator panel, variable
C_RAZ = 1 and at power on.
%R5.0 E_CNPRET CNC ready
Indicates that power can be applied to the machine. Set at power on and by the RAZ
key on the operator panel, variable C_RAZ =1. Reset by detection of an excessive
following error on an axis, poor signal or encoder complementary channel fault
detected on an axis.
%R6.7 AXMVT31 axis 31 in motion
to to to
%R6.0 AXMVT24 axis 24 in motion
Indicates axes 24 to 31 in motion during execution of a block in a part programme
or in MDI mode. Set at the start of execution of the block. Reset at the end of
execution of the block if it includes M00 or M01, at the rnd of execution of the block
in MDI mode, before carrying out axis clamping, by the RAZ key on the operator
panel, variable C_RAZ = 1.

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PLC Diagnostics

Variable Mnemonic Description

%R7.7 AXMVT23 axis 23 in motion
to to to
%R7.0 AXMVT16 axis 16 in motion
Indicates axes 16 to 23 in motion during execution of a block in a part programme
or in MDI mode. Set at the start of execution of the block. Reset at the end of
execution of the block if it includes M00 or M01, at the end of execution of the block
in MDI mode, before carrying out axis clamping. by the RAZ key on the operator
panel, variable C_RAZ = 1.
%R8.7 AXMVT15 axis 15 in motion
to to to
%R8.0 AXMVT8 axis 8 in motion
Indicates axes 8 to 15 in motion during execution of a block in a part programme
or in MDI mode. Set at the start of execution of the block. Reset at the end of
execution of the block if it includes M00 or M01, at the end of execution of the block
in MDI mode, before carrying out axis clamping. by the RAZ key on the operator
panel, variable C_RAZ = 1.
%R9.7 AXMVT7 axis 7 in motion
to to to
%R9.0 AXMVT0 axis 0 in motion
Indicates axes 0 to 7 in motion during execution of a block in a part programme or
in MDI mode. Set at the start of execution of the block. Reset at the end of execution
of the block if it includes M00 or M01, at the end of execution of the block in MDI
mode, before carrying out axis clamping, by the RAZ key on the operator panel,
variable C_RAZ = 1.
%RA.7 AXINI31 axis 31 initialised
to to to
%RA.0 AXINI24 axis 24 initialised
Indicates the axes on which origin setting is completed. Reset when origin setting
is completed on the corresponding axis. Set by a system restart (origin setting not
completed).
%RB.7 AXINI23 axis 23 initialised
to to to
%RB.0 AXINI16 axis 16 initialised
Indicates the axes on which origin setting is completed. Reset when origin setting
is completed on the corresponding axis. Set by a system restart (origin setting not
completed).
%RC.7 AXINI15 axis 15 initialised
to to to
%RC.0 AXINI8 axis 8 initialised
Indicates the axes on which origin setting is completed. Reset when origin setting
is completed on the corresponding axis. Set by a system restart (origin setting not
completed).
%RD.7 AXINI7 axis 7 initialised
to to to 14
%RD.0 AXINI0 axis 0 initialised
Indicates the axes on which origin setting is completed. Reset when origin setting
is completed on the corresponding axis. Set by a system restart (origin setting not
completed).

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Variable Mnemonic Description
R11.0 E10000
R11.1 E10001
R11.2 E10002
R11.3 E10003
R11.4 E10004
R11.5 E10005
R11.6 E10006
R11.7 E10007
R10.0 E10008
R10.1 E10009
R10.2 E10010
R10.3 E10011
R10.4 E10012
R10.5 E10013
R10.6 E10014
R10.7 E10015
RF.0 E10016
RF.1 E10017
RF.2 E10018
RF.3 E10019
RF.4 E10020
RF.5 E10021
RF.6 E10022
RF.7 E10023
RE.0 E10024
RE.1 E10025
RE.2 E10026
RE.3 E10027
RE.4 E10028
RE.5 E10029
RE.6 E10030
RE.7 E10031
%R13.3 POSBR4 Spindle 4 in position
For a spindle indexing or synchronisation request, indicates that spindle 4 is in
position or synchronised. Set when the required position is reached. Reset after
leaving the required position, by oscillations and by cancellation of function M19.
%R13.2 POSBR3 Spindle 3 in position
For a spindle indexing or synchronisation request, indicates that spindle 3 is in
position or synchronised. Set when the required position is reached. Reset after
leaving the required position, by oscillations and by cancellation of function M19.

14 - 6 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%R13.1 POSBR2 Spindle 2 in position
For a spindle indexing or synchronisation request, indicates that spindle 2 is in
position or synchronised. Set when the required position is reached. Reset after
leaving the required position, by oscillations and by cancellation of function M19.
%R13.0 POSBR1 Spindle 1 in position
For a spindle indexing or synchronisation request, indicates that spindle 1 is in
position or synchronised. Set when the required position is reached. Reset after
leaving the required position, by oscillations and by cancellation of function M19.
%R15.B E_INCJOG Current jog increment
The value of this variable is the image of the current jog increment:
0x0A Manual movement by 10-6 inches
0x09 Manual movement by 10-2 µm or 10-5 inches
0x00 Manual movement by 10-1 µm or 10-4 inches
0x01 Manual movement by 1 µm or 10-3 inches
0x02 Manual movement by 10 µm or 10-2 inches
0x03 Manual movement by 100 µm or 10-1 inches
0x04 Manual movement by 1000 µm or 1 inch
0x05 Manual movement by 10000 µm or 1 inch
0x06 Continuous jog
0x08 Movement by handwheel
The increment is in µm or inches depending on the value of variable C_UNIT.
%R16.B MODCOUR Current Mode
The value of the variable is the image of the current NC mode:
0x00 Auto mode AUTO
0x01 Single step mode SINGLE
0x02 Manual data input mode MDI
0x03 Dryrun mode DRYRUN
0x04 Sequence number search mode SEARCH
0x05 Edit mode EDIT
0x06 Test mode TEST
0x07 Manual mode MANUAL
0x08 Home mode HOME
0x09 Origin shift mode SHIFT
0x0A Tool setting mode TL SET
0x0B No mode active
0x0D Load mode LOAD
0x0F Unload mode UNLOAD
%R14.0 SC_USED Screen enabled in PCNC configuration
Variable set to indicate that the screen is used by a user application (transparent
mode inhibited).
Variable reset to indicate that the screen is used by the NUM CNC
application(transparent mode possible).
14

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Variable Mnemonic Description
%R17.B PGVISU Displayed Page Number
This variable is the image of the page displayed on the NC screen:
0x01 DIR. directory page
0x03 PROG. programme page
0x04 INFO information page
0x05 L/@ programme variable page
0x06 AXIS current point page
0x07 TOOLS tool correction page
0x08 PROCAM graphic programming page
0x19 Load page during machining
0x1A Unload page during machining
0x09 I/O input/output page
0x0A UTIL utility page
0x15 SHIFT shift page
0x17 Edit mode page
0x0E Load mode page
0x11 Unload mode page
%R18.B ERRMACH Machine Error Number
This variable contains the machine error number detected by the system (errors
30, 32, 33, 36 and 40-71) as a decimal code.
REMARK: Refer to the OPERATOR MANUAL for the list of machine errors.
%R19.B ID_KB_CN Operator panel or CNC active identifier
In a multipanel configuration, gives the number of the active panel (0 to 7).
In a multi-CNC configuration, gives the number of the active CNC (0 to 4).
%R1A.W PROGCOUR Active Programme Number
This variable contains the number of the active programme.
The value 0XFFFF (-1 ) indicates there is no active programme.
The value 0xFFFE (-2) indicates selection of the drip feed mode.
%R1C.W VITBR 1 Spindle 1 Speed Reference
Contains the hexadecimal code of the spindle 1 servo-drive reference in the
programmed speed range.
The absence of functions M3 and M4 in the part programme forces the variable to
zero.
%R1E.W VITBR2 Spindle 2 Speed Reference
Contains the hexadecimal code of the spindle 2 servo-drive reference in the
programmed speed range.
The absence of functions M3 and M4 in the part programme forces the variable to
zero.
%R20.W VITBR3 Spindle 3 Speed Reference
Contains the hexadecimal code of the spindle 3 servo-drive reference in the
programmed speed range.
The absence of functions M3 and M4 in the part programme forces the variable to
zero.
%R22.W ViTBR4 Spindle 4 Speed Reference
Contains the hexadecimal code of the spindle 4 servo-drive reference in the
programmed speed range.
The absence of functions M3 and M4 in the part programme forces the variable to
zero.

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PLC Diagnostics

14.2 Global Addresses PLC —> CNC

Variable Mnemonic Description
%W2.1 C_NMAUTO N/M AUTO functionality
Set to enable the AUTO N/M (2/3, 3/5, etc.) functionality.
This command is operative when command C_CYCLE goes low.
%W2.0 KB_INIT Keyboard initialisation
Set to enable identification of the configuration of keyboards and interconnected
CNCs. Identification must be carried out whenever the configuration is modified.
After identification, keyboard 1 is assigned to CNC 1.
%W3.7 C_M01 Optional stop (M01) enabled
A pulse forces a change of state to enable or inhibit optional stop depending on the
previous state.
%W3.6 C_SLASH Block skip enabled
A pulse forces a change of state to enable or inhibit block skip depending on the
previous state.
%W3.5 C_RAZER Reset machine error.
%W3.4 C_DGURG Emergency retract request
This request is taken into account in the AUTO, SINGLE and DRYRUN modes.
The current block is interrupted and the system branches to the last emergency
retract programme declared in the part programme by function G75.
if no emergency retract programme was defined, this command is processed in the
same way as C_ARUS.
%W3.3 C_RAX Axis recall selection
This request is taken into account when E_ARUS = 1 and all the axis jogs are
released. It is a bistable type command. The first pulse sets E_INTERV and
enables the axis jogs in both directions. If at least one axis has been moved in
INTERV mode, a second pulse sets E_RAX and enables a single direction of
movement of the axis jogs to return the slides to the initial position.
%W3.2 C_CYCLE CYCLE START pulse
Allows execution of the AUTO, SINGLE, MDI, DRYRUN, SEARCH, TEST LOAD
and UNLOAD modes. A pulse command must be used for C_CYCLE to prevent
resumption of machining after detection of M02 or a reset in the AUTO and
DRYRUN modes.
%W3.1 C_ARUS Machining stop request
This request is taken into account in the AUTO, SINGLE, MDI, DRYRUN and
incremental JOG modes. The first pulse stops machining . Machining is restarted
by action on CYCLE.
%W3.0 C_RAZ Reset request
Taken into account if there is no movement on the axes.
%W4.7 VREDUIT Causes a switch to low speed
Set to force the low speeds of movement set in words N3 and N4 of parameter P31
(see Parameter Manual).
%W4.6 INIBUTIL Utility inhibit
Set to inhibit access to the utilities.
Reset to enable access to the utilities. 14

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Variable Mnemonic Description
%W4.5 C_UNIT Display units (metric system or inches)
Set to enable dimension entry and display in inches.
Reset to enable dimension entry and display in the metric system.
%W4.4 PRESPUIS Motor power on.
This variable is reset to indicate a synchronised axis motor power failure to the NC
(after a synchronisation error). It is set to indicate power return and axis
synchronisation enable to the NC.
%W4.3 NARFIB No stop at end of block
Enables execution of a CYCLE in the AUTO, SINGLE, MDI, DRYRUN modes and
enables block sequencing in the AUTO and DRYRUN modes. Reset of this
variable causes the cycle to stop at the end of execution of the current block.
%W4.2 VITMAN2 Selection of rapid feed rates in manual modes 1 and 2
%W4.1 VITMAN1 Enable selection of rapid feed rates in the JOG and HOME modes or
setting the handwheel increment multiplier.
The feed rates are modulated by the feed rate potentiometer.
VITMAN1 VITMAN2 FEED RATE INCREMENT
(Parameter P31) HANDWHEEL
0 0 Normal JOG IU x 1
0 1 Slow JOG IU x 100
1 0 Fast JOG IU x 10
1 1 Fast JOG IU x 10
Where IU = internal system unit set by a machine parameter.
%W4.0 AUTAV Feed authorised on all the axis groups
Enables movements in all the modes with movement.
STOP in the CNC status window indicates that this operand is reset.
%W5.7 SC_SAVE CNC screen saver
Set to enable the CNC screen saver after five minutes of keyboard inactivity.
Reset to inhibit the screen saver and immediately reactivate the screen
%W5.6 SK_DISPL Softkey bar window display
Set to inhibit display of the softkey bar window.
Reset to enable display of the softkey bar window.
REMARK: Inhibiting the display does not inhibit use of the softkeys.
%W5.5 INIBCLAV Keyboard inhibit
Set to inhibit the alphanumeric QWERTY keyboard and function keys for the basic
softkeys which are then no longer processed by the CNC. The key codes are
however transmitted to the automatic control function by CARCLAV
%W5.4 IMPULS Operator panel pulse inputs
Disable the RAZ, ARUS, CYCLE, M01, / keys and the TCOMP softkey. Set to
disable the keys on the CNC operator panel and enable selection by the automatic
control function.
%W5.3 CORDYN Wear offset load enable
Set to enable load of the tool wear offsets by the automatic control function and
disable load from the operator panel.
%W5.2 JOGPUP JOG selection from the operator panel
Set to disable selection of the jog type by the CNC operator panel and enable
selection by the automatic control function.

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PLC Diagnostics

Variable Mnemonic Description

%W5.1 MODPUP Operator panel mode selection
Set to disable mode selection by the CNC operator panel and enable mode
selection by the automatic control function.
%W5.0 PUPABS CNC panel absent
Set to declare the CNC panel absent.
All the CNC operator panel functions are disabled and can be simulated by the
automatic control function.
%W6.7 JOGPOS31 Positive JOG on axis No. 31
to to to
%W6.0 JOGPOS24 Positive JOG on axis No. 24
%W7.7 JOGPOS23 Positive JOG on axis No. 23
to to to
%W7.0 JOG POS16 Positive JOG on axis No. 16
%W8.7 JOG POS15 Positive JOG on axis No. 15
to to to
%W8.0 JOGPOS8 Positive JOG on axis No. 8
%W9.7 JOGPOS7 Positive JOG on axis No. 7
to to to
%W9.0 JOGPOS0 Positive JOG on axis No. 0
%WA.7 JOGNEG31 Negative JOG on axis No. 31
to to to
%WA.0 JOGNEG24 Negative JOG on axis No. 24
%WB.7 JOGNEG23 Negative JOG on axis No. 23
to to to
%WB.0 JOGNEG16 Negative JOG on axis No. 16
%WC.7 JOGNEG15 Negative JOG on axis No. 15
to to to
%WC.0 JOGNEG8 Negative JOG on axis No. 8
%WD.7 JOGNEG7 Negative JOG on axis No. 7
to to to
%WD.0 JOGNEG0 Negative JOG on axis No. 0
W11.0 E20000
W11.1 E20001
W11.2 E20002
W11.3 E20003
W11.4 E20004
W11.5 E20005
W11.6 E20006
W11.7 E20007
W10.0 E20008
W10.1 E20009
W10.2 E20010
W10.3 E20011
14
W10.4 E20012
W10.5 E20013
W10.6 E20014

en-938979/0 14 - 11
Variable Mnemonic Description
W10.7 E20015
WF.0 E20016
WF.1 E20017
WF.2 E20018
WF.3 E20019
WF.4 E20020
WF.5 E20021
WF.6 E20022
WF.7 E20023
WE.0 E20024
WE.1 E20025
WE.2 E20026
WE.3 E20027
WE.4 E20028
WE.5 E20029
WE.6 E20030
WE.7 E20031
%W13.B C_INCJOG JOG increment command.
The variable value corresponds to the jog increment requested:
0x0A Manual movement by 10-6 inches
0x09 Manual movement by 10-2 µm or 10-5 inches
0x00 Manual movement by 10-1 µm or 10-4 inches
0x01 Manual movement by 1 µm or 10-3 inches
0x02 Manual movement by 10 µm or 10-2 inches
0x03 Manual movement by 100 µm or 10-1 inches
0x04 Manual movement by 1000 µm or 1 inch
0x05 Manual movement by 10000 µm or 1 inch
0x06 Continuous jog
0x08 Manual movement by handwheel
The jog increment is in µm or inches depending on the value of variable C_UNIT.
%W14.B MODEDEM Mode Requested
The value of the variable corresponds to the CNC mode requested:
0x00 Auto mode AUTO
0x01 Single step mode SINGLE
0x02 Manual data input mode MDI
0x03 Dryrun mode DRYRUN
0x04 Sequence number search mode SEARCH
0x05 Edit mode EDIT
0x06 Test mode TEST
0x07 Manual mode MANUAL
0x08 Home mode HOME
0x09 Origin shift mode SHIFT
0x0A Tool setting mode TL SET
0x0B No mode active
0x0D Load mode LOAD
0x0F Unload mode UNLOAD

14 - 12 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%W15.B MSG1 Message number to be displayed on line 1
The message is displayed on line 1 of the Error Message page. A message with
that number must be included in part programme %9999.9.
%W16.B MSG2 Message number to be displayed on line 2
The message is displayed on line 2 of the Error Message page. A message with
that number must be included in part programme %9999.9.
%W17.B SELECGR Axis Group Selection
Assigns all the data relative to one axis group (part programme, programme
variable, etc.) for display. The data entered from the CNC keyboard in MDI
mode is assigned to the axis group selected.
0 Selection of axis group 1
1 Selection of axis group 2
2 Selection of axis group 3
3 Selection of axis group 4
4 Selection of axis group 5
5 Selection of axis group 6
6 Selection of axis group 7
7 Selection of axis group 8
REMARK: Used only for axis multigroup machine-tools.
%W18.W PROGDEM Requested Programme Number
Used to load the requested programme number as active programme or request
machining in drip feed mode. The programme number or drip feed machining
request is read by the system on the rising edge of the reset flag C_RAZ = 1.
0 No programme number requested by the automatic control function. 1 to 0x270F
(9999) Programme number specified by the automatic control function.
-2 (0xFFFE) Machining in drip feed mode requested by the automatic control
function.
REMARK: The programme requested must be present in the CNC memory to be
installed as the active programme. If it is not present, the system
cancels the old active programme and the message <NO ACTIVE
PROGRAM> is displayed on the current programme page.
%W1A.B AFMAN1 Handwheel 1 Assignment
Contains the physical address of the axis to be moved. Refer to the Installation and
Commissioning Manual for assignment of the physical axis addresses.
%W1B.B AFMAN2 Handwheel 2 Assignment
Contains the physical address of the axis to be moved. Refer to the Installation and
Commissioning Manual for assignment of the physical axis addresses.
%W1C.B AFMAN3 Handwheel 3 Assignment
Contains the physical address of the axis to be moved. Refer to the Installation and
Commissioning Manual for assignment of the physical axis addresses.

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Variable Mnemonic Description
%W1D.B AFMAN4 Handwheel 4 Assignment
Contains the physical address of the axis to be moved. Refer to the Installation and
Commissioning Manual for assignment of the physical axis addresses.
%W1E.B POTBR1 Spindle 1 Potentiometer
A hexadecimal value corresponding to the Analogue to Digital input.
Hexadecimal Analogue to Digital input Spindle speed override code (anai(…)
function) percentage.
0x0 - 0 volts - 50%
0xFF - 10 volts - 100%
%W1F.B POTBR2 Spindle 2 Potentiometer
Same as POTBR1 for spindle 2.
%W20.B POTBR3 Spindle 3 Potentiometer
Same as POTBR1 for spindle 3.
%W21.B POTBR4 Spindle 4 Potentiometer
Same as POTBR1 for spindle 4.
%W22.3 STOPBR4 Spindle 4 stop requested by the PLC function
Latched command. The spindle remains stopped as long as this bit remains set.
When the bit is reset, the spindle can begin rotating again.
%W22.2 STOPBR3 Spindle 3 stop requested by the PLC function
Latched command. The spindle remains stopped as long as this bit remains set.
When the bit is reset, the spindle can begin rotating again.
%W22.1 STOPBR2 Spindle 2 stop requested by the PLC function
Latched command. The spindle remains stopped as long as this bit remains set.
When the bit is reset, the spindle can begin rotating again.
%W22.0 STOPBR1 Spindle 1 stop requested by the PLC function
Latched command. The spindle remains stopped as long as this bit remains set.
When the bit is reset, the spindle can begin rotating again.
%W23.3 COMBR4 Spindle 4 control
Set to enable spindle control by the automatic control function. The setting is
transmitted to the axis card by C_VITBR4.
%W23.2 COMBR3 Spindle 3 control
Set to enable spindle control by the automatic control function. The setting is
transmitted to the axis card by C_VITBR3.
%W23.1 COM8R2 Spindle 2 control
Set to enable spindle control by the automatic control function. The setting is
transmitted to the axis card by C_VITBR2.
%W23.0 COMBR1 Spindle 1 control
Set to enable spindle control by the automatic control function. The setting is
transmitted to the axis card by C_VITBR1.
%W24.W C_VITBR1 Spindle 1 Speed Setting
Used to send the spindle servo-drive reference in binary code on 14 bits plus sign.
Bit 15 of C_VITBR1 gives the sign of the setting.
%W26.W C_VIT8R2 Spindle 2 Speed Setting
Used to send the spindle servo-drive reference in binary code on 14 bits plus sign.
Bit 15 of C_VITBR2 gives the sign of the setting.

14 - 14 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%W28.W C_VITBR3 Spindle 3 Speed Setting
Used to send the spindle servo-drive reference in binary code on 14 bits plus sign.
Bit 15 of C_VITBR3 gives the sign of the setting.
%W2A.W C_VITBR4 Spindle 4 Speed Setting
Used to send the spindle servo-drive reference in binary code on 14 bits plus sign.
Bit 15 of C_VIT8R4 gives the sign of the setting.
%W2C.1 NJGMANIV Inhibits handwheel selection.
Inhibits the HAND softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W2C.0 NJG0001 Inhibits selection of the 0.001 mm increment.
Inhibits the .001 softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W2D.7 NJG001 Inhibits selection of the 0.01 mm increment.
Inhibits the .01 softkey in the jog key bar. Set to inhibit the key. Reset to enable the
key.
%W2D.6 NJG01 Inhibits selection of the 0.1 mm increment.
Inhibits the .1 softkey in the jog key bar. Set to inhibit the key. Reset to enable the
key.
%W2D.5 NJG1 Inhibits selection of the 1 mm increment.
Inhibits the 1 softkey in the jog key bar. Set to inhibit the key. Reset to enable the
key.
%W2D.4 NJG10 Inhibits selection of the 10 mm increment.
Inhibits the 10 softkey in the jog key bar. Set to inhibit the key. Reset to enable the
key.
%W2D.3 NJG100 Inhibits selection of the 100 mm increment.
Inhibits the 100 softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W2D.2 NJG1000 Inhibits selection of the 1000 mm increment.
Inhibits the 1000 softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W2D.1 NJG10000 Inhibits selection of the 10000 mm increment.
Inhibits the 10000 softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W2D.0 NJGILLIM Inhibits continuous jog selection.
Inhibits the FREE softkey in the jog key bar. Set to inhibit the key. Reset to enable
the key.
%W30.7 I_POM Inhibits selection of the homing mode.
Inhibits the HOME softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W30.6 I_PREF Inhibits selection of origin shift mode.
Inhibits the SHIFT softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W30.5 I_REGOUT Inhibits selection of automatic tool setting mode.
Inhibits the TLSET softkey in the mode key bar. Set to inhibit the key. Reset to 14
enable the key.

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Variable Mnemonic Description
%W30.2 I_CHARG Inhibits selection of the load mode.
Inhibits the LOAD softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W30.0 I_DCHG Inhibits selection of the unload mode.
Inhibits the UNLOAD softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W31.7 I_CONT Inhibits selection of the automatic mode.
Inhibits the AUTO softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W31.6 I_SEQ Inhibits selection of the single step mode.
Inhibits the SINGLE softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W31.5 I_IMD Inhibits selection of the manual data input mode.
Inhibits the MDI softkey in the mode key bar. Set to inhibit the key. Reset to enable
the key.
%W31.4 I_RAPID Inhibits selection of the dryrun mode.
Inhibits the DRYRUN softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W31.3 I_RNS Inhibits selection of the sequence number search mode.
Inhibits the SEARCH softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W31.2 I_MODIF Inhibits selection of the edit mode.
Inhibits the EDIT softkey in the mode key bar. Set to inhibit the key. Reset to enable
the key.
%W31.1 I_TEST Inhibits selection of the test mode.
Inhibits the TEST softkey in the mode key bar. Set to inhibit the key. Reset to enable
the key.
%W31.0 I_JOG Inhibits selection of the manual mode.
Inhibits the MANUAL softkey in the mode key bar. Set to inhibit the key. Reset to
enable the key.
%W34.7 DISC_TRQ31 Torque enabled on QVN axis No. 31
to to to
%W34.0 DISC_TRQ24 Torque enabled on QVN axis No. 24
Set to enable torque, reset to inhibit torque
%W35.7 DISC_TRQ23 Torque enabled on QVN axis No. 23
to to to
%W35.0 DISC_TRQ16 Torque enabled on QVN axis No. 16
Set to enable torque, reset to inhibit torque
%W36.7 DISC_TRQ15 Torque enabled on QVN axis No. 15
to to to
%W36.0 DISC_TRQ8 Torque enabled on QDD axis No. 8
Set to enable torque, reset to inhibit torque
%W37.7 DISC_TRQ7 Torque enabled on QDD axis No. 7
to to to
%W37.0 DISC_TRQ0 Torque enabled on QDD axis No. 0
Set to enable torque, reset to inhibit torque

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PLC Diagnostics

Variable Mnemonic Description

%W38.0 DISC_SDP Speed reference enable for QVN axes
Set to enable normal operation of QVN axes.
Reset to cancel the speed reference immediately on the QVN axes to enable
braking at maximum torque.
If the speed references are inhibited, they are forced low. At power on, the speed
references are inhibited. In the case of detection of a CNC error causing
E_CNPRET to go low, the speed reference is forced low for the QVN axes.
Cancellation of the error by a reset again allows the automatic control function to
enable or inhibit the speed references.
REMARK: It is recommended to inhibit DISC_SDP on an emergency stop and to
activate a feed stop so as not to generate an excessive following error.
%W39.2 INITPOS Automatic recall after maintenance.
Set to enable recall. Reset to cancel recall.
%W39.1 FORWARD Forward movement requested on path.
Set to enable the request.
Reset to inhibit the request
%W39.0 BACKWARD Backward movement requested on path.
Set to enable the request.
Reset to inhibit the request.

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14.3 CNC —> PLC Axis Group Addresses
REMARK The inputs from the axis groups are contained in eight 128-byte blocks. These are
variables %Rg00 to %Rg7F where g equals 1 to 8 for groups 1 to 8.
Variable Mnemonic Description
%Rg01.6 E_DEF1 Fault on group g
to Indicates a programming error or the absence of a part programme on the
E-DEF8 group. Set to indicate that the group is faulty.
%Rg01.5 NO_POS1 Axis on wait for positioning
to When accurate positioning is required by programming (functions G09, M00,
NO_POS8 M02 or M10) in MDI or JOG mode whenever movement is stopped, signal
NO_POSg is transmitted while the axis is on wait for positioning. Set to indicate that
the axis is on wait for positioning.
%Rg01.4 E_DGURG1 Emergency retraction in progress on group g
to Indicates execution of an emergency retraction programme. Set after read of
E_DGURG8 C_DGURGg = 1 by the CNC if the emergency retraction programme is enabled.
Reset by detection of M00 or M02.
%Rg01.2 E_CYCL1 Cycle in progress on group g
to Indicates that the group is executing a part programme block. Reset: the CNC
E_CYCL8 is waiting for flag C_CYCLEg = 1 to execute the part programme or the next block.
Set: indicates that a block is being executed.
%Rg01.0 E_RAZ1 Reset in progress on group g
to Pulse bit with a duration of 100 ms that indicates a reset on the group.
E_RAZ8 While this pulse is set, the data from the automatic control function are ignored. Set
by the RAZ key on the operator panel, by a reset request from the automatic control
function C_RAZg = 1, at the end of execution of a part programme (M02) or at CNC
power on. This variable is reset after 100 ms
%Rg02.B NUMCYC1 Current machining cycle number on group g
to Used to read the machining cycle subroutine number from %10000 to
NUMCYC8 %10255 (0 for %10000 to 0xFF for %10255).
%Rg03.1 FILET1 Thread cutting on group g
to Indicates execution of a thread cutting cycle: G31 (thread chasing),
FILET8 G33 (thread cutting), G38 (sequenced thread cutting) or G84 (rigid tapping). Set
by execution of function G31, G33, G38 or G84. Reset by cancellation of the
function
%Rg03.0 RAPID1 Rapid positioning (G00) on group g
to Indicates execution of G0 in the current block of the part programme.
RAPID8 Set by execution of function G0. Reset by cancellation of function G0.

14 - 18 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%Rg04.W MSSCR1 Encoded M function without response from group g
to This variable is used to read on-the-fly encoded M functions without report from
MSSCR8 M200 to M899 (e.g. M210 sends MSSCRg == 210 to the automatic control
function). These functions are considered pre-move and modal by the system. The
part programme is continued without waiting for an acknowledgement. Used in
part programmes, they are accessible for read by the automatic control function
and must be decoded in the user programme. Only one modal encoded M function
can be included in a part programme block. One modal and one non-modal
encoded M function can be included in the same part programme block. M
functions must always be decoded by sequential task TS0.
%Rg06.W POTAVC1 Feed rate override percentage on group g
to Contains the ADC input from 0 to 10 volts corresponding on the CNC to a feed
PCTAVC8 feed rate override percentage between 0 and 120 percent.
%Rg1E.W MCODCR1 Encoded M function with response received from group g
to This variable is used to read the encoded M functions with report up to M199
MCODCR8 (e.g. M92 sends %MCODCRg == 92 to the automatic control function). These
functions are considered post-move and non-modal by the system. The automatic
control function determines whether or not they are modal. Used in part program-
mes, they are accessible for read by the automatic control function and must be
decoded in the user programme. Only one non-modal encoded M function can be
included in a part programme block. One modal and one non-modal encoded M
function can be included in the same part programme block. M functions must
always be decoded by sequential task TS0.
%Rg20.7 M999_1 Masking by programming of M997, M998
to
M999_8
%Rg20.6 M998_1 Unmasking by programming of M999, M997
to
M998_8
%Rg20.5 M997_1 Forced block sequencing
to
M997_8
%Rg20.3 M49_1 Force 100% feed rate and spindle speed override
to
M49_8
%Rg20.2 M48_1 Re-enable feed rate and spindle speed override
to
M48_8
%Rg20.1 M11_1 Axis unclamp
to
M11_8
%Rg20.0 M10_1 Axis clamp
to
M10_8
14

en-938979/0 14 - 19
Variable Mnemonic Description
%Rg21.7 M12_1 Programme stop
to
M12_8
%Rg21.5 M45_1 Select spindle 6 speed range
to
M45_8
%Rg21.4 M44_1 Select spindle 5 speed range
to
M44_8
%Rg21.3 M43_1 Select spindle 4 speed range
to
M43_8
%Rg21.2 M42_1 Select spindle 3 speed range
to
M42_8
%Rg21.1 M41_1 Select spindle 2 speed range
to
M41_8
%Rg21.0 M40_1 Select spindle 1 speed range
to
M40 8
%Rg22.7 M19_1 Spindle indexed stop
to
M19 8
%Rg22.6 M09_1 Coolant off
to
M09_8
%Rg22.5 M08_1 Coolant 1
to
M08_8
%Rg22.4 M07_1 Coolant 2
to
M07_8
%Rg22.3 M06_1 Tool change
to
M06_8
%Rg22.2 M05_1 Spindle stop
to
M05_8
%Rg22.1 M04_1 Spindle CCW rotation
to
M04_8
%Rg22.0 M03_1 Spindle CW rotation
to
M03_8

14 - 20 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%RG23.7 M61_1 Disable current spindle in a group
to
M61_8
%Rg23.2 M02_1 End of part programme
to
M02_8
%Rg23.1 M01_1 Optional stop
to
M01_8
%Rg23.0 M00_1 Programme stop
to
M00_8
%Rg24.3 M63_1 Spindle reference applied to spindle 4
to
M63_8
%Rg24.2 M62_1 Spindle reference applied to spindle 3
to
M62_8
%Rg24.1 M65_1 Spindle reference applied to spindle 2
to
M65_8
%Rg24.0 M64_1 Spindle reference applied to spindle 1
to
M64_8
%Rg25.3 M69_1 Spindle 4 measurement enabled
to
M69_8
%Rg25.2 M68_1 Spindle 3 measurement enabled
to
M68_8
%Rg25.1 M67_1 Spindle 2 measurement enabled
to
M67_8
%Rg25.0 M66_1 Spindle 1 measurement enabled
to
M66_8
%Rg7C.L OUTIL1 Tool number requested by group g
to Contains the tool numbers (decimal values from 0 to 65535).
OUTIL8 T functions are considered as pre-move and modal by the system, which does not
wait for a response.

en-938979/0 14 - 21
14.4 PLC —> CNC Axis Group Addresses
REMARKS The outputs to the axis groups are contained in eight 128-byte blocks. These are
in variables %Wg00 to %Wg7F where g equals 1 to 8 for groups 1 to 8.
Variables C_MODE1 to C_MODE8, C_CYCLE1 to C_CYCLE8, C_RAZ1 to
C_RAZ8 and C_DGURG1 to C_DGURG8 are enabled only for PLC axes
Variable Mnemonic Description
%Wg00.7 C_MODE1 Activates AUTO or SINGLE mode on PLC axis groups g
to Reset: AUTO mode enabled on the next block. Set: SINGLE mode
C_MODE8 enabled for the current block. This flag is meaningful only if the group is valid
%Wg00.6 C_FAST1 Latched high speed command during a cycle
to This command is used during a cycle (C_CYCLEg = 1). Set to enable
C_FAST8 movement at the highest possible speed. Reset to enable movement at the work
rate.
%Wg00.5 CRM1 M function response for group g
to Reset: places the system on wait without processing the next functions in the
CRM8 block being executed. Set: enables processing to continue.
%Wg00.4 APPSS1 Subroutine call for group g
to During execution of a part programme, APPSS is set for a branch to
APPSS8 subroutine %9999.g (where g is the group number). Latching of the bit or a new
subroutine call is ignored during execution of the subroutine. No response is sent
by the system during execution of the subroutine. The subroutine should send the
machine processor a response to cancel the bit (M function, external parameter,
etc.). If only one CNC axis group is declared, programme %9999 is called (i.e.
%9999.0).
%Wg00.3 ARBUT1 Block interrupt on group g
to Set to stop movement on the axis group, then go to the next block or
ARBUT8 jump to another block. Function G10 associated with its arguments must be
present in the part programme.
%Wg00.2 VALID1 Group g enable
to Set to enable use of the axis group. Enabling or inhibiting are effective
VALID8 only after a reset or M02.
%Wg00.1 C_FMEXT1 End of external movement control on group g
to Reset to inhibit cancellation of CYCLE in SINGLE and MDI modes or sequencing
C_FMEXT8 to the next block in AUTO and DRYRUN modes. Set to allow normal execution of
the mode. This variable is tested at the end of execution of each block.
%Wg00.0 C_AUTAV1 Feed authorisation on group g
to This variable is active if general feed authorisation bit AUTAV = 1.
C_AUTAV8 Reset to stop movement on the axis group in all modes with movements.
Movement is resumed when C_AUTAVg = 1.

14 - 22 en-938979/0
PLC Diagnostics

Variable Mnemonic Description

%Wg01.4 C DGURG1 Emergency retraction request for group g
to This request is accepted in AUTO and SINGLE modes. The current block is
C_DGURG8 interrupted and the system branches to the last emergency retraction programme
declared in the part programme by function G75. If no emergency retraction
programme is specified, this signal is processed in the same way as C_ARUS.
%Wg01.2 C_CYCLE1 Cycle start request on PLC axis group g
to Allows execution of the AUTO and SINGLE modes for the PLC axis
C_CYCLE8 groups. A pulse command must be used for C_CYCLEg to prevent resumption of
machining after detection of M02 or a reset in the AUTO mode. This flag is ignored
unless the group is valid.
%Wg01.0 C_RAZ1 Reset request on PLC axis group g
to Taken into account if there is no movement on the axes. It is during a
C_RAZ8 reset on a group that flag VALIDg is taken into account and the presence of the part
programme assigned to the PLC group is detected.
%Wg02.B POTAV1 Feed Rate Potentiometer for Group g
to Hexadecimal code corresponding to the ADC input value.
POTAV8 Hexadecimal ADC input feed rate override code (function anai(.)) percentage
0x0 = 0 volts = 0% 0xFF = 10 volts = 120%

en-938979/0 14 - 23
14.5 Standard Internal Variables
There are other internal variables in bit, byte, word or long word format. Saved variables begin with %M and variables
not saved after power down with %V. These two types of variables are otherwise equivalent.
Memory access differs according as the variable is in bit, byte, word or long word format. The extension defines the
variable format.

Internal Variables
%V xxxx . b
The extension defines the format:
.0 to .7 Bit number from 0 to 7
.B Signed integer on 8 bits (byte)
.W Signed integer on 16 bits (word)
.L Signed integer on 32 bits (long word)
.& Internal address format (refer to PLC Ladder Programming manual 938846
for more information).
.[ ] Indexed address mode (refer to PLC Ladder Programming manual 938846
for more information)
Logical number of the variable. The range is:
- %V0 to %V7FFF (32 KB)
- %V7FFF (32 KB).
The letter determines whether or not the variable is saved:
- %V denotes a non-saved variable
- %M denotes a saved variable.

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PLC Diagnostics

14.6 Displaying the PLC Variables

14.6.1 Displaying PLC Internal or I/O Variables
It is very easy to display a PLC internal or input/output variable (see Chapter 7 for more information on inputs and
outputs). Proceed as follows:
1. Press the PLC I/O softkey (F9) below the screen
2. Type 2 or use the cursors to select option 2, PLC MEMORY, then press ENTER
3. The PLC Memory screen is displayed. It contains a small prompt labelled “Address” in the lower left-hand corner
for entry of an address. For instance, if you type %I0100.0 and press ENTER, the contents of the requested
address are displayed.

PLC MEMORY

%W24.0 $05 0 0 0 0 0 1 0 1
%W25.1 $F1 1 1 1 1 0 0 0 1
%W26.2 $43 0 1 0 0 0 0 1 1
%W125.B $25 +37
%W126.B $97 -23
%W127.W $F852 -30802
>%W128.L $0463E247 +73654855

4 3 2 1

1- Values of bit variables highlighted in the corresponding bytes

2- Decimal values of byte, word or long word variables
3- Hexadecimal values of byte, word or long word variables
4- Variables
For display of bit values, the contents of the address are always displayed as 8 bits.
Example: Entry of addresses %I0B00.0 and %Q0A01.4 and corresponding displays:
%I0B00.0 $01 0 0 0 0 0 0 0 1
%Q0A01.4 $10 0 0 0 1 0 0 0 0
In this example, bits 0 and 4 are requested. Both bits are highlighted (inverse video) on the screen.
For display of variables in byte, word or long word format, both the hexadecimal and decimal values are displayed.
Hexadecimal values are preceded by $ and decimal values by + or -.

en-938979/0 14 - 25
Entering Multiple Addresses
To enter more than one address at a time, simply leave a space between entries as shown below:
ADDRESS %M100.W %V2A.B %I600.7

Adding Addresses to the Display

To add addresses to those already displayed, press the PAGE DOWN key to display the ADDRESS prompt, then enter
+ followed by the additional addresses:
ADDRESS +%Q703.4 %R3.0 %W100.0

Deleting an Address from the Display

Select the address to be deleted with the cursor keys, then press the minus sign “-” and ENTER. The address is
cleared.

14.6.2 Displaying the Ladder Programme

Proceed as follows to display the Ladder programme:
1. Press the PLC I/O softkey (F9)
2. Type 5 or use the cursors to select option 5, PLC ANIMATION, then press ENTER
3. The Ladder Directory screen is displayed. Use the cursor keys to select the module to be displayed and press
ENTER.

LADDER directory
Name Size Date Time
TS0 .XLA 2674 08/07/94 13:28:13

1 File(s), 2674 Byte(s)

QUIT

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PLC Diagnostics

4. The Ladder animation screen is displayed.

- L A D D E R a n i m a t i o n - T S 0 . X L A : 0 / 1 6

Symbols : Label : PRG_MIN Current step: 0 No. step : 0

Size : 2674 Comment : Programme minimum NO1

Text :

Value :

%W4.7

%W4.O

%W4.3

%W100.1
%W100.O

%W200.5

FILE SEARCH OPTION DEC OFF WRITE QUIT

The contacts or rungs which are RED (colour screen) or LIGHT GREY (monochrome screen) are in HIGH or TRUE
state. Contacts or rungs which are BLACK are in LOW or FALSE state.

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14.7 Utility 7 - Ladder Programming
A ladder utility is available to assist the maintenance staff in diagnosing a PLC-related problem. It is utility 7, accessed
by the following procedure:

Accessing Utility 7
Step On the CNC You can see
1 Press UTIL softkey F11 Operator Utility Menu
2 Select menu option 0 and Maintenance Utility menu
press ENTER
3 Select menu option 7 and PLC Utility menu
press ENTER

Exiting Utility 7
Step On the CNC You can see
1 Press EXIT softkey F11 PLC Utility menu
2 Press CTRL + S Normal CNC screen
When the ladder utility opens, the following screen is displayed:

PLC APPLICATION MANAGEMENT

- PLC OPERATION
- Monitor and %TS time profile
- File management
- I/O configuration
- Software backup
- Animation

-- enter a command (Exit X OFF) --

../.. EXIT

! CAUTION
It is possible to delete the entire contents of the PLC by accessing File Management then
using the function Delete a file or Format the volume. Exercise extreme caution when
working in this menu!
The above menu gives access to the functions listed by pressing the first letter of the function name. For instance,
press P to access PLC OPERATION. All the submenus are accessed in the same way. Always use the first letter
of the commands available on the screen.

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PLC Diagnostics

14.7.1 PLC Operation

Selecting PLC Operation from the main menu of utility 7 displays the following screen. The PLC status field indicates
whether the PLC is running or stopped. Any PLC errors are reported on the next line. The list of errors is given below.

PLC OPERATION
PLC status: RUNNING
(No error)
TF Activity:
(0-7) 0 0 0 0 0 0 0 0
(8-15) 0 0 0 0 0 0 0 0
TH Activity:
(0-7) 0 0 0 0 0 0 0 0
(8-15) 0 0 0 0 0 0 0 0

Reset saved variables

../.. EXIT

PLC RUN Status Messages

Messag Comment
No error PLC operating correctly
Bad I/O bus configuration Cause
Unidentified card present
Card missing
Discrepancy between programmed configuration and real confi-
guration
Watchdog programming error
Corrective action
Check the input/output configuration (see Sec. 18.2.5 of Manual
938846). Check the state of %R97F.B (see Sec. 3.8.5 of Manual
938846).
Check %INI in the user programme (card and watchdog configu-
ration variables)
Erroneous I/O bus behaviour Cause
Link error on the bus
Corrective action
Check the state of bus signal %Rrc39.B (see Sec. 3.7.3)
Check the continuity of the fibre-optic ring
Contact NUM Customer Support
14

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PLC HALTED Status Messages

Message Comment
Internal monitor fault Cause
Serious internal error
Corrective action
Contact NUM Customer Support
Application time limit overrun Cause
RTC overrun (endless loop in a programme)
Corrective action
Correct the user programme
Unknown PLC error Cause
Serious internal error
Corrective action
Contact NUM Customer Support
Bad I/O bus configuration Cause
Unidentified card present
Card missing
Discrepancy between programmed configuration and real confi-
guration
Watchdog programming error
Corrective action
Check the input/output configuration (see Sec. 18.2.5 of Manual
938846).
Check the state of %R97F.B (see Sec. 3.8.5 of Manual 938846).
Check %INI in the user programme (card and watchdog configu-
ration variables)
Erroneous I/O bus behaviour Cause
Link error on the bus
Corrective action
Check the state of bus signal %Rrc39.B (see Sec. 3.7.3)
Check the continuity of the fibre-optic ring
Contact NUM Customer Support
Too many boards in I/O bus Cause
Too many inputs and outputs for the system
Corrective action
Decrease the number of input and output cards to remain within
authorised limits

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PLC Diagnostics

Background Task Activity

The activity of the background tasks is displayed by 16 counters associated with tasks %TF0 to %TF15.
Whenever a background task has been totally or partially processed during an RTC cycle, the task counter is
incremented by 1. This function is used to display tasks that are dormant, executing, the number of RTC cycles
required for execution of a task, etc.

Hardware Task Activity

The activity of the hardware tasks is displayed by 16 counters associated with tasks %TH0 to %TH15. Whenever a
hardware task has been processed, the task counter is incremented by 1.

CPU Commands
The commands GO, STOP and INIT are used to control the PLC during user programme debugging.

Operation Command Comment

Dtart the PLC Type G for Go Watchdog set
User programme runs
Stop the PLC Type S for Stop Watchdog reset
User programme stops
The HALTED status is displayed on the screen
page
System initialisation Type I for INIT Requires stopping the PLC
- Clears all errors
- Initialises the inputs/outputs

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14.7.2 Monitor and %TS Time Profile
Selecting Monitor and %TS Time Profile displays the following screen:

MONITOR AND %TS TIME PROFILE

Monitor Average: 0% Max: 0% Application time limit overrun: 0
TS0: Average: 0% Max: 0%
TS1: Average: 0% Max: 0%
Monitor Average: 0% Max: 0% Application time limit overrun: 0
TS0: Average: 0% Max: 0%
TS2: Average: 0% Max: 0%
Monitor Average: 0% Max: 0% Application time limit overrun: 0
TS0: Average: 0% Max: 0%
TS3: Average: 0% Max: 0%
Monitor Average: 0% Max: 0% Application time limit overrun: 0
TS0: Average: 0% Max: 0%
TS4: Average: 0% Max: 0%
Monitor Average: 0% Max: 0% Application time limit overrun: 0
TS0: Average: 0% Max: 0%
TS5: Average: 0% Max: 0%
Commands: Valid / Reset Max

../.. EXIT

This function displays the percentage of time occupied by the monitor and the %TS tasks each PLC cycle.
It shows:
- The average time occupied by the monitor each cycle and the maximum time occupied by the monitor
- The average time occupied by each %TS task
- The maximum time occupied by each %TS task and the application time overruns each cycle.
The percentage is calculated with reference to the time allocated to the monitor and user programme, i.e.:
- 18 ms for Series I and Series II processors
- Value in ms set in P99 for UCSII processors.
Commands
Three commands are available:
"V" Validate (enable) time monitoring
"I" Inhibit time monitoring
"R" Reset the times.

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PLC Diagnostics

14.7.3 PLC File Management

Selecting File Management displays the following screen:

PLC FILES MANAGEMENT

Inhibition of the PLCTOOL link

Application directory
File delete
Format the volume

PLC: 12040 used/17884 free

-- Enter a command (Exit F11) --

../.. EXIT

Commands
Four commands are available:
"I"/"V" Validate or invalidate the port configured exclusively for PLCTools
"A" Select the application directories. There are three directories: LADDER, C CODE and USER FILES
"D" Delete a PLC file
"F" Format the volume, which deletes all the PLC files from the memory.

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14.7.4 I/O Configuration
Selecting I/O Configuration displays the following screen:

I/O CONFIGURATION

Racks Slots

0 (P8) C B x 9 x 7 6 5 x x x 1 0
3 (E12) C B A 9 x x x x x 3 2 1 0
4 (E12) x x x x x x x x x 3 2 1 0

-- Commands <R#> or <C##> or <F11> --

../.. EXIT

This screen shows the racks and the slots fitted with cards. Slots marked x are not fitted with cards. The slots with
numbers or letters are equipped with cards.

Commands
"R" This command followed by a rack number from 0 to 7 shows information on the rack selected
"C" This command followed by a two-digit slot number flashes a message indicating the type of I/O card
currently plugged into the slot.

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PLC Diagnostics

14.7.5 Software Backup

Selecting Software Backup displays the following screen:

APPLICATION BACKUP

- Download the software

- Load the software
- Check-up of the downloading

-- Enter a command (Exit F11) --

../.. EXIT

The UNLOAD, LOAD and VERIFY functions are discussed in an earlier section. Refer to Section 13.8 for more
information.

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Machine Parameters

15 Machine Parameters

15.1 List of Parameters 15 - 3

15.2 Utility 5 - Machine Setup Data 15 - 6 15
15.3 Often Accessed Machine Parameters 15 - 8
15.3.1 P16 Home Switch Position in Machine
Dimensions 15 - 8
15.3.2 P18 Reversal Error 15 - 8
15.3.3 P42 Spindle Origins 15 - 9

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Machine Parameters

NOTICE 15
The information presented below is in condensed format. For more detailed information,
please refer to the Parameter Manual 938818.

15.1 List of Parameters

Parameter Category Description
P0 Axis declaration Displayed axes
P1 Axis declaration Modulo and limited excursion rotary axes
P2 Axis declaration Measured axes
P3 Axis declaration Servo-controlled and interpolated axes
P4 Axis declaration Axes programmed by diameter
Internal system measurement
P5 Axis declaration Axis group machine configuration
Lathe or milling machine groups
Front/Rear turrets
P6 Spindles Number of controlled spindles
Spindle type
Spindle assignments to axis groups
P7 Miscellaneous Initialisation in inches or metric units
Direction of automatic spindle search
Transmission of T and M functions to the machine processor in SEARCH and
TEST modes
Forcing of T functions
Interaxis calibration table enable Initialisation in G94 or G95
Forcing of manual mode
Homing selection
Subroutine call on reset
Feed stop with rigid tapping
Speed variation with gradual acceleration
P8 Axis declaration Axes with clamps
P9 Axis declaration Axis assignment to groups
P10 Measurements Axis measurement direction
P11 Measurements Axis measurement conversion coefficient
P12 Measurements Direction of handwheel measurement
P13 Measurements Handwheel measurement conversion coefficient
P14 Axis declaration Handwheels
P15 Axis travel Direction of homing
Switch status test
P16 Axis travel Reference switch position in machine dimensions
P17 Axis travel Axis travel limit
P18 Axis travel Reversal error compensation
P19 Servo-control Very high speed machining
P20 Servo-control Direction of axis speed reference
P21 Servo-control Servo-system loop gain coefficient
P22 Servo-control In-position window
P23 Servo-control Maximum following error
P24 Servo-control Synchronised axis control

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Parameter Category Description
P25 Measurements Poor signal and encoder channel complementarity check declaration
P26 Measurements Poor signal and encoder channel complementarity check
P27 Axis declaration Duplicated axis coupling definition
P28 Axis declaration Synchronised axis coupling enable
P30 Servo-control Maximum axis traverse rates
P31 Servo-control JOG speed and reduced speed
P32 Servo-control Maximum permissible acceleration
P33 Servo-control Approach speed
P34 Measurement Definition of measurement sensor type and parameters
P35 Miscellaneous Subroutine call by M function
P36 Measurement Measurement sensor graduation and number of graduations
P37 Communication Character format in DNC1
P38 Communication Translation of special DNC1 characters
P39 Communication DNC1 timeouts
P40 Spindles Spindle measurement conversion
P41 Spindles Spindle reference reversal
P42 Spindles Spindle origins
P43 Spindles Maximum spindle speed
P44 Spindles Indexing in-position window
P45 Spindles Spindle servo-system gain
P46 Spindles Spindle 1 speed range
P47 Spindles Spindle 2 speed range
P48 Spindles Spindle 3 speed range
P49 Spindles Spindle 4 speed range
P50 Miscellaneous Sampling period (CNC and QVN)
P51 Miscellaneous Minimum block execution time
P52 Servo-control Servo-system error tolerated on circles
P55 Servo-control Speed anticipation coefficient, number of terms used to calculate the filtered
reference for very high speed machining
P56 Servo-control Servo-loop time constant
P57 Servo-control Dynamic movement control
P58 Miscellaneous Interaxis calibration table reservation
Programme stack size
P59 Miscellaneous Graphic, display and print configurations
P62 Spindles Spindle acceleration
Minimum spindle reference in hole bottom
P63 Spindles Cycle axis integration time constant
Cycle axis position anticipation time constant
Spindle zero crossing anticipation time constant
P64 Axis declaration Carried or carrier axes
P65 Axis declaration Axes with quantified movements

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Machine Parameters

Parameter Category Description

P70 QVN Mapping by cards 15
P71 QVN Axes controlled by QVN
P72 QVN Direction of motor rotation
P73 QVN Maximum motor speed
P74 QVN Proportional action coefficient of the speed servo-loop corrector
P75 QVN Integral action coefficient of the speed servo-loop corrector
P80 Miscellaneous Xoff character choice
P84 Communication File upload timeout
P95 Miscellaneous Part programme memory segment size
P96 Miscellaneous Type of machine for PROCAM
Language selection
P97 Axis declaration Number of axis groups in the system
P98 Miscellaneous Integrated machine processor programming language selection
P99 Miscellaneous Maximum time allocated to the PLC application
P100 Communication MAPWAY/ETHWAY network and station number
P110 Communication UNI-TELWAY master settings
P111 Communication UNI-TELWAY slave settings
P112 Communication Settings of the line assigned to PLCTOOL

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15.2 Utility 5 - Machine Setup Data
Utility 5 gives access to the machine parameters for editing, backup/restore and display.

Accessing Utility 5
Step On the CNC You can see
1 Press UTIL softkey F11 Operator Utility Menu
2 Select menu option 0 and Maintenance Utility menu
press ENTER
3 Select menu option 5 and Machine Setup Data utility
press ENTER menu

Exiting Utility 5
Step On the CNC You can see
1 Press EXIT softkey F11 Machine Setup Data utility
menu
2 Press CTRL + S Normal CNC screen

MACHINE SETUP DATA

>0 DISPLAY
1 CHANGE
2 LOAD
3 UNLOAD
4 CHECK

?❚
../.. EXIT

To select a function, type the corresponding number. For instance, type 1 to edit the parameters.

15 - 6 en-938979/0
Machine Parameters

Moving from Parameter to Parameter

Use one of the following commands to move from one parameter to another: 15
"PgDn" Next parameter
"Pxx" Parameter number

Moving up and down N words within a Parameter

Down arrow Move down
"Nxx" Word number

Editing a Word
1. Place the cursor on the word to be edited (sign > opposite the word)
2. Type #
3. Press ENTER
4. The line is displayed in the command line at the bottom of the screen
5. Enter the new value and confirm by pressing ENTER.

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15.3 Often Accessed Machine Parameters
15.3.1 P16 Home Switch Position in Machine Dimensions

Description
Used to set the measurement origin (ORPOM) of an axis inside or outside the travel limits.

Principle
The word number gives the physical address of the axis.
Physical axis @ List of words Switch position in internal measurement unit
@0 Word N0
@1 Word N1
@2 Word N2
‘‘
‘‘
@31 Word N31
The values are expressed in the internal measurement unit: mm/100, µm, µm/10 or µm/100 for linear axes (see Sec.
4.8 of manual 938818) and deg/10000 for rotary axes.
To determine the sign of ORPOM, go to the desired measurement origin OM and set the initialisation point.
Each word contains the position of the home switch on the corresponding axis in machine dimensions. The sign is
determined by the direction from the measurement origin OM to the datum switch, taking into account the normalised
axis direction.
UNI-TE request (see UNI-TE Protocol User’s Manual).
The measurement origin on an axis can be modified by a UNI-TE request. A reset (CNC reset) resets the CNC to the
state specified by P16.

15.3.2 P18 Reversal Error

Description
Used to correct positioning errors due to backlash.

Principle
The word number gives the physical address of the axis.
Physical axis @ List of words
@0 Word N0
@1 Word N1
@2 Word N2
‘‘
‘‘
@31 Word N31
The values are expressed in the internal measurement unit: mm/100, µm, µm/10 or µm/100 for linear axes (see Sec.
4.8 of manual 938818) and deg/10000 for rotary axes.

15 - 8 en-938979/0
Machine Parameters

The absolute value contained in a word gives the maximum backlash on the corresponding axis. The sign gives the
direction of movement to which backlash correction applies and the sign of the correction. 15
Value > 0: Positive correction applied when the axis moves in the positive direction.
Value < 0: Negative correction applied when the axis moves in the negative direction.
UNI-TE request (see UNI-TE Protocol User’s Manual)
The backlash error compensation can be modified by a UNI-TE request. A reset (CNC reset) resets the CNC to the
state specified by P18.

15.3.3 P42 Spindle Origins

Description
Used to define the spindle origin positions.

Principle
This parameter includes four decimal values defining the origin positions of spindles 1 to 4.
Spindle 1 Word N0
Spindle 2 Word N1
Spindle 3 Word N2
Spindle 4 Word N3
The values are expressed in the internal measurement units (see Sec. 8.5 of manual 938818).
The spindle origin setting is effective on the first encoder marker pulse encountered during the first revolution:
- if P42 = 0 -> Spindle measurement = 0 on first marker pulse,
- if P42 = x -> Spindle measurement = x on first marker pulse.
UNI-TE request (see UNI-TE Protocol User’s Manual)
The spindle origins can be modified by a UNI-TE request. A reset (CNC reset) resets the CNC to the state specified
by P42.

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PCNC

16 PCNC

16.1 Using in the PC 16 - 3

16.1.1 Switching between the PC and CNC 16 - 3
16.1.2 OS/2 Keyboard and Mouse Command
Summary 16 - 3
16.2 OS/2 Window Session 16 - 8 16
16.3 Hard Drive Directory Structure 16 - 8
16.3.1 Software Versions 16 - 8
16.4 Making Utility Diskettes 16 - 9
16.5 Hard Drive Backup/Restore 16 - 9
16.5.1 Backup Procedure 16 - 9
16.5.2 Restore Procedure 16 - 9
16.6 OS/2 Text Editor 16 - 10
16.7 Mouse Enabling 16 - 10
16.8 Default System Files 16 - 11
16.8.1 CONFIG.SYS 16 - 11
16.8.2 AUTOEXEC.BAT 16 - 12

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PCNC

Some versions of the NUM 1060 come equipped with an integral PC (Personal Computer) built into the rack. There
are some special maintenance issues which should be considered for a PCNC version.
The most important item to consider for maintenance is that of hard drive backup and restore functions. Since the
system has a built in hard drive, it is very important that the contents of this disk be backed up. In the event that a hard
drive does fail, you must be able to replace the drive and reload the software quickly to get the machine back up. This
chapter is devoted to the configuration of the PC. 16
16.1 Using in the PC
The first thing you must learn is to do is to navigate around the PC. There are numerous keystroke and mouse
commands which you will need to know to be proficient at this. This section describes those functions.

16.1.1 Switching between the PC and CNC

From CNC to PC Display
Pressing ALT+F9 on the keyboard displays a screen similar to the one on the right.

From PC to CNC Display

1. Locate the minimised window icon and open it by double clicking it with the mouse.
2. Locate the NUM Symbol icon within this window and double click it with the mouse.

16.1.2 OS/2 Keyboard and Mouse Command Summary

Keyboard The following tables list some of the most common tasks you can do, using either the
keyboard or a mouse.
The plus (+) sign between key names means to press and hold down the keys in the
order shown and release them together.
Mouse When a column is left blank under the Mouse heading, it means that there is no
equivalent mouse function. The keyboard must be used.

The following terms are used to describe actions taken with a mouse.
Click Press and release a mouse button. Instructions explain whether you should click
mouse button 1 or 2.
Double-Click Press and release mouse button 1 twice in quick succession.
Drag Move an object across the computer screen with a mouse.
Open Point to an ojbect and double click. Instructions explain which object to point to.
Point Move the mouse pointer.
Select Point to an object and click mouse button 1. Instructions explain which object to point
to.

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System Tasks
Task Keys Mouse
Help F1 Select the word Help
Restart the system Ctrl+Alt+Del
Switch to the next window. Alt+Tab Select the window
Switch to the next window or full Alt+ESC Press both mouse buttons at the
screen session same time; then open window

Display the Window List Ctrl+ESC Point to an empty area on the

desktop then click both mouse
buttons at the same time .

Object Tasks
Task Keys Mouse
Move among objects Arrow keys Point to the object
Select an object Use the arrow keys to move among Select the object
the objects. Press the spacebar to
select an object
Select more than one object Shift+F8 to begin Add mode. Press and hold the Ctrl key.
Use the arrow keys to move among Select an object. Repeat as needed.
objects. Press the Spacebar Release the Ctrl key when done
to make each selection.
Repeat as needed.
Press Shift+F8 again to end Add.
Select all objects Press Ctrl+/ Press and hold mouse button 1;
then drag the pointer over every
object
Deselect all objects Press Ctrl+\ Select an empty area on the desktop
Open an object Select it; then press Enter Point to the object then Double-Click
Delete an object Select it; then press Shift+F10. Point to the object then press
Select Delete from the pop-up and hold down mouse button 2.
menu. Drag the object to the Shredder
object. Release mouse button 2
Print an object Select it; then press Shift+F10. Point to the object then press
Select Print from the pop-up menu and hold down mouse button 2.
Drag the object to the Printer object.
Release mouse button 2
Move an object Select it; then press Shift+F10. Point to the object then press
Select Move from the pop-up menu and hold down mouse button 2.
Drag the object to another folder
object. Release mouse button 2

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PCNC

Task Keys Mouse

Copy an object Select it; then press Shift+F10. Press and hold down the Ctrl key;
Select Copy from the pop-up menu then point to the object.
Press and hold down mouse button 2.
Drag the object to where you want
a copy to appear. Release mouse 16
button 2; then release the Ctrl key.
Rename an object Select it; then press Shift+F10 Press and hold down the Alt key;
Press ->; then press Enter. Select select the name (title). Release
the General tab. Select the Title the Alt key. Edit the name.
field; then edit the name Select an area away from the name.
Display the pop-up menu for the Press Alt+Shift+Tab then press Point to an empty area of the desk
desktop folder Ctrl+\; then press Shift+F10 top folder then click mouse button 2
Display the pop-up menu for an Select it; then press Shift+F10 Point to the object; then click mouse
object button 2
Select the first choice in a Home Select the choice
pop-up menu
Select the last choice in a End Select the choice
pop-up menu
Select a choice using the under- Type the underlined letter
lined letter
Get Help Select an object; Point to the object then click
then press F1 mouse button 2. Select Help
Move between the object and the Press Alt+F6 Select the window or object
Help window

Window Tasks
Task Keys Mouse
Get Help F1 Select the word Help; then select the
type of help you want
Display the pop-up menu Alt+Spacebar Point to the title bar menu for a
window icon; then click mouse
button 2
Move a window Alt+F7; then use the arrow keys Point to the title bar icon; then press
and hold down mouse button 2.
Drag the window to a new location.
Release mouse button 2
Size a window Alt+F8; then use the arrow keys Point to the border; then press and
hold down mouse button 2. Drag the
border of the window in any direc-
tion. Release mouse button 2

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Task Keys Mouse
Set a default size for a window Press Alt; then press S. Use the up, Press and hold the Shift key;
down, left, or right cursor keys to then point to a corner of the window
adjust two of the borders; border. Press and hold mouse
then press Enter. Note: If you press button 1; then drag the border to the
the mnemonic key for Hide, desired size.
Minimise, or Maximise, instead of Release mouse button;
the S key for Size, the selected then release the Shift key
choice will become the default size
of the window.
Minimise a window Alt+F9 Select the Minimise button
Hide a window Alt+F11 Select the Hide button
Maximise a window Alt+F10 Select the Maximise button
Close a window Alt+F4 Double-click on the title bar icon
Move up through the contents of Page Up or PgUp Select the area above the slider box
a window, one page at a time on the scroll bar
Move down through the contents Page Down or PgDn Select the area below the slider box
of a window, one page at a time on the scroll bar
Move to and from the menu bar F10 Select the menu bar or the window

Notebook Tasks
Task Keys Mouse
Get Help F1 Select the Help pushbutton
Move to the next page Alt+Page down Select a notebook tab
Move to the previous page Alt+Page up Select a notebook tab
Move the cursor from the notebook Alt+Up Arrow Select a notebook tab
page to a tab
Move the cursor from a tab to the Alt+Down Arrow Select the notebook page
notebook page
Move to the next field Tab Select the field
Move to the next item within a field Up, Down, Left, or Right Arrow Select the item
Select an item in a single selection Enter Select the item
field
Select an item in a multiple Spacebar Select the button or box next
selection field. to the item

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PCNC

Help Window Tasks

Task Keys Mouse
Switch between a help window Alt+F6 Select the window
and the object or window for which
help was displayed
Display General help F2 Select Help; then select
16
General help
Display Keys help F9 Select Help; then select
Keys help
Display Help index F11 or Shift+F1 Select Help; then select
Help index
Display Using help Shift+F10 Select Help; then select
Using help
Display help for a highlighted Use Tab to move the cursor to the Double-Click on the
word or phrase highlighted word or phrase; highlighted word or phrase
then press Enter
Display the previous help window Esc Select the Previous push
button
Search for a word or phrase Ctrl+S Select Services; then select
Search

Master Help Index Tasks

Task Keys Mouse
Open the Master Help index Enter Double-Click on the Master
Help Index
Move through the topics, one fine Up or Down cursor keys Select the topic
at a time
Move down through the topics, Page Down or PgDn Select the area below the
one page at a time. slider box on the scroll bar
Move up through the topics, Page Up or PgUp Select the area above the
one page at a time slider box on the scroll bar
Move to the topics beginning Type the letter of the alphabet Select the letter of the
with a letter alphabet
Switch between an entry and Alt+F6 Select the window
the Master Help Index
Display related information Use Tab to move the cursor to the Double-click on an entry
entry listed under related informa- listed under related informa-
tion; then press Enter tion
Return to the Previous help window Esc Select the Previous push
button

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16.2 OS/2 Window Session
During system maintenance, it may be necessary to open an OS/2 session to check the directories on the hard disk
or manipulate files. Access to this mode is from the Desktop.

Procedure
1. Find and double-click the OS/2 system icon on the desktop.
2. Locate the OS/2 Window Session icon in the OS/2 System window, and double-click it.
3. This opens an OS/2 windowed session. This session allows DOS-like commands, such as choose directory (CD),
make directory (MD), copy file (COPY), etc. To leave this session, type EXIT and press ENTER.
From this session you can browse the hard drive to determine if all is well with OS/2 and the special NUM files stored
on the hard drive. See Section 16.3.

16.3 Hard Drive Directory Structure

Strict compliance with the structure of certain directories containing files dedicated to the NUM application is required.
The files listed below must be located in the specified directories.

C:\NUM\DRIVER\MEM_GLB.SYS

C:\NUM\GRAPHIC \CODES.NUM
\GPCCODES.NUM
\GR_PC.EXE
\NUM12x18.DLL
\NUM12x36.DLL
\NUM16x12.DLL
\NUM16x24.DLL
\NUM24x56.DLL
\NUM6x18.DLL
\NUM8x12.DLL
\NUM9x12.DLL

C:\OS2\DLL\NUMHOOKS.DLL

16.3.1 Software Versions

The files in these directories exist in several versions, depending on the software installed on the CNC. Since not all
the versions are mutually compatible, it is not recommended to replace files by other files which have a different index.
In case of doubt, check with your local NUM agent, specifying the version of software on your CNC.

16 - 8 en-938979/0
PCNC

16.4 Making Utility Diskettes

In order to backup and restore the system hard drive, it is necessary to make a set of utility diskettes. These diskettes
are created from the OS/2 Desktop:
- Find and double-click the OS/2 System icon on the desktop
- In the window that opens, select and double-click the SYSTEM SETUP icon
- Find and double-click the UTILITY DISK icon and follow the instructions on the screen.
16
16.5 Hard Drive Backup/Restore
In order to make hard drive backup diskettes you must be in a pure OS/2 session with no NUM files running. In order
to accomplish this, use the utility diskettes made in section 16.4.

16.5.1 Backup Procedure

1. Power down the CNC completely.
2. Insert utility diskette 1 into the floppy drive and power on the CNC.
3. You will be prompted for loading each diskette in order.
4. After OS/2 has finished booting, the machine will be inoperable, but you can run the PC.
5. Insert utility diskette 3 into the floppy drive.
6. Type "Backup C: A: /S" then press ENTER.
7. You will be prompted to insert as many as thirty-five (35) diskettes during this process. So be prepared and have
enough diskettes on hand.
8. When you are prompted that the backup is completed, remove the last diskette from the floppy drive, and power
down the CNC.
9. Power up the CNC after 1 to 2 minutes.
10. Hard drive backup is completed.

16.5.2 Restore Procedure

1. Power down the CNC completely.
2. Insert utility diskette 1 into the floppy drive and power on the CNC.
3. You will be prompted for loading each diskette in order.
4. After OS/2 has finished booting, the machine will be inoperable, but you can run the PC.
5. Insert utility diskette 3 into the floppy drive.
6. Type "Restore A: C: /S" then press ENTER.
7. You will be prompted to insert as many as thirty-five (35) diskettes during this process.
8. When you are prompted that the restore is completed, remove the last diskette from the floppy drive, and power
down the CNC.
9. Power up the CNC after 1 to 2 minutes.
10. Hard drive restoration is completed.

REMARK There are other backup methods that are easier to use, but they require available
of a special device, such as tape streamer or a removable hard disk. A method
based on the Iomega Zip drive has been tested. For more information, ask your
local NUM dealer.

en-938979/0 16 - 9
16.6 OS/2 Text Editor
OS/2 has a built-in text editor which is accessed via an OS/2 session.

Procedure
1. Find and double-click the OS/2 system icon on the desktop.
2. Locate the OS/2 Window Session icon in the OS/2 System window, and double-click it.
3. This opens an OS/2 windowed session. This session allows DOS-like commands, such as choose directory (CD),
make directory (MD), copy file (COPY), etc. To leave this session, type EXIT and press ENTER.
4. Type "ED flename.ext" and press ENTER. The editor starts and the file opens.
5. To exit the editor, double click on the upper left-hand corner of the window and you will be prompted to save your
file etc.
6. To leave this session type EXIT at the prompt and press ENTER.
From this editor you can edit the PC’s CONFIG.SYS or AUTOEXEC.BAT files.

16.7 Mouse Enabling

In order to enable or disable the mouse, you will have to access the system setup window. The procedure is outlined
below.

Procedure
1. Find and double-click the OS/2 system icon on the desktop.
2. Locate the SYSTEM SETUP icon in the OS/2 System window, and double-click it.
3. The System Setup window opens.
4. Locate the CONFIGURE PREINSTALLED SYSTEM ICON and double-click it.
5. Click the MOUSE selection and press the OK button.
6. Select the type of mouse which you have. Typically two-button mice use "SERIAL POINTING DEVICE" while
three-button mice use "LOGITECH M SERIES". But you might have to experiment to find the right selection.
7. Click the OK button when your selections are made, and the CNC will tell you that you will have to reboot to activate
the new configuration.
8. Close all windows on the PC, and return to the CNC.
9. Power down the CNC.
10. After 1 to 2 minutes, power up the CNC and the new mouse configuration will be active.

16 - 10 en-938979/0
PCNC

16.8 Default System Files

16.8.1 CONFIG.SYS

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16.8.2 AUTOEXEC.BAT

16 - 12 en-938979/0
Option Grid Settings

17 Option Grid Settings

17.1 Viewing the Options 17 - 3

17.1.1 Number of Axes 17 - 3
17.1.2 Memory Sizes 17 - 4
17.1.3 Option Setting History 17 - 4
17.1.4 System Bus Hardware Configuration 17 - 5
17.1.5 PLC Bus Hardware Configuration 17 - 5
17.2 Setting the Options 17 - 6
17.2.1 Option Data 17 - 6
17.2.2 Settings 17 - 7 17
17.2.3 PERSOTool 17 - 7

en-938979/0 17 - 1
17 - 2 en-938979/0
Option Grid Settings

Another very important topic is that of the option settings. If it ever becomes necessary to change a rack or add an
option, you will need the procedures in this section.

17.1 Viewing the Options

Proceed as follows to access the option infor-
mation:
0 1 2 3 4 5 6 7 8 9
10 11 12
1. Press the PLC l/O key (F10). X X 0
2. Type 8 and press ENTER.
3. The screen shown on the right is displayed. O
X

X
X
X
X 1
2
3
17
4
Each option present in the CNC is denoted by P 5
the presence of an ‘X’. The option numbers are 6

shown along the top and down the right side.

T 7
8
I 9
For example: Option number 95 is circled on the 13 14 15 16 17 18 19 20 21 22 23 24 25
screen. O 0
1
N 2
3
S 4
5
6
7
8
9

17.1.1 Number of Axes

This screen shows how many CNC or PLC axes
and measured spindles are enabled in the CNC.
AXES NUMBER
It also shows the maximum number of
interpolated axes, and which axes are
designated for PLC group usage only. NUMBER OF CNC OR PLC AXES : 7
Proceed as follows to access this information: NUMBER OF SPINDLES : 2
1. Press the PLC l/O key (F10).
2. Type 8 and press ENTER.
NUMBER OF INTERPOLATED AXES : 5
3. Press PAGE DOWN once.
4. The page showing the number of axes is NUMBER OF PLC ONLY AXES : 2
displayed.

en-938979/0 17 - 3
17.1.2 Memory Sizes
This screen shows the memory size available
for part programme storage (Zones 0, 1, 2 and MEMORY SIZES
3 together) and PLC code storage.
Proceed as follows to access this information:
1. Press the PLC l/O key (F10).
2. Type 8 and press ENTER. PART PROGRAM STORAGE : 1024
3. Press PAGE DOWN twice.
4. The MEMORY SIZES page is displayed. PLC PROGRAM STORAGE : 256

TAILLE ZONE MMI : 800

17.1.3 Option Setting History

This screen shows when the CNC was first and
last configured and by whom.
HISTORY
Proceed as follows to access this information:
1. Press the PLC l/O key (F10).
2. Type 8 and press ENTER.
3. Press PAGE DOWN three times. FACTORY OUT :
4. The HISTORY screen is displayed.
26 / 2 / 92 15:20:65 CABE-EF

LAST MODIFIED ON :
8 / 6 / 94 10:37:23 D2R2

17 - 4 en-938979/0
Option Grid Settings

17.1.4 System Bus Hardware Configuration

This screen shows the type of cards and the
respective part numbers for all the cards plugged
SYSTEM BUS HARDWARE CONFIGURATION
into the CNC bus. The cards are displayed in the
same order as in the rack. Address Designation File number Vers Ident.

Proceed as follows to access this information: Unknown card 000 000 000 8 $0007F8
0 4M V2 graphic processor 204 202 778 0 $005340
1. Press the PLC l/O key (F10). 1 1M PLC 204 201 935 0 $004B00
2 V2 1,7M memory 204 202 301 0 $008D80
2. Type "8" and press ENTER.
3. Press PAGE DOWN four times.
3
4
4 V1 14b encoder axes 204 201 982 0 $000E00 17
4. The System Bus configuration screen is 5
6
displayed. 7
8
9
10
11
12
13
.../...

17.1.5 PLC Bus Hardware Configuration

This screen shows the type of cards and the
respective part numbers for all the cards plugged
PLC BUS CONFIGURATION (RACK 0)
into the PLC bus. The cards are displayed in the
same order as in the rack.
Address Designation File number Vers. Ident.
Proceed as follows to access this information: 0 Main serial bus 204 201 857 0 $000000
1. Press the PLC l/O key (F10). 0 130W power supply with optic F. 204 201 950 0 $000000
2. Type "8" and press ENTER. 1
2
3. Press PAGE DOWN five times. 3
4. The PLC bus configuration screen is 4
5 32 inputs board 204 201 926 0 $000A00
displayed. 6 32 relayed outputs board 204 201 746 0 $000100
7
8
9
10
11
12
13

en-938979/0 17 - 5
17.2 Setting the Options
The options are set using utility 12. Proceed as follows to access this utility.

Accessing Utility 12
Step On the CNC You can see
1 Press UTIL softkey F11 Operator Utility Menu
2 Select menu option 0 and Maintenance Utility menu
press ENTER
3 Select menu option 12 and Options locking menu
press ENTER

Exiting Utility 12
Step On the CNC You can see
1 Press EXIT softkey F11 Options locking menu
2 Press CTRL+S Normal CNC screen

17.2.1 Option Data

During the machine’s lifetime, the user may need extra functions corresponding to a different customisation. The option
data are printed on a piece of paper supplied by NUM. A typical listing is shown below.

Example of customisation grid

JOB REFERENCE : XXXXX 88
EEPROM SOFTWARE # : SIMU EEP
CNC SOFTWARE # : 282686C1
USER PLC SOFTWARE # :
PARAMETER TABLE : F8
OPTIONS PRESENT:
COMM. DEV.
61258 11
61371 13
61581 42
61511 47
60
110
NUMBER OF CNC OR PLC AXES : 7
NUMBER OF SPINDLES : 2
NUMBER OF INTERPOLATED AXES : 5
NUMBER OF PLC ONLY AXES : 1
PART PROGRAM STORAGE : 768
PLC PROGRAM STORAGE : 256
GRID:
140000 210000 0 20000 0 0 0 0
KEY: 13846C75
DATE: 18 5 92 TIME: 9 15 8
IDENTIFICATION: CABE-EF
RESUME:
XXXXXX 00 / 140000 210000 0 20000 0 0 0 0
7 2 5 2/128 64 / CABE-EF / 138467C5

17 - 6 en-938979/0
Option Grid Settings

17.2.2 Settings
When utility 12 opens, the following menu is displayed:
0 JOB REFERENCE
1 AXES NUMBER
2 MEMORY SIZES
3 OPTIONS LIST
4 DATE
5
6
LOCKING
EDITION
17
To select a menu option, press the number followed by ENTER. Inside each menu there are more data to be entered.
All the data should be taken from the printed option list given to you by NUM.
On each of the submenus you will see prompts on the bottom left-hand comer of the CRT. These prompts are used
for entering the settings.

Example: AXIS NUMBER submenu:

AXES NUMBER
NUMBER OF CNC OR PLC AXES: 7
NUMBER OF SPINDLES: 1
NUMBER OF INTERPOLATED AXES: 5
NUMBER OF PLC ONLY AXES: 0

(A, B, IS, XA)

Use the prompt along the bottom as follows:

- A 7 ENTER Changes NUMBER OF CNC OR PLC AXES
- B 1 ENTER Changes NUMBER OF SPINDLES
- IS 5 ENTER Changes NUMBER OF INTERPOLATED AXES
- XA 0 ENTER Changes NUMBER OF PLC ONLY AXES
Once you have entered all the data on all the submenus, you can finally select the most important menu option, number
5. This menu option will lock the current setting into the control and erase the old ones. When locking is completed
you can connect a printer and print out the current grid using menu item 6, EDITION. But this is usually not required
since you already have a piece of paper with the options on it.

17.2.3 PERSOTool
The options can also be loaded using the PERSOTool software. The procedure for this is given in Manual 938973,
pages 9-14.

en-938979/0 17 - 7
17 - 8 en-938979/0
Main Diagnostics

18 Main Diagnostics

System cannot be
powered up

No Messages Yes
displayed
on the screen

Message
No Yes Yes with request for No
Key beeps
acknowledgement
18
Write down Write down
Check mains
Check the CRT message and the message and
power supply
acknowledge contact NUM

No No Check the
OK OK
message
description
Yes Yes

Replace CNC
Replace Contact End
power supply
the CRT NUM
unit
Locate and
correct
the problem No
OK

Yes

End Contact
NUM

en-938979/0 18 - 1
Machine
cannot be
powered up

Error
Yes
messages
displayed

DEF LED
No
Correct the lit on machine
cause processor

Yes Check messages in

PLC OPERATION
Replace page of utility 7
Reboot machine
processor

Yes
End Fault No PLC stopped
cleared
No
Yes
Yes Code
Reboot PLC
End incoherent
No

Contact NUM, End

Reload the indicating
application the messages

End

18 - 2 en-938979/0
Initial Massages

19 Initial Messages

A number of information and error messages may appear while the system is booting up. These messages need to
be acknowledged. They are listed below with their meaning and possible cause

PARAM TABLE INDEX ERROR The table of machine parameters Information message followed by an
doesn’t match the CNC software index acknowledgement request to allow
May appear after a software upgrade parameter update.

REINIT TAB (Y) Follows the above message to request Answer Y

acknowledgement

EEPROM BACKED UP? Follows the above messages. The Answer Y if a backup copy exists
upgrade involves editing of the
parameters, so it is necessary first to
back them up

WRITING IN EEPROM Information message, indicating that the Nothing to do

parameters are being updated 19
TOO MANY AXES OR SPINDLES The number of slave axes or spindles Acknowledge the message, then correct
declared in the machine parameters the machine parameters (P2, P3 and/or
exceeds the maximum number P6) and reboot the system. Programme
authorised in the configuration control of the machine is inhibited as
long as this message appears at power
up

WRONG NUMBER OF PLC AXES The configuration specifies a minimum Acknowledge the message, validate the
number of PLC axes that does not exist required number of PLC axes and
reboot the system. Programme control
of the machine is inhibited as long as
this message appears at initialisation

OPTIONS NOT VALID Error in the options grid Reload a correct customisation with the
PERSOTool utility if possible.
Otherwise, contact NUM Customer
Support

MEAS. OFFSET SPACE FULL The area dedicated to measurement Edit the measurement offset tables
offsets is full (utility 2) to delete the excess data

CUSTOMISATION NOT FINAL System not configured Operation is possible, but the
configuration is necessary to be able to
benefit from the warranty.
Contact NUM Customer Support

SYSTEM NOT COVERED BY Continuation of the above message Contact NUM Customer Support
WARRANTY

CONTINUE Request for acknowledgement Answer Y

BOOTING SYSTEM-CNC Initialisation in progress Momentary information message. If this

message remains displayed, contact
NUM Customer Support

en-938979/0 19 - 1
MACHINE PARAM ERROR Error in a machine parameter Acknowledge the message and check
the machine parameters (size, contents)

ACKNOWLEDGE (Y/N) Request for acknowledgement Answer Y after reading the above
messages

CKS ERROR IN PARAM TABLE Checksum error in the machine Reload the parameters. If the message
parameter table remains displayed, contact NUM
Customer Support

END OF CNC TESTS Information message; the start-up tests This message should only be displayed
are finished momentarily. If it remains displayed,
there is a hardware problem. Contact
NUM Customer Support

SAMPLING PERIOD TOO SMALL The sampling period defined by P50 is Set P50 as a minimum to the value
too short for the number of axes indicated by the next message
declared

IT MUST BE AT LEAST Continuation of previous message Set word N1 of P50 to a value higher
than the one specified

MISSING AXIS At least one of the axes declared in P2 Check the axis ports, and check that P2
was not detected as connected to the matches the machine configuration
axis cards

SAMPLING PERIOD MUST BE A The sampling period for DISC axes must Set words N0 and N1 of P50 so that N0
MULTIPLE OF PERIOD QVN AND be a multiple of the sampling period of is a multiple of N1 and greater than 2 ms
EQUAL AT LEAST AT 2 ms FOR the QVN axis cards (P50 N)
AXIS QVN

WARNING : SAMPLING PERIOD On certain 1020/1040 and UCSII Set word N0 of P50 to an integer
IS NOT A MULTIPLE OF 2 ms systems, the sampling period must be a multiple of 2000
multiple of 2 ms

TRANSMISSION ERROR On an absolute measurement system Check the SSI encoder wiring. The
MESURE DURING (SSI), a transmission error occurred problem may also be due to the encoder
POM AXIS during homing itself or the axis card

NO TRANSMISSION MESURE On an absolute measurement system Check the encoder wiring. The problem
DURING POM AXIS (SSI), no data were transmitted during may also be due to the encoder
homing

SSI / MIXT or REFERENCE MARK Incompatible encoder type declared in Make sure the axis cards support the
SENSOR parameter P34 (absolute encoder for an type of encoder connected.
REFUSAL: CONNECTING AXIS axis card which does not support them) Check parameter P34
ACCES CONFLICT
Refer to P34

SAMPLING PERIOD QVN MUST On DISC systems, the QVN card refresh Set word N1 of P50
BE BETWEEN rate must be between 0.4 and 1 ms
0.4 ms and 1ms BY STEP OF
0.05 ms

19 - 2 en-938979/0
Card Part Numbers

20 Card Part Numbers

Power Supply Cards

130 W power supply 206202724
60 W power supply with fibre-optic link 282900003
60 W power supply without
fibre-optic link 206202725

Graphic Processors
1 MB V2 graphic processor 204202374
4 MB V2 graphic processor 204202778
4 MB V3 graphic processor 204203485

Machine Processors
1 MB V1 machine processor 204201935
4 MB V1 machine processor 204203035
4 MB V2 machine processor 204203123
20
CNC Processors
1 MB CNC processor 204201775
4 MB CNC processor 204202771
4 MB arbiter CNC processor 204203288

UCSII Modules
UCS II module 206202886
UCSII module 206203542

PCNC Modules
80 MB V1 PCNC module 206203115
170 MB V1 PCNC module 206203489
270 MB V2 PCNC module 206203502
500 MB V2 PCNC module 206203950

Memory Cards
2 MB 512 RAM memory 204202247
2 MB 768 RAM memory 204202248
2 MB 1.7 RAM memory 204202249
2-4 MB 512 V2 memory 204202229
2-4 MB 768 V2 memory 204202300
2-4 MB 1.7 V2 memory 204202301

en-938979/0 20 - 1
Axis Cards
4x16-bit V1 axis card 204202277
4x14-bit V1 axis card 204201982
3x14-bit V1 axis card 204202278
2x14-bit V1 axis card 204202279
4x16-bit V2 axis card 204202668
4x14-bit V2 axis card 204202222
3x14-bit V2 axis card 204202669
2x14-bit V2 axis card 204202670
4x16-bit abs axis card 204203002
4x14-bit abs axis card 204203000
3x14-bit abs axis card 204203000
QVN axis card 204202069

Input/Output Cards
32 relayed outputs 204201746
32 inputs 24 VDC 204201926
32I/24O 204202385
64I/48O 204202956
32I/24O 204203167

Miscellaneous Cards
IT/serial lines 204202370
Interrupt 204202371
Analogue inputs/outputs 204202613

1020/1040 Motherboards
1020/1040 motherboard 204203310

Memory Banks
4 MB DRAM 204202892
512 KB SRAM 204202894
2 MB SRAM 204203390

20 - 2 en-938979/0
List of Errors

Appendix A - List of Errors

A.1 Miscellaneous and Machine Errors A-3

A.2 Parametric Programming Errors A-5
A.3 Profile Geometry Programming (PGP) Errors A-5
A.4 Miscellaneous errors A-6
A.5 Axis Overtravel Errors A-6
A.6 Structured Programming Errors A-7
A.7 Axis Faults A-7
A.8 Errors in Pocket Cycles A-8

en-938979/0 A-1
A-2 en-938979/0
List of Errors

A.1 Miscellaneous and Machine Errors

Error No. Description
N1 Unknown character/Axis not recognised by the system
Too many digits after a function
Plus or Minus sign not allowed by a function
Wrongly formatted symbolic variable i.e.: F[SPEED] with [SPEED] = 123456
N2 Unknown G Function
N3 Attribute of a G code wrongly positioned
N4 Structured Programming Option disabled
N5 Geometric Programming Option not enabled
N8 Tool corrector number too high
N9 Too many consecutive non working blocks
N17 Missing close bracket
N20 M02 missing
N21 Incoherent definition of the billet in 3D
N25 Unknown sub-programme or sequence number
N26 Sub-programme nesting too deep - 4 maximum
N27 Tool Radius Correction: / in m/c reference mode G52 / In tapered threading
N28 Syntax error in CCSPD or working radius definition
G96 Must Be Followed By S
G97 Must Be Followed By S A
Starting Radius undefined
X or U are not programmed in this block nor in a previous one
N29 Error in the spindle speed
With auto Range Selection, S word not in any range
Without auto Range Selection, S not available in the programmed range
No programmed Range in CCSPD / No Suitable Range For S in G97
N30 Reader unconnected or faulty. Line fault in DNC or Plotter
N32 Axis referencing error
N33 All axis groups waiting for synchronisation
N34 Minimum radius for interpolation reached - G21
N35 Searched for sequence number not found
N36 Part programme memory full
N37 Maximum feed exceeded in thread chasing
N38 Control of a spindle already affected to another group
N39 Axis synchronisation fault
N40 Excessive following error on axis 0
N41 Excessive following error on axis 1
N42 Excessive following error on axis 2
N43 Excessive following error on axis 3
N44 Excessive following error on axis 4
N45 Excessive following error on axis 5
N46 Excessive following error on axis 6

en-938979/0 A-3
Error No. Description
N47 Excessive following error on axis 7
N48 Excessive following error on axis 8
N49 Excessive following error on axis 9
N50 Excessive following error on axis 10
N51 Excessive following error on axis 11
N52 Excessive following error on axis 12
N53 Excessive following error on axis 13
N54 Excessive following error on axis 14
N55 Excessive following error on axis 15
N56 Excessive following error on axis 16
N57 Excessive following error on axis 17
N58 Excessive following error on axis 18
N59 Excessive following error on axis 19
N60 Excessive following error on axis 20
N61 Excessive following error on axis 21
N62 Excessive following error on axis 22
N63 Excessive following error on axis 23
N64 Excessive following error on axis 24
N65 Excessive following error on axis 25
N66 Excessive following error on axis 26
N67 Excessive following error on axis 27
N68 Excessive following error on axis 28
N69 Excessive following error on axis 29
N70 Excessive following error on axis 30
N71 Excessive following error on axis 31
N72 Incomplete data, relative to the previous block
N75 G20 to G21 or G22 transition:
last block in G20 incomplete: programmed in PGP or with tool tip correction or with X<0
first block in G21 without X and Y or in G22 without Y and Z G21 or G22 to G20 transition:
last block in G21 or G22 incomplete or first block in G20 with tool tip correction in G21 or G22,
the starting radius is either negative or zero
N76 In G21: turning or milling fixed cycles are not allowed
N77 Tool type not compatible with the operation
N78 Syntax error in synchronising axis groups
G78P:4 digits max, the decimal part being < the number of axis groups
G78Q:4 digits max in ascending order
M00, M01 or M02 not allowed with G78P

A-4 en-938979/0
List of Errors

A.2 Parametric Programming Errors

Error No. Description
N91 Unknown parameter or variable
An unsigned function assigned a negative parameter?
N92 Error in assignment to a parameter or variable.
the parameter value exceeds the limit for the assigned function
N93 Error in the definition of a parameter or in the expression of a test:
L function not followed by one of the relational symbols =, <, >, &, !
appending with +,-,*,/, to a prohibited function
N94 Impossible operation: / square root of a negative number or division by zero?
N95 Trying to write to a read-only parameter
N96 Preceding block “look ahead”, conflicts with external parameter access
L100 ... programmed in definition of a profile of a G64
N97 Demands of a parameter in G76 not possible:
Equals symbol missing after the parameter number
Less than 10 characters reserved to write in the value
N98 Writing out of an axis group with a dynamic operator already used by another group

A.3 Profile Geometry Programming (PGP) Errors

Error No. Description
N101 PGP: insufficient data in the programming of a circle. A
Circle programmed on two parallel axes
N102 PGP: when programming a line by angle and one co-ordinate,
the missing co-ordinate cannot be calculated
N106 In G2 G3 3rd axis programmed without helical option
N107 PGP: if circle programmed by its radius and end point, the end point is more than twice the radius away
If circle programmed by its end point and centre, the trajectory misses the end point
Circle programming on two parallel axes (with l,J,K / see error 101)
N110 PGP: syntax error in the first of 2 blocks
N 111 PGP: syntax error in the second block
N112 PGP: line-line intersection in which:
first block start and second block end points coincide
or angle of first line = angle of second Line
N113 PGP: the values programmed in the two blocks do not allow the line intersection or the tangent
point to be calculated
N 114 PGP: intersection or tangent point not defined by ET+, ET-, ES+ or ES-
N121 PGP: syntax error in last of 3 blocks.
N122 PGP: the first two blocks are non-secant lines.
N123 PGP: data in the 3 blocks doesn’t allow the tangent points to be calculated
N124 PGP: second-third block tangent point not defined by ET+ or ET
N130 No axis movement in 1 of the 2 blocks connected by a fillet or chamfer

en-938979/0 A-5
Error No. Description
N131 M0, M1 or M2 is not allowed in a block with a fillet or chamfer
Programme sequence deficient end point, cannot be calculated
N135 A chamfer can only be ebtween 2 lines
N136 More than 2 non movement blocks between 2 elements whose intersection point or tangency is to be
calculated
N137 Change of interpolation plane even though the block is not valid

A.4 Miscellaneous errors

Error No. Description
N138 Change of interpolation plane must be in G40
N139 Two parallel axes programmed in the same block must be in G52 or G0
N140 Programming error in radius correction:
too many non-compensated blocks between 2 compensating ones
the following functions are forbidden in G41, G42:M0,M1,M2, access to external parameters and write
access to E8xxxx or L100 series parameters
N141 Parallel carried axes: programming a circle whose start point was programmed with one axis and whose
end point with its associated parallel axis
N143 G73/G74 is not allowed in radius correction mode
N144 Quantified axis displacement is different from the increment
N145 G29: abs. value (P*P + Q*Q + R*R) > 1 mm (normal vector is not unit vector)
N146 G29: correction in space
- at least one dimension P,Q or R missing
- at least one dimension X/U Y/V or Z/W missing
N147 Syntax error in G43
N148 Number of interpolated axes bigger than the maximum allowed
N149 Tool radius too large in relation to the programmed trajectory

A.5 Axis Overtravel Errors

Error No. Description
N150 X axis out of limits
N151 Y axis out of limits
N152 Z axis out of limits
N153 U axis out of limits
N154 V axis out of limits
N155 W axis out of limits
N156 A axis out of limits
N157 B axis out of limits
N158 C axis out of limits
N159 Move demanded on an unhomed axis

A-6 en-938979/0
List of Errors

A.6 Structured Programming Errors

Error No. Description
N190 Too many nested jumps or loops
N191 Syntax error in structured programming:
structured programming in MDI is not allowed
the index of a FOR loop must be: L variable or symbol or an E80000, E81000, or E82000 parameter
syntax error with PUSH or PULL
DO missing following a WHILE
IF ,THEN , ELSE programming in MDI
N192 Unknown key word, in this program context
N193 Structural error
N195 Stack overflow
Number of defined constants exceeds the reservation
N196 Error in the table-index declaration
N197 Use of an undeclared symbol
N198 Syntax error in declaring the symbol for a variable
N199 Syntax error in declaring a variable

A.7 Axis Faults

Error No. Description
N210 Axis 0 encoder signal fault A
N211 Axis 1 encoder signal fault
N212 Axis 2 encoder signal fault
N213 Axis 3 encoder signal fault
N214 Axis 4 encoder signal fault
N215 Axis 5 encoder signal fault
N216 Axis 6 encoder signal fault
N217 Axis 7 encoder signal fault
N218 Axis 8 encoder signal fault
N219 Axis 9 encoder signal fault
N220 Axis 10 encoder signal fault
N221 Axis 11 encoder signal fault
N222 Axis 12 encoder signal fault
N223 Axis 13 encoder signal fault
N224 Axis 14 encoder signal fault
N225 Axis 15 encoder signal fault
N226 Axis 16 encoder signal fault
N227 Axis 17 encoder signal fault
N228 Axis 18 encoder signal fault
N229 Axis 19 encoder signal fault
N230 Axis 20 encoder signal fault
N231 Axis 21 encoder signal fault
N232 Axis 22 encoder signal fault
N233 Axis 23 encoder signal fault
N234 Axis 24 encoder signal fault

en-938979/0 A-7
Error No. Description
N235 Axis 25 encoder signal fault
N236 Axis 26 encoder signal fault
N237 Axis 27 encoder signal fault
N238 Axis 28 encoder signal fault
N239 Axis 29 encoder signal fault
N240 Axis 30 encoder signal fault
N241 Axis 31 encoder signal fault
N245 Error in digital servo-control

A.8 Errors in Pocket Cycles

Error No. Description
N260 Executive memory busy
N261 Program number too high
N262 NU number not amongst those authorised
N263 TEST or GRAPHIC mode obligatory after initial load or modification
N264 No dimension programmed in the profiling plane
N265 First positioning block missing - The profile definition must start with G0 or G1
N266 Insufficient memory
N267 Invalid character in pocket syntax
N268 Incomplete pocket block or containing unauthorised data
N269 Incomplete profiling block
N270 Pocket definition partially or totally missing
N271 Tool orientation not perpendicular in relation to profiling plane
N272 Real tool incompatible with pocket’s machining data
N273 Change of profiling plane between pocket definition and execution
N274 Two pocket definitions overlapped
N275 NU0 programmed with G59
N276 Zero pocket depth
N277 Incomplete start or end point coordinates in pocket definition
N278 Spindle rotation inconsistent with that requested in pocket definition
N279 G Function unauthorised in pocket programming block
N280 First profiling block incomplete
N281 Profile inconsistency
N282 Incorrect pocket parameter
N283 Outer profile must exist and be unique
N284 Error in profile definition
N285 Too many profiles
N286 Tool pass too great relative to the tool dia.
N287 Tool pass too shallow in relation to the dimensions
N288 Finishing OP start point at a re-entrant angle or an area not yet roughed: change the entry point
N289 Tool diameter too big
N290 Pocket: Internal error
N291 Finishing stars point outside the profile
N292 Double positioning at start of profile

A-8 en-938979/0
Part 2

NUM DRIVE
Axis Motors

21 Axis Motors

21.1 General 21 - 3
21.2 Characteristics and Performance 21 - 3
BMH Axis Motors 21 - 4
General Characteristics 21 - 4
Identification 21 - 4
Detailed Characteristics 21 - 5
BMH055 Axis Motors 21 - 6
BMH055 Motor Characteristics Compared with
Other BMH Motors 21 - 6
Sensors 21 - 6
BMG Axis Motors 21 - 7
General Characteristics 21 - 7
Identification 21 - 7
Detailed Characteristics 21 - 8
21.3 Sensors 21 - 9
21.4 Thermal Probes 21 - 11
21.5 Maintenance 21 - 11
21.5.1 Checking Motor Insulation 21 - 11
21.5.2 Measuring the Winding Impedance 21 - 11
21.6 Technical Characteristics of Brushless Motors 21 - 12
21.7 Technical Characteristics of BMS Motors 21 - 13 21
21.8 Technical Characteristics of BMH Motors 21 - 15

en-938979/0 21 - 1
21 - 2 en-938979/0
Axis Motors

21.1 General
NUM DRIVE axis motors are brushless motors.
These motors have samarium cobalt magnets. They feature a high power-to-weight ratio, a high dynamic speed range
and a compact size. They can withstand a high applied overtorque without becoming demagnetised.
Several lines of motors are available:
- BMS brushless servo-motors with or without brake (delivered until the end of 1993)
- BMH brushless servo-motors with or without brake (available since September 1993)
- BMG high-inertia brushless servo-motors without brake (available since April 1995)
- BML compact brushless servo-motors without brake (available since November 1994)
These motors can be used with several different types of NUM DRIVE servo-drives with sinusoidal and flux vector
control.

21.2 Characteristics and Performance

The detailed mechanical characteristics of the axis motors (overall dimensions, shaft loads) are given in NUM DRIVE
Catalogue en-938919/3, Chapter 1.
For interfacing the motors and associated servo-drives, refer to the installation and maintenance manuals for the
servo-drives:
UAC Manual 738F003/C
MNDA Manual 738F006/E 21
MDLA Manual 738F008/C

en-938979/0 21 - 3
21 BMH Axis Motors

Characteristics

General Characteristics

- General characteristics as per IEC 34.1

- Sm Co magnets on the rotor periphery
- Torque range: 0.4-100 Nm at 1500-8000 rpm
- Protection class: IP65 as per IEC 529
- Shaft end protection IP54 as per IEC 529
- Power outputs by terminal box or connector
- Sensor outputs by connector
- Optional 24 VDC brake
- Thermal protection by thermal switch
- Winding insulation class: H (180 degrees) as per VDE 0530 (BMH055 class F)
- Out-of-round, concentricity, perpendicularity between flange and shaft as per DIN 42955 R
- End plate as per IEC 72.2
- Shaft end and key as per IEC 72.1
- Authorised mounting positions: IMB5 - IMV1 - IMV3 as per DIN 42950
- Balancing: classe S as per ISO 2373
- Ambient operating temperature rage 0-40°C

See NUM DRIVE Catalogue, page 1-5 for the characteristics of motor BMH055.

Identification

Typical: reference

BMH 142 2 N 1 R A 2 L
BMH series
axis motor
Size Shaft end
L: smooth (standard)
C: keyed
Length
Connector (s)
Speed 2: frontward (standard)
1: rearward
Power output
1: on terminal box (standard) Brake
5: on connector A: no brake (standard)
F: brake
Sensor
R: resolver with 3 pole pairs (standard)
U:resolver with 1 pole pair
T: resolver with encoder fitting
D: digital sensor (for DISC)

Note: Connectors must be ordered separately. See NUM DRIVE Catalogue, Chapter 3.

21 - 4 en-938979/0
BMH Axis Motors 21

Detailed Characteristics

Nominal Nominal Rotor Rotor Optional brake Motor weight Thermal Rated Power to
torque speed inertia inertia time rms nominal
at low without with Torque Current without with constant current torque
Pos. BMH... speed brake brake brake brake (100K) and speed
Motor Wdim
(100K) (100K)
Cn (1) ωn T th In
[Nm] [rpm] [g.m2] [g.m2] [Nm] [A] [kg] [kg] [min] [Arms] [kW]
1 055 2 S 0.4 8000 0.024 0.025 1 1.4 20 1.1 0.25
2 075 1 N 1.3 3000 0.08 0.12 2.5 0.5 3.5 3.85 20 2.2 0.41
3 075 1 V 1.3 6000 0.08 0.12 2.5 0.5 3.5 3.85 20 3 0.82
4 075 2 N 2.3 3000 0.12 0.16 2.5 0.5 4.3 4.65 23 2.7 0.72
5 075 2 V 2.3 6000 0.12 0.16 2.5 0.5 4.3 4.65 23 3.5 1.45
6 075 4 N 4 3000 0.21 0.25 5 0.5 6 6.35 26 3.5 1.26
7 095 2 N 4.3 3000 0.30 0.41 5 0.7 6.7 7.5 26 3.5 1.35
8 095 2 V 4.3 6000 0.30 0.41 5 0.7 6.7 7.5 26 5.9 2.70
9 095 3 N 6 3000 0.41 0.52 5 0.7 8 8.8 29 5.2 1.88
10 095 3 V 6 6000 0.41 0.52 5 0.7 8 8.8 29 10.3 3.77
11 095 5 N 9.2 3000 0.64 0.75 11 0.7 10.5 11.3 33 5.8 2.89
12 115 2 N 7.4 3000 0.70 1.07 12 0.8 9.6 10.9 29 5.5 2.32
13 115 2 V 7.4 6000 0.70 1.07 12 0.8 9.6 10.9 29 10.5 4.65
14 115 3 K 10.5 2000 0.97 1.34 12 0.8 11.7 13 33 5.3 2.20
15 115 3 N 10.5 3000 0.97 1.34 12 0.8 11.7 13 33 9.2 3.30
16 115 3 V 10.5 6000 0.97 1.34 12 0.8 11.7 13 33 12.6 6.60
17 115 4 K 13.3 2000 1.25 1.62 12 0.8 13.8 15.1 36 6.2 2.79
18 115 4 N 13.3 3000 1.25 1.62 12 0.8 13.8 15.1 36 10.1 4.18
19 115 4 V 13.3 6000 1.25 1.62 12 0.8 13.8 15.1 36 17.6 8.36
20 115 6 N 18.7 3000 1.80 2.17 22 0.8 17.9 19.2 41 12 5.87
21 142 2 K 12 2000 1.59 2.54 20 1 17.2 19.4 30 6 2.51
22 142 2 N 12 3000 1.59 2.54 20 1 17.2 19.4 30 10.4 3.77
23 142 2 R 12 4250 1.59 2.54 20 1 17.2 19.4 30 11.5 5.34
24 142 3 K 17 2000 2.19 3.14 20 1 20.1 22.3 34 9.5 3.56
25 142 3 N 17 3000 2.19 3.14 20 1 20.1 22.3 34 11.7 5.34
26 142 3 R 17 4250 2.19 3.14 20 1 20.1 22.3 34 16.9 7.57
27 142 4 K 22 2000 2.79 3.74 20 1 23 25.2 37 10.4 4.61
28 142 4 N 22 3000 2.79 3.74 20 1 23 25.2 37 15.6 6.91
29 142 4 R 22 4250 2.79 3.74 20 1 23 25.2 37 20.8 9.79
30 142 7 N 35 3000 4.29 5.24 40 1 31.7 33.9 42 24.2 11
31 190 2 K 25 2000 5.14 8.25 40 1.5 32.1 36.2 38 16.6 5.24
32 190 2 N 25 3000 5.14 8.25 40 1.5 32.1 36.2 38 19.9 7.85
33 190 2 R 25 4250 5.14 8.25 40 1.5 32.1 36.2 38 29.2 11.1
34 190 3 K 36 2000 7.10 10.2 40 1.5 37.3 41.4 43 19.7 7.54
35 190 3 N 36 3000 7.10 10.2 40 1.5 37.3 41.4 43 27.8 11.3
36 190 4 K 48 2000 9.04 12.1 40 1.5 42.4 46.5 48 20.6 9.63
37 190 4 N 48 3000 9.04 12.1 40 1.5 42.4 46.5 48 30.3 14.5
38 190 5 H 56 1500 11 14.1 80 1.5 47.6 51.7 52 20 8.79
39 190 5 L 56 2500 11 14.1 80 1.5 47.6 51.7 52 31.4 14.7
40 190 7 K 75 2000 14.90 18 80 1.5 58 62.1 59 27.9 15.7
41 190 A K 100 2000 20.75 23.8 80 1.5 73.9 78 74 44 21

(1) To obtain the low speed torque corresponding to a 60 K temperature rise, apply a coefficient of 0.77.
For motor/servo-drive associations, refer to the chapter on the servo-drive concerned.

en-938979/0 21 - 5
21 BMH Axis Motors

BMH055 Axis Motors

BMH055 Motor Characteristics Compared with Other BMH Motors

- Winding insulation class: F (155°C) as per VDE 0530

- Out-of-round, concentricity, perpendicularity between flange and shaft as per DIN 42955 R
- Resolver with 1 pole pair
- Control and power connections by special connectors (see Chapter 3)
- Not configured for encoder
- DISC version not available
- Requires a resolver interface (see the chapter on the associated servo-drive).

Identification

BMH 055 2 S 5 U A 1 L

Series

Size Shaft end

L: smooth (standard)
Length C: keyed

Connector(s)
Speed 2: rearward (standard)
1: frontward
Power output

Sensor resolver Brake

with 1 pole pair A: no brake (standard)
F: brake

Sensors

The standard motor is equipped with a resolver with 3 pole pairs (resolver with 1 pole pair optional). This provides
several functions:

- It gives the angular position of the rotor to allow static switching.

- It measures the rotor speed via the associated servo-drive.

This information is used by the speed governor.

- It can also provide incremental position outputs for the position controller (encoder simulation output). For further
details on this function, see the chapter on the associated servo-drive.

- Connections are always made using a connector.

Note: For a DISC application, the resolver is replaced by a digital sensor that supports all the above
functions.

21 - 6 en-938979/0
BMG Axis Motors 21

Caracteristics

General Characteristics

- General characteristics as per IEC 34.1

- Sm Co magnets on the rotor periphery
- Torque range: 1.3-36 Nm at 2000-3000 rpm
- Protection class: IP65 as per IEC 529
- IP54 shaft end
- Power outputs by terminal box or connector
- Sensor outputs by connector
- Optional 24 VDC brake
- The terminal protection by thermal switch
- Winding insulation class: H (180 degrees) as per VDE 0530
- Out-of-round, concentricity, perpendicularity between flange and shaft as per DIN 42955 R
- End plate as per IEC 72.2
- Shaft end and key as per IEC 72.1
- Authorised mounting positions: IMB5 - IMV1 - IMV3 as per DIN 42950
- Balancing: classe S as per ISO 2373
- Ambient operating temperature rage 0-40°C
- No parking brake possible

Identification

Typical reference

BMG 142 2 N 1 R A 2 L
BMG series
axis motor
Size Shaft end
L: smooth (standard)
C: keyed
Length
Connector (s)
Speed 2: rearward (standard)
1: frontward
Power output
1: on terminal box (standard) No brake (unavailable)
5: on connector

Sensor
R: resolver with 3 pole pairs (standard)
U:resolver with 1 pole pair
T: resolver with encoder fitting
D: digital sensor (for DISC)

Note: Connectors must be ordered separately. See NUM DRIVE Catalogue, Chapter 3.

en-938979/0 21 - 7
21 BMG Axis Motors

Detailed Characteristics

Nominal Nominal Rotor Motor Thermal Rated Power

torque speed inertia weight time rms to nominal
at low constant current torque
Pos. BMG ... speed (100K) and speed
Motor (100K) Wdim
(100K)
Cn (1) ωn T therm In
[Nm] [rpm] [g.m2] [kg] [min] [Arms] [kW]

1 075 1 N 1.3 3000 0.254 4 20 2.2 0.41

2 075 2 N 2.3 3000 0.304 4.8 23 2.7 0.72

3 095 2 N 4.3 3000 0.86 7.6 26 3.5 1.35

4 095 3 N 6 3000 0.97 8.9 29 5.2 1.88

5 115 2 N 7.4 3000 2.45 11.2 29 5.5 2.32

6 115 3 N 10.5 3000 2.73 13.3 33 9.2 3.30

7 142 2 N 12 3000 6.7 20.4 30 10.4 3.77

8 142 3 N 17 3000 7.3 23.3 34 11.7 5.34

9 142 4 K 22 2000 7.9 26.2 37 10.4 4.61

10 142 7 N 35 3000 9.7 34.9 42 24.2 11

11 190 2 K 25 2000 20.9 38.1 38 16.6 5.24

12 190 3 N 36 3000 22.9 43.3 43 27.8 11.3

(1) To obtain the low speed torque corresponding to a 60 K temperature rise, apply a coefficient of 0.77.
For motor/servo-drive associations, refer to the chapter on the servo-drive concerned.

21 - 8 en-938979/0
Axis Motors

21.3 Sensors
The motors are equipped with an internal sensor measuring the rotor angle.
Different types of sensors can be used:
1. 6-pole resolver Sensor code R
2. 2-pole resolver Sensor code U
3. DISC encoder Sensor code D
This section describes a motor equipped with a resolver. For the DISC encoder, refer to the DISC manuals.

Technology and Principle

VS1

OR
TAT R
S TO VS1 Transformer
RO D Active
FIEL θ part part

Primary
zy,zy,

VS2
zy,zy,
zy,zy,

Secondary
zy,zy,
|zy,zy,|{
zy,|{zy,|{

Primary Secondary
zy,|{zy,|{

VS2
zy,|{zy,|{

21
zy,|{zy,|{
y,|{z|{zy,
|{zy,|{zy,
|{zy,zy,|{
y,|{z|{zy,
zy,zy,{

Input VS1 VS2

zy,zy,

VS = U sin ω t Outputs

VS1 = KU sin θ sin ω t

VS2 = KU cos θ sin ω t

The resolver is mounted directly on the motor shaft (hollow shaft) to minimise space, and enhance integration.
It does not include any switches. It is therefore highly reliable and requires no maintenance.
It operates according to the principle of magnetic induction. It has two parts:
- Transformer T1 whose primary is wired to the stator and whose secondary is wired to the rotor, supplied by a 10 kHz
carrier frequency
- Transformer T2, whose primary, called field winding, integrated in the rotor, is supplied from the secondary of
transformer T1 (10 kHz carrier). This field winding, which rotates with the rotor, generates a rotating field which
induces a variable signal in the two secondaries, called armature windings, placed in the stator.
The two secondaries of T2 (armature) are situated 90 degrees apart such that the rotor angle can be determined by
combining their outputs. The accuracy is + 6 electrical arc minutes.

en-938979/0 21 - 9
When processed, the position signal can be used by the servo-drive to perform the following functions:
- Static commutation (selsyn operation)
- Generation of the speed signal (speed loop)
- General of a digital position signal (position loop).

Signals measured at the servo-drive input (the terminals vary according to the servo-drive used; see the
section on servo-drives).

Carrier (9750 Hz, 10 V peak)

Terminals A and B of the motor connector

Green and black wires

Cosinusoidal signal
Terminals C and D of the motor connector
White and black wires

Sinusoidal signal
Terminals E and F of the motor connector
Red and black wires

NUM DRIVE servo-drives monitor the presence of the resolver signals (open circuit, pole reversal, etc.).
Alarms (differing according to the servo-drive used) indicate the presence of a resolver connection fault.
If a resolver alarm is present, but the servo-drive input signals are correct, the presence of the internal sinusoidal and
cosinusoidal signals can be checked using the PC communication tool with the servo-drive (PC Set Link for UAC and
MNDA, and DPM for MDLA).
These tools can also be used to check that the reading on the e-gain (resolver gain) test point is between 0 and 255.
Readings close to 0 (input signals too high) or 255 (signals too low) generate a resolver alarm.
A faulty resolver can easily be replaced by an electromechanical technician.
Part number of 6-pole resolver: RESOLVER N303 410256303
Part number of 2-pole resolver: RESOLVER N301 410252301
When installing the new resolver, it is very important to set the resolver at exactly the right angle or there is a risk of
motor runaway or loss of torque.

21 - 10 en-938979/0
Axis Motors

A setting procedure is described in the Installation and Maintenance Manuals for the associated servo-drives.
Manual 738E003/C for UAC
Manual 738E006/E for MNDA
Manual 738E008/C for MDLA
This procedure, although simple, requires use of the SPM or MPM communication software, a PC and a digital
multimeter.
After replacement of the motor, the resolver or its wire, always repeat the automatic calibration procedure with PC Set
Link (SPM software packages).

21.4 Thermal Probes

The motor temperature is monitored by a thermal switch mounted on the motor frame. If it fails, this thermal switch
is very easy to replace. It is located inside the motor terminal box.
For motor:
BMS : TERMF11160C 410211160 (160 °C)
BMH/BMG : TERMF1150C 410211150 (150 °C)
BMH DISC : TERMF190C 410211090 (90 °C)

21.5 Maintenance 21
NUM DRIVE brushless motors have life-lubricated bearings and require no maintenance.
If repeated Overcurrent alarms are detected by the servo-drive, check the winding impedance and insulation from the
protective earth.

21.5.1 Checking Motor Insulation

The insulation resistance must be measured by a special insulation tester (e.g. Megger) which can output 1000 VDC.
Disconnect the motor cables. Earth the thermal switch and the brake if any.
Interconnect the three phases of the motor. Then apply the test voltage to the windings and earth.

The insulation resistance must be > 2 MΩ

If the measured value is lower, check for moisture inside the motor power connections, before deciding that the
windings are faulty.

21.5.2 Measuring the Winding Impedance

The motor winding impedance is generally very low (a few tenths of an ohm to a few ohms, depending on the motor).
It is therefore difficult to measure with a conventional multimeter.

en-938979/0 21 - 11
21.6 Technical Characteristics of Brushless Motors
(Table headings on following pages)
Cnom : Nominal torque (Nm)
wnom : Nominal speed (rpm)
Wdim : Power at nominal torque and speed Wdim = Cnom x wnom x 2P/60
Inom : Rated current (at nominal torque) (Arms)
Kt : Torque constant = Cnom/Inom (Nm/A)
Ef : Electromotive force of a winding (V/1000 rpm)
Jr : Motor inertia (g.m2)
Ke : Speed constant = Ef/w(V.s)
P = Cw = Kt.lf.w
If: Current in a winding = phase current (wye coupling)
Ef: Voltage in a winding
U: Voltage between phases = Vf. 3 (wye coupling)
P = U.lf.cos∅. 3 = Ef. 3 .If. 3 = 3.Ef.If = 3.Ke.w.lf (neglecting the power factor)
Therefore Ke = Kt / 3
Rf : Winding resistance (mohm) (value at 20°C)
Lf : Winding inductance (mH)
Te : Electrical time constant (ms) = Lf/Rf
Tm : Mechanical time constant (ms)
Tth : Thermal time constant (min)

21 - 12 en-938979/0
Axis Motors

21.7 Technical Characteristics of BMS Motors

TYPE BMS Cnom wnom Wdim Inom Kt Ef Jr Ke Rf Lf Te Tm Tth

(Nm) (rpm) (kW) (Arms)(mN/A) (V) (g.m2) (V.s) (mOhm) (mH) (ms) (ms) (min)
/1000 rpm at 20 °C

BMS 75 1 18125 1.3 3000 0.41 2.2 0.59 20.13 0.07 0.20 5126.45 18.43 3.60 3.16 20
BMS 75 1 1891 1.3 6000 0.82 3 0.43 14.65 0.07 0.14 2716.94 9.77 3.60 3.14 20
BMS 75 2 1891 2.3 3000 0.72 2.7 0.85 29.30 0.12 0.28 3898.21 17.94 4.60 1.96 23
BMS 75 2 1870 2.3 6000 1.45 3.5 0.66 22.54 0.12 0.22 2306.63 10.62 4.60 1.96 23
BMS 75 4 1861 4 3000 1.26 3.5 1.14 39.38 0.21 0.38 2815.88 15.42 5.48 1.38 26
BMS 75 4 1840 4 6000 2.51 5.3 0.75 25.76 0.21 0.25 1210.80 6.63 5.48 1.37 26
BMS 95 2 18102 4.3 3000 1.35 3.5 1.23 42.26 0.30 0.41 3059.51 23.29 7.61 1.85 20
BMS 95 2 1860 4.3 6000 2.70 5.9 0.73 24.86 0.30 0.24 1058.66 8.06 7.61 1.84 20
BMS 95 3 1863 6 3000 1.88 5.2 1.15 39.14 0.41 0.38 1489.32 12.85 8.63 1.42 23
BMS 95 3 1832 6 6000 3.77 10.3 0.58 19.88 0.41 0.19 384.24 3.32 8.64 1.42 23 21
BMS 95 5 1860 9.2 2000 1.93 5 1.84 62.16 0.64 0.61 1935.01 18.85 9.74 1.13 26
BMS 95 5 1852 9.2 3000 2.89 5.8 1.59 53.87 0.64 0.53 1453.40 14.16 9.74 1.14 26
BMS 95 5 1826 9.2 6000 5.78 11.6 0.79 26.94 0.64 0.26 363.35 3.54 9.74 1.14 26
BMS 115 2 1886 7.4 3000 2.32 5.5 1.35 46.00 0.70 0.45 1609.45 17.09 10.62 1.91 29
BMS 115 2 1845 7.4 6000 4.65 10.5 0.70 24.07 0.70 0.23 440.66 4.68 10.62 1.90 29
BMS 115 3 1884 10.5 2000 2.20 5.3 1.98 67.41 1.00 0.66 1918.45 23.41 12.20 1.50 33
BMS 115 3 1848 10.5 3000 3.30 9.2 1.14 38.52 1.00 0.38 626.43 7.65 12.21 1.49 33
BMS 115 3 1835 10.5 6000 6.60 12.6 0.83 28.09 1.00 0.28 333.06 4.06 12.19 1.49 33
BMS 115 4 1868 13.3 2000 2.79 6.2 2.15 72.76 1.30 0.72 1507.54 19.99 13.26 1.31 36
BMS 115 4 1842 13.3 3000 4.18 10.1 1.32 44.94 1.30 0.44 575.11 7.63 13.27 1.32 36
BMS 115 4 1824 13.3 6000 8.36 17.6 0.76 25.68 1.30 0.25 187.79 2.49 13.26 1.32 36
BMS 115 6 1842 18.7 2000 3.92 9.4 1.99 67.41 1.80 0.66 766.47 11.18 14.59 1.08 41
BMS 115 6 1833 18.7 3000 5.87 12 1.56 52.97 1.80 0.52 473.18 6.90 14.58 1.08 41
BMS 115 6 1818 18.7 6000 11.75 21.9 0.85 28.89 1.80 0.28 140.78 2.05 14.56 1.08 41
BMS 142 2 3654 12 2000 2.51 6 2.00 69.88 1.60 0.67 1855.20 21.97 11.84 2.22 30
BMS 142 2 3631 12 3000 3.77 10.4 1.15 40.11 1.60 0.38 611.40 7.24 11.84 2.21 30
BMS 142 2 3628 12 4250 5.34 11.5 1.04 36.23 1.60 0.35 498.79 5.91 11.85 2.21 30

en-938979/0 21 - 13
TYPE BMS Cnom wnom Wdim Inom Kt Ef Jr Ke Rf Lf Te Tm Tth
(Nm) (rpm) (kW) (Arms)(mN/A) (V) (g.m2) (V.s) (mOhm) (mH) (ms) (ms) (min)
/1000 rpm at 20 °C

BMS 142 2 3618 12 6000 7.54 17.9 0.67 23.29 1.60 0.22 206.13 2.44 11.84 2.21 30
BMS 142 3 3632 17 2000 3.56 9.5 1.79 62.14 2.20 0.60 798.29 10.94 13.70 1.65 34
BMS 142 3 3626 17 3000 5.34 11.7 1.45 50.49 2.20 0.48 526.99 7.22 13.70 1.65 34
BMS 142 3 3618 17 4250 7.57 16.9 1.01 34.96 2.20 0.34 252.58 3.46 13.70 1.65 34
BMS 142 3 3615 17 6000 10.68 20.3 0.84 29.13 2.20 0.28 175.40 2.40 13.68 1.66 34
BMS 142 4 3628 22 2000 4.61 10.4 2.12 72.49 2.80 0.71 723.58 10.85 14.99 1.38 37
BMS 142 4 3619 22 3000 6.91 15.6 1.41 49.19 2.80 0.47 333.18 5.00 15.01 1.41 37
BMS 142 4 3614 22 4250 9.79 20.8 1.06 36.25 2.80 0.35 180.90 2.71 14.98 1.38 37
BMS 142 4 3610 22 6000 13.82 29.1 0.76 25.89 2.80 0.25 92.29 1.38 14.95 1.38 37
BMS 142 7 3624 35 1500 5.50 11.1 3.15 108.74 4.30 1.05 779.34 13.42 17.22 1.02 42
BMS 142 7 3616 35 2000 7.33 16.6 2.11 72.50 4.30 0.70 346.37 5.96 17.21 1.02 42
BMS 142 7 3611 35 3000 11.00 24.2 1.45 49.84 4.30 0.48 163.72 2.82 17.22 1.02 42
BMS 142 7 369 35 4250 15.58 29.6 1.18 40.78 4.30 0.39 109.60 1.89 17.24 1.02 42
BMS 190 2 3630 25 2000 5.24 16.6 1.51 52.11 5.10 0.50 375.78 8.10 21.56 2.56 38
BMS 190 2 3625 25 3000 7.85 19.9 1.26 43.43 5.10 0.42 260.96 5.62 21.54 2.55 38
BMS 190 2 3617 25 4250 11.13 29.9 0.84 29.53 5.10 0.28 120.67 2.60 21.55 2.61 38
BMS 190 3 3628 36 1500 5.65 16.9 2.13 72.97 7.10 0.71 389.75 9.37 24.04 1.86 43
BMS 190 3 3624 36 2000 7.54 19.7 1.83 62.54 7.10 0.61 286.35 6.88 24.03 1.86 43
BMS 190 3 3617 36 3000 11.31 27.8 1.29 44.30 7.10 0.43 143.67 3.45 24.01 1.86 43
BMS 190 4 3626 48 1500 7.54 17.5 2.74 89.96 9.00 0.91 389.77 10.07 25.84 1.49 48
BMS 190 4 3622 48 2000 10.05 20.6 2.33 76.12 9.00 0.78 279.07 7.21 25.84 1.48 48
BMS 190 4 3615 48 3000 15.08 30.3 1.58 51.90 9.00 0.53 129.73 3.35 25.82 1.49 48
BMS 190 5 3622 56 1500 8.80 20 2.80 95.68 11.00 0.93 317.59 8.64 27.20 1.37 52
BMS 190 5 3616 56 2000 11.73 27.5 2.04 69.58 11.00 0.68 167.98 4.57 27.21 1.37 52
BMS 190 5 3614 56 2500 14.66 31.4 1.78 60.89 11.00 0.59 128.61 3.50 27.21 1.36 52
BMS 190 7 3620 75 1400 11.00 20.9 3.59 121.66 15.00 1.20 326.10 9.51 29.16 1.17 61
BMS 190 7 3615 75 2000 15.71 27.9 2.69 91.25 15.00 0.90 183.43 5.35 29.17 1.17 61
BMS 190 A 369 100 2000 20.94 44 2.27 78.30 21.00 0.76 79.39 2.63 33.13 0.98 65

21 - 14 en-938979/0
Axis Motors

21.8 Technical Characteristics of BMH Motors

TYPE BMH Cnom wnom Wdim Inom Kt Ef Jr Ke Rf Lf Te Tm Tth

(Nm) (rpm) (kW) (Arms)(mN/A) (V) (g.m2) (V.s) (mOhm) (mH) (ms) (ms) (min)
/1000 rpm at 20 °C

BMH 75 1 N 1.3 3000 0.41 2.2 0.59 20.13 0.07 0.20 5126.45 18.43 3.60 3.16 20
BMH 75 1 V 1.3 6000 0.82 3 0.43 14.65 0.07 0.14 2716.94 9.77 3.60 3.14 20
BMH 75 2 N 2.3 3000 0.72 2.7 0.85 29.30 0.12 0.28 3898.21 17.94 4.60 1.96 23
BMH 75 2 V 2.3 6000 1.45 3.5 0.66 22.54 0.12 0.22 2306.63 10.62 4.60 1.96 23
BMH 75 4 N 4 3000 1.26 3.5 1.14 39.38 0.21 0.38 2815.88 15.42 5.48 1.38 26
BMH 95 2 N 4.3 3000 1.35 3.5 1.23 42.26 0.30 0.41 3059.51 23.29 7.61 1.85 20
BMH 95 2 V 4.3 6000 2.70 5.9 0.73 24.86 0.30 0.24 1058.66 8.06 7.61 1.84 20
BMH 95 3 N 6 3000 1.88 5.2 1.15 39.14 0.41 0.38 1489.32 12.85 8.63 1.42 23
BMH 95 3 V 6 6000 3.77 10.3 0.58 19.88 0.41 0.19 384.24 3.32 8.64 1.42 23
BMH 95 5 N 9.2 3000 2.89 5.8 1.59 53.87 0.64 0.53 1453.40 14.16 9.74 1.14 26 21
BMH 115 2 N 7.4 3000 2.32 5.5 1.35 46.00 0.70 0.45 1609.45 17.09 10.62 1.91 29
BMH 115 2 V 7.4 6000 4.65 10.5 0.70 24.07 0.70 0.23 440.66 4.68 10.62 1.90 29
BMH 115 3 K 10.5 2000 2.20 5.3 1.98 67.41 1.00 0.66 1918.45 23.41 12.20 1.50 33
BMH 115 3 N 10.5 3000 3.30 9.2 1.14 38.52 1.00 0.38 626.43 7.65 12.21 1.49 33
BMH 115 3 V 10.5 6000 6.60 12.6 0.83 28.09 1.00 0.28 333.06 4.06 12.19 1.49 33
BMH 115 4 K 13.3 2000 2.79 6.2 2.15 72.76 1.30 0.72 1507.54 19.99 13.26 1.31 36
BMH 115 4 N 13.3 3000 4.18 10.1 1.32 44.94 1.30 0.44 575.11 7.63 13.27 1.32 36
BMH 115 4 V 13.3 6000 8.36 17.6 0.76 25.68 1.30 0.25 187.79 2.49 13.26 1.32 36
BMH 115 6 N 18.7 3000 5.87 12 1.56 52.97 1.80 0.52 473.18 6.90 14.58 1.08 41
BMH 142 2 K 12 2000 2.51 6 2.00 69.88 1.60 0.67 1855.20 21.97 11.84 2.22 30
BMH 142 2 N 12 3000 3.77 10.4 1.15 40.11 1.60 0.38 611.40 7.24 11.84 2.21 30
BMH 142 2 R 12 4250 5.34 11.5 1.04 36.23 1.60 0.35 498.79 5.91 11.85 2.21 30
BMH 142 3 K 17 2000 3.56 9.5 1.79 62.14 2.20 0.60 798.29 10.94 13.70 1.65 34
BMH 142 3 N 17 3000 5.34 11.7 1.45 50.49 2.20 0.48 526.99 7.22 13.70 1.65 34
BMH 142 3 R 17 4250 7.57 16.9 1.01 34.96 2.20 0.34 252.58 3.46 13.70 1.65 34
BMH 142 4 K 22 2000 4.61 10.4 2.12 72.49 2.80 0.71 723.58 10.85 14.99 1.38 37
BMH 142 4 N 22 3000 6.91 15.6 1.41 49.19 2.80 0.47 333.18 5.00 15.01 1.41 37

en-938979/0 21 - 15
TYPE BMH Cnom wnom Wdim Inom Kt Ef Jr Ke Rf Lf Te Tm Tth
(Nm) (rpm) (kW) (Arms)(mN/A) (V) (g.m2) (V.s) (mOhm) (mH) (ms) (ms) (min)
/1000 rpm at 20 °C

BMH 142 4 R 22 4250 9.79 20.8 1.06 36.25 2.80 0.35 180.90 2.71 14.98 1.38 37
BMH 142 7 N 35 3000 11.00 24.2 1.45 49.84 4.30 0.48 163.72 2.82 17.22 1.02 42
BMH 190 2 K 25 2000 5.24 16.6 1.51 52.11 5.10 0.50 375.78 8.10 21.56 2.56 38
BMH 190 2 N 25 3000 7.85 19.9 1.26 43.43 5.10 0.42 260.96 5.62 21.54 2.55 38
BMH 190 2 R 25 4250 11.13 29.9 0.84 29.53 5.10 0.28 120.67 2.60 21.55 2.61 38
BMH 190 3 K 36 2000 7.54 19.7 1.83 62.54 7.10 0.61 286.35 6.88 24.03 1.86 43
BMH 190 3 N 36 3000 11.31 27.8 1.29 44.30 7.10 0.43 143.67 3.45 24.01 1.86 43
BMH 190 4 K 48 2000 10.05 20.6 2.33 76.12 9.00 0.78 279.07 7.21 25.84 1.48 48
BMH 190 4 N 48 3000 15.08 30.3 1.58 51.90 9.00 0.53 129.73 3.35 25.82 1.49 48
BMH 190 5 H 56 1500 8.80 20 2.8 95.68 11.00 0.93 317.59 8.64 27.20 1.37 52
BMH 190 5 L 56 2500 14.66 31.4 1.78 60.89 11.00 0.59 128.61 3.50 27.21 1.36 52
BMH 190 7 K 75 2000 15.71 27.9 2.69 91.25 15.00 0.90 183.43 5.35 29.17 1.17 61
BMH 190 A K 100 2000 20.94 44 2.27 78.30 21.00 0.76 79.39 2.63 33.13 0.98 65

21 - 16 en-938979/0
Spindle Motors

22 Spindle Motors

22.1 General 22 - 3
22.2 Characteristics and Performance 22 - 3
AMS - IM - HM Spindle Motors 22 - 4
AMS Motor Identification 22 - 4
IM Motor Identification 22 - 4
Technical Characteristics 22 - 5
UAC Servo-Drives 22 - 6
Power-Speed and Torque-Speed Curves for AMS
and IM Motors 22 - 6
Association with AMS 100 Spindle Motors 22 - 7
Association with AMS 132 Spindle Motors 22 - 8
Association with AMS 160 Spindle Motors 22 - 9
Associations with AMS 180 Spindle Motors 22 - 10
22.3 Sensors 22 - 11
22.3.1 Resolver 22 - 11
22.3.2 High Resolution Sensor 22 - 13
22.4 Thermal Probes 22 - 14
22.5 Maintenance 22 - 14
22.5.1 Checking Motor Insulation Resistance 22 - 14
22.5.2 Measuring the Winding Impedance 22 - 14
22.6 Electrical Characteristics of the Spindle Motors Described in the Catalogue 22 - 15

en-938979/0 22 - 1
22 - 2 en-938979/0
Spindle Motors

22.1 General
The spindle motors of the NUM DRIVE line are induction motors.
They are asynchronous squirrel cage motors equipped with a speed measurement sensor to control motor slip very
accurately.
Several lines of motors are available:
- Series IM and HM spindle motors
- Series AMS spindle motors (this more recent line of motors is gradually replacing the IM line)
- AM132 liquid-cooled spindle motors
- MotorSpindle motor-driven spindles
This motor technology achieves optimum spindle motor integration in the machine and simplifies the mechanical
parts to the utmost.
- Hollow rotor
- Liquid-cooled stator
- High-resolution sensor + cog wheel.
These motors are used in conjunction with UAC and MDLS flux vector control and sinusoidal control servo-drives.

22.2 Characteristics and Performance

The detailed mechanical characteristics of the spindle motors (overall dimensions, shaft loads) are given in NUM
DRIVE Catalogue en-938919/3, Chapter 2.
For interfacing the motors and associated servo-drives, refer to the installation and maintenance manuals for the
servo-drives:
UAC Manual 738F003/C
22

en-938979/0 22 - 3
22 AMS - IM - HM Spindle Motors

Identification

AMS Motor Identification

Typical reference

AMS 100 S B 1 R 22 L R 0

AMS series

Size Shaft seal

0: IP54 (standard)
1: IP 65
Length
Rotor balanging
Speed R: class R (standard)
S: class S
Sensor
R: resolver with 3 pole pairs (standard) Shaft end
H: high-resolution sensor L: keyed (standard)
U: resolver with 1 pole pair C: smooth

Note: The connectors must be ordered separately. See NUM DRIVE Catalogue, Chapter 3.

IM Motor Identification

Typical reference

IM 180 M 2Y - 4814 L E R
IM series
(resolver)
Rotor balancing
HM series R: class R (standard)
(high resolution sensor) S: class S
Size
E: IP54 shaft (standard)
D: IP65 shaft
Length

Shaft end
Type L: smooth (standard)
C: keyed

Note: The connectors must be ordered separately. See NUM DRIVE Catalogue, Chapter 3.

22 - 4 en-938979/0
AMS - IM - HM Spindle Motors 22

Technical Characteristics

- General characteristics as per IEC 34.1

- Protection class: IP 65 as per IEC 529
- Shaft end: IP54
- Termal protection by thermal switch
- Winding insulation class: H (180°)
- Out-of-round, concentricity, perpendicularity between flange and shaft as per DIN 42955 R
- Mounting: flange (or foot) with smooth holes as per IEC 72-2
- Shaft end and key as per IEC 72-1
- Authorised mounting positions: IMB5 - IMV1 - IMV3 as per DIN 42950
- Balancing as per ISO 2373: class R standard - class S optional
- Ambient operating temperature range: 0-40°C

AMS Power Weight Inertia Thermal Three-phase fan

motors S1 [kg] [kg.m2] time constant [V] [A]
[kW] [min]
AM 100 S 3.7 37 0.009 32
AMS 100 M 5.5 4.9 0.014 35 380 0.11

AMS 100 G 9 71 0.023 38

AMS 132 S 15 105 0.055 45

AMS 132 M 19.5 131 0.075 50 380 0.20

AMS 132 L 22 183 0.113 55

AMS 160 M 36 215 0.25 57

AMS 160 L 36 290 0.37 61 380 0.3

IM - HM Power Weight Inertia Thermal Three-phase fan

motors S1 [kg] [kg.m2] time constant [V] [A]
[kW] [min]

IM 180 M 55 415 0.57 63 220 0.78

Noise level dB [A]

as per ISO 1680 - Second session, 1986.

Motor Noise level

dB [A]

AMS 100 70

AMS 132 68
AMS 160 —

IM 180 71

en-938979/0 22 - 5
22 UAC Servo-Drives

Motor/Servo-Drive Associations

Power-Speed and Torque-Speed Curves for AMS and IM Motors

Power Torque

Pmax S3 intermittent
Cmax S3
Pn
Pm Cn
S1 continuous Cs
S1
Cg
Cm
ωn ωs ωg ω lim Speed ωn ωs ωg ω lim Speed

Pn = Continuous power [kW]

Pmax = Overload power [kW]
Pm = Power at max. speed [kW]
ω n = Base speed [rpm]
Cn = Constant torque between ω=0 and ωn [Nm]
Cmax = Overload torque between ω=0 and ωn [Nm]
ω s = Maximum speed for operation at constant power at S3 [rpm]
ω g = Maximum speed for operation at constant power at S1 [rpm]
Cg = Torque corresponding to speed ωg [Nm]
Cs = Torque corresponding to speed ωs in overload state S3 [Nm]
ω lim = Max. speed [rpm]
Cm = Torque at max. speed [Nm]
lcont = Motor continuous current rating [Arms]
l ms = Motor overload current [Arms]

Duty Cycles

S2 S3 S6

Cycle time Cycle time

M N R N V

Load

Electrical
losses

Tempe- θ θ θ
max max max
rature

Time Time Time

_ f m= N x100 (%) f m= N x100 (%)
N+R N+V
N = Operation at Pmax
R = Idle
V = Off-load operation
f m= Duty cycle

22 - 6 en-938979/0
UAC Servo-Drives 22

Motor/Servo-Drive Associations

Association with AMS 100 Spindle Motors

CONTINUOUS OPERATION S1 OVERLOAD

3UAC
Motor Servo- Pn ωn Cn ωg Cg Pm ωlim Cm Icont Pmax Cmax Cs Ims S2 S3 S6
drive % %
kW rpm Nm rpm Nm kW rpm Nm Arms kW Nm Nm Arms min 10 min 10 min

AMS 100S B M5030I 51 2.2 150 14 6500 3 2.2 6500 3 14 3.7 24 5.5 21 12 40 30

AMS 100S B L5050I 51 3.7 150 24 6500 5.5 3.7 6500 5.5 21 5.5 35 8 30 12 40 30

AMS 100M B L5050I 51 5.5 1500 35 6500 8 5.5 6500 8 26 7.5 47 11 35 12 40 30

AMS 100G B L5075I 51 9 1500 57 6500 13 9 6500 13 39 12.5 80 18 52 12 40 30

AMS 100S D M5030I 51 2.2 1500 14 6500 3 1.1 12000 1 14 3.7 24 5.5 21 12 40 30

AMS 100S D L5050I 51 3.7 1500 24 6500 5.5 1.8 12000 1.4 21 5.5 35 8 30 12 40 30

AMS 100M D L5050I 51 5.5 1500 35 6500 8 2.8 12000 2.2 26 7.5 47 11 35 12 40 30

AMS 100G D L5075I 51 9 1500 57 8200 10.5 6.2 12000 5 39 12.5 80 15 52 12 40 30

For AMS 100 motor, ωs= ωg

en-938979/0 22 - 7
22 UAC Servo-Drives

Motor/Servo-Drive Associations

Association with AMS 132 Spindle Motors

CONTINUOUS OPERATION S1 OVERLOAD

3UAC...
Motor Servo-drive Pn ωn Cn ωg Cg Pm ωlim Cm Icont Pmax Cmax ωs Ims S2 S3 S6
% %
kW rpm Nm rpm Nm kW rpm Nm Arms kW Nm rpm Arms min 10 min 10 min

1 AMS 132 S A L5050I 51 5 750 64 6000 8 2.8 7000 4 26 7.5 95 5000 35 30 45 37

2 AMS 132 S C L5075I 51 10 1500 64 6000 16 8 7000 11 39 14 89 5000 52 30 45 37

3 AMS 132 S E G50100I 51 15 1750 82 4000 36 10 7000 13.5 52 23 110 3300 70 14 35 30

4 AMS 132 M A L5075I 51 7.5 750 95 6000 12 5.7 7000 8 39 10 127 5000 52 30 45 37

5 AMS 132 M C G50100I 51 15 1500 95 6000 24 12.5 7000 17 52 21 134 5000 70 30 45 37

6 AMS 132 M E G50150I 51 19.5 1850 100 5500 34 19 7000 26 75 35 149 4500 105 14 35 30

7 AMS 132 L A G50100I 51 11 750 140 6000 17 9 7000 12.5 52 15 191 5000 70 30 45 37

8 AMS 132 LE G50150I 51 22 1250 168 4200 50 15 7000 20 75 36 229 3300 105 14 35 30

AMS 132 high speed

1a AMS 132 S F L5050I 51 5 750 64 6000 8 2 10000 2 26 7.5 95 5000 35 30 45 37

2a AMS 132 S G L5075I 51 10 1500 64 6000 16 6 10000 6 39 14 89 5000 52 30 45 37

3a AMS 132 S H G50100I 51 15 1750 82 4000 36 7.5 10000 7 52 23 110 3300 70 14 35 30

4a AMS 132 M F L5075I 51 7.5 750 95 6000 12 4 10000 4 39 10 127 5000 52 30 45 37

5a AMS 132 M G G50100I 51 15 1500 95 6000 24 9 10000 8 52 21 134 5000 70 30 45 37

6a AMS 132 M H G50150I 51 19.5 1850 100 5500 34 13.5 10000 13 75 35 149 4500 105 14 35 30

7a AMS 132 L F G50100I 51 11 750 140 6000 17 7 9000 7.5 52 15 191 5000 70 30 45 37

8a AMS 132 LI L5075I51 12.5 815 146 2300 52 3 9000 3 39 16.8 202 2000 52 14 35 30

9a AMS 132 L H G50150I 51 22 1250 168 4200 50 12 9000 13 75 36 229 3000 105 14 35 30

Note: Pos 3 and 3a : Puissance 17 kW 2000 rpm en S2 / 45 min

See NUM DRIVE Catalogue,
6 and 6a 24 2250 rpm en S2 / 35 min
power versus speed curve
8 and 8a 26 1500 rpm en S2 / 60 min
The performance figures are given for a temperature of 40 °C with the motor thermally stabilised

22 - 8 en-938979/0
UAC Servo-Drives 22

Motor/Servo-Drive Associations

Association with AMS 160 Spindle Motors

MOTOR CONTINUOUS OPERATION S1 OVERLOAD

UAC
Pos. servo-drive Pn ωn ÷ ωg wlim Pm Cm Icont Pmax Cmax ωs Ims S2 S3 S6
Type Connec- % %
AMS 160 tion kW rpm rpm kW Nm Arms kW Nm rpm Arms min 10 min 10 min

Υ* 650 1300 2.7 264 24.2 355 1300

1 MA1 50100I51 18 52 70 18 40 35
(1)
∆* 1300 2600 5.4 132 24.2 178 2400

Υ* 1200 2400 8500 7.3 208 36.4 290 2400

2 MB1 50150I51 26 75 105 18 40 35
∆* 2400 4800 14.5 104 36.4 145 4500

3 MC1 ∆*
50200I51 36 1700 2800 10 202 100 47 300 2600 140 18 40 35
(1)

Υ* 500 1000 2.8 344 24.2 463 1000

4 LA1 50100I51 18 52 70 18 40 35
∆* 1000 2000 5.6 172 24.2 231 1850
6500
Υ* 950 1900 7.6 260 36.4 364 1900
5 LB1 50150I51 26 75 105 18 40 35
∆* 1900 3800 15.2 130 36.4 182 3550

6 LC1 ∆ 50200I51 36 1050 2000 6500 11.6 328 100 48 437 1800 140 18 40 35
(1)

* With change of the electrical speed (the associated motor must have a G14 or G15 relay card).
The performance figures are given for an ambient temperature of 40°C with the motor thermally stabilised.

en-938979/0 22 - 9
22 UAC Servo-Drives

Motor/Servo-Drive Associations

Associations with AMS 180 Spindle Motors

CONTINUOUS OPERATION S1 OVERLOAD

MOTOR 3UAC
Servo- Pn ωn Cn ωg Cg Pm ωlim Cm Icont Pmax Cmax ωs Ims S2 S3 S6
Connec- drive % %
Type tion kW rpm Nm rpm Nm kW rpm Nm Arms kW Nm rpm Arms min 10 min 10 min

Υ* 26 500 500 1000 250 3.7 7000 5 75 36.4 700 350 105
IM 180 M G50150I 51 18 40 35
2Y-4814
∆* 26 1000 250 2000 125 7.4 7000 10 75 36.4 350 189 105

∆* 36 950 362 1900 181 9.8 7000 13.3 100 50.4 506 253 140
IM 180 M
2Y-4814 G50200I 51 18 40 35
∆∆* 26 1900 181 3800 90 19.6 7000 26.6 100 50.4 253 135 140

IM 180 M ΥΥ 55 1050 500 2100 250 16.5 7000 22.5 145 76 690 372 200
X50300I 51 18 40 35
2Y-4814

* Change of electrical connection (the associated servo-drive must have a relay card).

22 - 10 en-938979/0
Spindle Motors

22.3 Sensors
The motors are equipped with an internal sensor measuring the rotor speed.
Different types of sensors can be used:
1. 6-pole resolver Sensor code R
2. 2-pole resolver Sensor code U
3. High-resolution sensors Sensor code H

22.3.1 Resolver
Technology and Principle

VS1

OR
AT
ST TOR VS1 Transformer
RO D Active
FIEL θ part part

Primary
zy,zy,

VS2
zy,zy,
zy,zy,

Secondary
zy,zy,
zy,|{|zy,
{|zy,{|zy,

Primary Secondary
{|y,z{|zy,

VS2
{|zy,{|zy,
{|zy,{|zy,
{|y,z{|zy,
|{zy,|{zy,
|{zy,{|zy,
{|y,z{|zy,
y,z{zy,

Input VS1 VS2

zy,

22
zy,

VS = U sin ω t Outputs

VS1 = KU sin θ sin ω t

VS2 = KU cos θ sin ω t

en-938979/0 22 - 11
Signals measured at the servo-drive input (the terminals vary according to the servo-drive used; see the
section on servo-drives).

Carrier (9750 Hz, 10 V peak)

Terminals A and B of the motor connector
Green and black wires

Cosinusoidal signal
Terminals C and D of the motor connector
White and black wires

Sinusoidal signal
Terminals E and F of the motor connector
Red and black wires

NUM DRIVE servo-drives monitor the presence of the resolver signals (open circuit, pole reversal, etc.).
Alarms (differing according to the servo-drive used) indicate the presence of a resolver connection fault.
If a resolver alarm is present, but the servo-drive input signals are correct, the presence of the internal sinusoidal and
cosinusoidal signals can be checked using the PC communication tool with the servo-drive (PC Set Link for UAC and
CPM for MDLS).
These tools can also be used to check that the reading on the e-gain (resolver gain) test point is between 0 and 255.
Readings close to 0 (input signals too high) or 255 (signals too low) generate a resolver alarm.
A faulty resolver can easily be replaced by an electromechanical technician.
Part number of 6-pole resolver: RESOLVER N303 410256303
Part number of 2-pole resolver: RESOLVER N301 410252301
Contrary to brushless axis motors, angular setting of the stator is not required when installing a new resolver.
However, it must be checked that connection of the sinusoidal and cosinusoidal signals complies with the diagram.
After replacement of the motor, the resolver or its wire, always repeat the automatic calibration procedure with PC Set
Link (SPM software packages) on software packages UAC S3.82 or S3.90.

22 - 12 en-938979/0
Spindle Motors

22.3.2 High Resolution Sensor

For spindles used for the C axis function, the motors are equipped with a high resolution sensor consisting of a cog
wheel (256 or 512 teeth) and a magnetoresistive sensor.
The sensor consists of a magnet and a Wheatstone bridge supplied with +5 V and including two fixed resistors and
two magnetoresistors. When the cog wheel passes in front of the sensor, the resistance of the magnetoresistors
varies, generating a sinusoidal waveform across the bridge (256 or 512 sinusoidal cycles per revolution).
The sinusoidal waveform is then divided again by the servo-drive software, which may increase the encoder resolution
up to 1,000,000 pulses per motor revolution at very low speeds.
One of two types of sensors and cog wheels is used, depending on the motor.

AMS and HM motors

- Sensor without zero pulse 62AF
- Single cog wheel with 256 teeth.
The high resolution sensor signals are processed by a daughterboard located on the servo-drive control card: ACQ
card for UAC or EF06B960327 P/N 418960237 for MDLS.
Card part numbers: 2UACCAXIS411, P/N 418401411.
The procedure for checking and adjusting this sensor is described in the UAC Commissioning Manual 738E003/C
(pages 75 and 76).
Replacement of a sensor on a motor must always be carried out by a NUM technician.

MS, MSA MotorSpindle

- Sensor with zero pulse 63AB
- Double cog wheel with 512 teeth 22
The sensor signals are processed by card 2UACHR411, P/N 418411411 located on the servo-drive control card.
In addition to processing the sensor signals, this card supports an encoder simulation function which provides
incremental signals (RS422) used for position measurement by the CNC.
- Low resolution output (1024 pulses per revolution) used for spindle measurement
- High resolution output (default 65535 pulses per revolution) used for C axis measurement.
The procedure for checking and adjusting this sensor is described in the UAC Commissioning Manual 738E003/C
(pages 77-79) or MDLS Commissioning Manual 738013/A (pages 78-80).
Replacement of a sensor on a motor must always be carried out by a NUM technician.
Incorrect adjustment of the motor sensor signals can trigger alarms RSL fixed (UAC) or 09 (MDLS) if the signals are
too low or EXP flashing (UAC) or 25 (MDLS) if the signals are too high.

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22.4 Thermal Probes
The motor temperature is monitored by two thermal switches wired in series in the windings. In case of failure of these
probes, they cannot be replaced. However, it is possible to bypass a failed probe by changing the external wiring (see
wiring diagrams in Commissioning Manuals).

AMS Motors
Green
B
Black
A
Black
C
H White IM/HM Motors
D
Red Motor Spindle
F
Black
E "C.S"
G
K Blue
Motor A
N.C. J thermal N.C. ST Thermal probes
Black C
H probes ST
B

22.5 Maintenance
NUM DRIVE spindle motors are asynchronous squirrel cage motors with life-lubricated bearings. They do not require
any maintenance.
If repeated overcurrent alarms are detected by the servo-drive, check the winding impedance and insulation resistance
from the protective earth.

22.5.1 Checking Motor Insulation Resistance

The insulation resistance must be > 2 MΩ

If the measured value is lower, check for moisture inside the motor power connections, before deciding that the
windings are faulty.

22.5.2 Measuring the Winding Impedance

The motor winding impedance is generally very low (a few tenths of an ohm to a few ohms, depending on the motor).
It is therefore difficult to measure with a conventional multimeter.
The most accurate methods for measuring low resistance require the use of a Wheatstone bridge or, for indirect
measurement, consist of applying a constant current to the winding and measuring the voltage (R = V/I).

22 - 14 en-938979/0
Spindle Motors

22.6 Electrical Characteristics of the Spindle Motors Described in the

Catalogue
Motor ST for Notes Connec- Rated I Id start of defluxing Resist. sigma Acceleration time
type S3.82 tion I moyot module at 20°C * Is - sec. (rpm)
-A- -A- - rpm - - A - - V - Vca - mΩ - - mH - 0-ω1 0-ω2 0 - ω max
AMS 100SB1 1142BU Y 14 30 2620 14 2.439 433 3.78 0.08(2200) 0.36(6200) 0.4(6500)
AMS 100SD1 11427U Y 14 30 2620 14 2.439 433 3.78 0.08(2200) 0.36(6200) 2.7(12000)
AMS 100SB1 11424U Y 21 50 2290 16 1.394 433 3.78 0.4(6500)
AMS 100SD1 Y
AMS 100MB1 11341U Y 26 50 2280 22 1.916 228 2.07 0.04(1500) 0.2(5000) 0.34(6500)
AMS 100MD1 11340U Y 26 50 2280 22 1.916 228 2.07 0.04(1500) 0.2(5000) 2.1(12000)
AMS 100GB1 11334U Y
AMS 100GD1 11333U Y

AMS 132SA1 11418U Y 26 50 1280 22 1.916 198 3.42 0.06(1000) 0.09(5000) 2.5(7000)
AMS 132SC1 11419U Y 39 75 2080 31 2.7 88 1.52 0.13(2000) 0.72(6000) 1.06(7000)
AMS 132SE1 11412U ∆ 52 100 2340 35 1.52 1.138 0.11(2000) 0.52(6000) 1.24(7000)
AMS 132SF1 11402U Y 26 50 1280 22 1.916 198 3.42 0.06(1000) 0.49(4000) 4(8000)
AMS 132SG1 11403U Y 39 75 2080 31 2.7 88 1.52 0.1(1500) 0.72(6000) 1.6(8000)
AMS 132SH1 11413U ∆ 52 100 2340 35 1.52 1.138 0.11(2000) 0.52(6000) 2.6(10000)
AMS 132MA1 11420U Y 39 75 1440 38 3.31 98 1.609 0.06(1000) 1(6000) 1.56(7000)
AMS 132MC1 11421U Y 52 100 1950 51 2.22 55 0.905 0.1(1500) 0.72(6000) 1.02(7000)
AMS 132ME1 11408U ∆ 75 150 2650 62 2.69 98 0.0005 0.12(2000) 0.5(6000) 0.67(7000)
AMS 132MF1 11404U
AMS 132MG1 11405U
Y
Y
39
52
75
100
1440
1950
38
51
3.31
2.22
98
55
1.609
0.905
0.06(1000)
0.1(1500)
1(6000)
0.72(6000)
2.45(8000)
1.46(8000)
22
AMS 132MH1 11409U ∆ 75 150 2650 62 2.69 98 0.0005 0.12(2000) 1.2(9000) 1.6(10000)
AMS 132LA1 11422U Y 52 100 1310 42 1.83 69 1.33 0.07(1000) 1.4(6000) 1.8(7000)
AMS 132LE1 11410U Y 75 150 1710 60 2.61 38.5 0.0007 0.05(1000) 0.75(6000) 1.1(7000)
AMS 132LI1 11442U Y 39 75 860 29 2.52 156 2.79 0.06(1000) 0.38(3000) 11(9000)
AMS 132LF1 11406U Y 52 100 1310 42 1.83 69 1.33 0.07(1000) 1.14(6000) 2.8(8000)
AMS 132LH1 11411U Y 75 150 1710 60 2.61 38.5 0.0007 0.05(1000) 0.75(6000) 2.5(9000)

AMW 132LC1 11446U Low range Y 88 150 1610 70 3.048 64 0.06(1000) 0.5(5000) 1.3(7000)
AMW 132LC1 11446U High range ∆ 3465 90 3.91 0.12(1000) 0.5(5000) 0.8(7000)

AMS 160MA1 11452U Low range Y 52 100 700 38 1.65 130 3.4 0.06(750) 7.4(6000) 26(8500)
AMS 160MA1 11452U High range ∆ 1505 45 1.96 0.1(750) 2.4(6000) 7(8500)
AMS 160MB1 11453U Low range Y 75 150 1270 56 2.43 49 1.25 0.08(1000) 2.5(6000) 8.2(8500)
AMS 160MB1 11453U High range ∆ 2475 76 3.30 0.15(1000) 1.48(6000) 3.1(8500)
AMS 160MC1 11454U ∆ 100 200 1700 71 1.55 87 0.738 0.12(1500) 2.1(7000) 3.8(8500)
AMS 160LA1 11455U Low range Y 52 100 500 35 1.52 144 4.3 0.04(500) 8(5000) 19.6(6500)
AMS 160LA1 11455U High range ∆ 100 1090 46 2 0.08(500) 2.5(5000) 5.4(6500)
AMS 160LB1 11456U Low range Y 75 150 990 53 2.31 52 1.5 0.05(500) 2.45(5000) 5.5(6500)
AMS 160LB1 11456U High range ∆ 150 1915 75 3.27 0.085(500) 1.45(5000) 2.45(6500)
AMS 160LC1 11457U ∆ 100 200 1105 70 1.52 110 1.12 0.08(1000) 1.75(5000) 4(6500)

AMS 180LB1 11379U ∆ 169 300 1650 133 36.5 0.328 0.85(5000)

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UAC Line

23 UAC Line

23.1 General 23 - 3
23.2 Rack 23 - 3
23.2.1 Rack Identification 23 - 4
23.2.2 Module Extraction from Rack 23 - 6
23.3 Power Connections 23 - 7

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23 - 2 en-938979/0
UAC Line

23.1 General
UAC servo-drives are multiaxis drives provided in a prewired cooled rack.
The power supply is connected directly to the 380 VAC mains.
Braking can be resistive or regenerative.
The associated servo-drives are fully digital. They can control axis motors or spindle motors, which is why they are
named UAC for Universal AC Controller (they are differentiated by software). This makes maintenance much easier.
These servo-drives brake the associated motor until it comes to a full stop, even in case of an unexpected mains failure.
Flux vector control makes speed and torque control very accurate.
Many options are available:
- Relay cards for remote I/O
- Multiposition indexing cards
- Analogue output cards
- Encoder simulation
- Antipitch control (electronic backlash compensation).
The servo-drives are set up and customised from a PC using the PC Set Link software common to all the servo-drives
in the line.

23.2 Rack

1MAIF UAC 4M 1M

Power supply size: M, L, G, X

Servo-drives: Number and size: M, L, G, X

23
The rack contains one or more axis, spindle and/or MotorSpindle servo-drives plus a Power Supply or Regenerative
Power Supply module always located in the rightmost slot of the rack.
A slide-in unit containing the fans* is located in the top of the rack.
Pulling out the slide-in unit gives access to the M power terminals.
The servo-drive and power supply interconnections are already completed inside the rack.

∗ Rack width:
- Less than 380 mm: 1 fan
- Between 380 mm and 569 mm: 2 fans
- Above 570 mm: 3 fans.

en-938979/0 23 - 3
Mounting hole Power terminals

Fans

Mounting
holes

Slide-in fan unit

23.2.1 Rack Identification

Main rack components

Rack nameplate
Fan

Sliding fastener
Screw fastener
to lock the fan unit
Error LED -
Servo-drive module Error LED
Power supply module

Servo-drive module
Power supply module

23 - 4 en-938979/0
UAC Line

! IMPORTANT
The letter P denotes a Power Supply.
The letters X/Y/Z denote an axis motor servo-drive
The letter S denotes a spindle motor servo-drive
The letters X1 and X2 denote a drive with backlash compensation.

Rack nameplate

Rack type Rack serial number

Electrical characteristics Electrical wiring of the output

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23.2.2 Module Extraction from Rack

Servo-drive and Power Supply Module Extraction from Rack

Sliding fastener

! IMPORTANT
So as not to endanger the safety of maintenance staff, make sure the system has been
powered down for at least 5 minutes before proceeding to module insertion or ex-
traction, to allow complete discharge of the high voltage capacitors.
Move the sliding fastener corresponding to the servo-drive or power supply module to be
extracted and pull out the module as shown.
Be careful when reinserting the module and make sure the quick-lock connectors are
correctly positioned in the rack.
Reposition the sliding fastener on the module.

23 - 6 en-938979/0
UAC Line

23.3 Power Connections

See UAC Manual 738E003/C:
- Chapter 2: pages 21-26 and page 32
- Chapter 5: pages 96 et seq.

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23 - 8 en-938979/0
PWS Power Supply Modules

24 PWS Power Supply Modules

24.1 Resistive Braking Power Supply Module 24 - 3

24.1.1 Technical Characteristics 24 - 3
24.1.1.1 Power Supply Module 24 - 3
24.1.1.2 Power Supply Modules with External
Braking Resistor 24 - 4
24.1.1.3 External Braking Resistors - Overall
Dimensions and Mounting 24 - 5
24.1.2 Maintenance 24 - 6
24.1.2.1 Alarms 24 - 6
24.1.2.2 Fuses 24 - 9
24.2 Regenerative Power Supply Module 24 - 10
24.2.1 Technical Characteristics 24 - 10
24.2.1.1 Regenerative Power Supply Module 24 - 10
24.2.2 Configuration 24 - 11
24.2.3 Maintenance 24 - 12
24.2.3.1 Alarms 24 - 12
24.2.3.2 Brownouts 24 - 16

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PWS Power Supply Modules

24.1 Resistive Braking Power Supply Module

24.1.1 Technical Characteristics
24.1.1.1 Power Supply Module

Technical Characteristics

Power Supply Unit 3PWS30M 3PWS75L 3PWS150G 3PWS300XRE∗

Power supply consumption kW 12 30 60 130

No-load dissipation W 20 20 20 20
Maximum dissipation W 70 165 280 630
External braking Continuous power kW 1.2 1.8 3 External resistor
resistor Peak power kW 30 30 60 External resistor
AC input voltage V 380 V +10% -15% 50/60 Hz
DC voltage on intermediate bus V 535 VDC for 380 VC
Forced cooling Flow rate: 2m/sec
Protection class IP 10
Operating temperature range °C 0°C to +40°C
Storage temperature range °C -25°C to +70°C
Relative humidity max 90%
Module dimensions mm 62x348x353 105x348x353 190x348x353 190x581x353
Weight Kg 7.7 15.5 26.7 31

The power supply module converts the 380 VAC 50/60 Hz mains input to the DC level required for supply of the servo-
drives. All the interconnections are made via the plug-in connectors located in the back of the module.
The power supply module does not require any wiring by the installer. The LEDs on the front of the module
facilitate diagnostic in case of a fault on the power supply. 24
∗ This power supply module is available only with external braking resistors.

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24.1.1.2 Power Supply Modules with External Braking Resistor
If required by the machine cycle, the PWS module may be equipped with one or more external braking resistors to
increase the recoverable continuous power or externalise the heat source outside the rack. For the technical
characteristics of modules 3PWS30MRE, 3PWS75LRE, 3PWS150GRE and 3PWS300XRE, refer to the above table,
except for the data concerning the internal resistor and the weight (for the weight, see the table below).
A single set of one or more resistors is connected to module 3PWS30MRE; two sets of one or more resistors are
connected to modules 3PWS75LRE, 3PWS150GRE and 3PWS300XRE. The external braking resistors are available
in two continuous power ratings: 1.3 kW (code KFIG1) and 2.6 kW (code KFIG2). Each braking resistor has a rating
of 13.5 ohms. The resistor can be connected in series/parallel to increase the power dissipation capability, provided
the resistance of each set is never below 13.5 ohms for 3PWS30MRE/75LRE/150GRE or 6.5 ohms for 3PWS300XRE
(for 3PWS300XRE from revision 1012A up). It is essential to comply with this requirement so as not to damage
the PWS.

Power supply module Unit 3PWS30MRE 3PWS75LRE 3PWS150GRE 3PWS300XRE

with external
braking resistor

Weight kg 6.6 12.2 20.1 31

24 - 4 en-938979/0
PWS Power Supply Modules

24.1.1.3 External Braking Resistors - Overall Dimensions and Mounting

Rating 1.3 kW - 13.5 Ω (code KFIG1)

Rating 2.6 kW - 13.5 Ω (code KFIG2)

Weight 3.8 6.6

Terminal block

Tol. ± 2 mm

! CAUTION
If the duty cycle used includes a large number of accelerations and decelerations, the
resistor case may reach high temperatures. In this case, install it out of reach.
For correct heat dissipation, the resistor must always be mounted vertically with the terminal
block at the bottom as shown in the figure.

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24.1.2 Maintenance

24.1.2.1 Alarms
PWS alarms are exclusively hardware and are not stored after a power failure, contrary to UAC alarms.
A PWS fault cuts off power to all the UAC servo-drives in the rack.

PWS Power Supply Module - Status and Alarm LEDs

STATUS PWN Green LED Module power on

CLP Yellow LED Braking resistor inserted

ALARM OVE Red LED Internal power supply overvoltage

THP Red LED PWS heat sink overheating COP
COP Red LED Braking resistor overload
UVL Red LED Undervoltage on mains

24 - 6 en-938979/0
PWS Power Supply Modules

PWS Power Supply Module - Status LEDs

PWN
The green PWN LED is lit when the module is powered.

CLP The yellow LED is lit when the motor is being braked and power is being dissipated
by the braking resistor.

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PWS Power Supply Module - Alarm LEDs

Cause Corrective action

A During braking, the braking resistor A Pheck for correct dimensioning of

was not able to absorb all the power PWS/UAC in terms of maximum power
generated by the motor
OVE B The braking resistor circuit is faulty B Replace the module.

C Replace the resistor if it is external

A The rack fan is not running A Check that the fan slide-in unit is
correctly engaged (see Sec. 23.2, Rack)

THP
B The temperature inside the rack is too B Check with the machine manufacturer
high (> 45°C) for correct heat exchange

The duty cycle is characterised by very Use a less strenuous duty cycle by
frequent accelerations/decelerations increasing the time between
decelerations

The resistor has heated to above

COP 250°C

A The mains voltage is below 300 VAC A Check the mains voltage

B Open circuit in one of the three phase B Check for presence of the three phases
wires and the fuses inside the module
UVL

Note: In case of a mains power failure, the voltage reaches the UVL protection trigger threshold while the capacitors
are discharging. Before reconnecting the mains, always make sure all the LEDs on the module are unlit (max. 30 sec.).

24 - 8 en-938979/0
PWS Power Supply Modules

24.1.2.2 Fuses
The PWS modules are equipped internally with input protection fuses.

Fast-blow brush type fuses

for semiconductors

3 PWS 30M 3 fuses 80 A / 1000 V

3 PWS 75L 3 fuses 160 A / 1000 V
3 PWS 150M 3 fuses 160 A / 1000 V
3 PWS 300X 3 fuses 250 A / 1000 V

Protective
cover
Fast-acting fuses

Fuse retaining nut

24
(M10)

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24.2 Regenerative Power Supply Module
24.2.1 Technical Characteristics

24.2.1.1 Regenerative Power Supply Module

The regenerative power supply module directly recovers mains power during braking of the motor.
The external braking resistor (code KFIG1) is used only in case of a mains power failure occurring during braking.

Technical Characteristics

Regenerative Power Supply Modules Unit 3PWS75LRR 3PWS150GRR

Power consumption kW 30 60
AC input voltage V 380 V +10%-15% 50/60 Hz
DC voltage on intermediate bus V 535 VDC for 380 VC
Forced cooling Flow rate: 2m/sec
Protection class IP 10
Operating temperature range °C 0°C to +40°C
Storage temperature range °C -25°C to +70°C
Relative humidity max 90%
Module dimensions mm 105x348x353 190x348x353
Weight Kg 11.5 17

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PWS Power Supply Modules

24.2.2 Configuration
The regenerative power supply is mounted in a UAC rack.

Racks with PWS75

The rack is the same regardless of whether a normal or a regenerative power supply is used (see UAC installation
manual, pages 23 and 25).

Racks with PWS150

Different rack types are used for normal and regenerative power supplies.
The regenerative power supply must always be used with the following external components:
- A three-phase choke coil (RL75 or RL150) applying an inductive load to the power supply and limiting the AC ripple
current
- A capacitive filter HPPM166 (3x16.6 µF, 440 V) decreasing the noise generated by the power supply
- An external braking resistor KFIG1 (13.5 ohms, 1300 W), not used during normal operation but providing the
following functions:
. A soft start of the power supply by limiting the load in the wires at start-up
. Braking in case of a mains power failure
- Fuses: unlike the normal power supply, the fuses are not integrated and must be installed by the customer.
Fuses to be used (see Marketing Note of 22 June 1993):
- 3PWS75LRR: Brush 63 AFE or equivalent Protistors
Nominal voltage = 660 Vrms, I2t at 660 Vrms = 700 A2.s in 3 ms
- 3PWS150GRR: Brush 140 AFE or equivalent Protistors
Nominal voltage = 660 Vrms, I2t at 660 Vrms = 1500 A2.s in 3 ms

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24.2.3 Maintenance

24.2.3.1 Alarms

Regenerative PWS Module - Status and Alarm LEDs

Regenerative PWS LEDs

Status PWN Green LED Module powered

CLP Yellow LED Module regenerating

PHL (sw) Red LED Mains voltage < Un - 20% or open circuit on a phase
DES (hw) Red LED Current spike in a transistor
OVE (sw) Red LED Internal overvoltage in power supply module
THP (hw) Red LED Heat sink overheating
TOT (SW Red LED Not active
UVL (sw) Red LED Mains voltage < Un - 20%
OVE+TOT (hw) Red LED Internal overvoltage in power supply module
TOT+UVL (hw) Red LED Overcurrent
PHL+OVE (sw) Red LED Mains voltage > Un + 20%
PHL+TOT (sw) Red LED Incorrect synchro connection
PHL+UVL (sw) Red LED EPROM fault

sw = software alarms
hw = hardware alarms

24 - 12 en-938979/0
PWS Power Supply Modules

PWS Power Supply Module - Status LEDs

PWN
The green PWN LED is lit when the module is powered.

CLP The yellow LED is lit when the motor is being braked and the power is being
regenerated from the mains.

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Regenerative PWS Module - Alarm LEDs
Cause Corrective action

PHL Open circuit on a phase or mains Check the mains voltage

voltage < Un - 20%

A Selsyn connection error (terminals A Check the power wiring

9T/10S/11R of rack terminal block M)
DES

B Interference on mains due to B Check the mains

brownouts occurring in rapid
succession

A The module was not able to regenerate A Check for correct dimensioning of the
all the motor power during braking regenerative PWS/UAC in terms of
maximum power
OVE
B Regeneration circuit failure B Replace the regenerative PWS module

A The rack fan is not running A Check that the fan slide-in unit is
correctly engaged (see Sec. 23.2, Rack)

THP B The temperature inside the rack is too B Check with the machine manufacturer
high for correct heat exchange

A The mains voltage is below 320 VAC A Check the mains voltage

UVL

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PWS Power Supply Modules

Cause Corrective action

A The module was not able to A Check for correct dimensioning of the
regenerate all the motor power during regenerative PWS/UAC in terms of
braking maximum power
OVE
B Regeneration circuit failure B Replace the regenerative PWS module
TOT

A Selsyn connection error (terminals A Check the power wiring

9T/10S/11R of rack terminal block M)

B The module was not able to supply all B Check for correct dimensioning of the
TOT the current required by the motor regenerative PWS/UAC in terms of
UVL
power during an acceleration maximum power

PHL The mains voltage is above Un + 20% Check the mains voltage
OVE

PHL
One of the selsyn not connected
(terminals 9T/10S/11R of rack
Check the power wiring 24
terminal block M)
TOT

PHL
Software error Replace the module

UVL

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24.2.3.2 Brownouts
The regenerative system is disconnected when brownouts occur on the mains, then reconnected when power is
restored.
If the brownout lasts more than three cycles, the system stops and a fault is indicated.

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UAC Servo-Drives

25 UAC Servo-Drives

25.1 Technical Characteristics 25 - 3

25.2 Hardware Implementation 25 - 4
25.2.1 ACQ Card 25 - 5
25.2.1.1 Replacing the RAM 25 - 7
25.2.1.2 Different Types of ACQ Cards 25 - 7
25.2.1.3 Compatibility of ACQ Cards with
Software Versions 25 - 8
25.2.1.4 Connector mb (ACQ card) 25 - 9
25.2.2 IP1 Card 25 - 10
25.2.3 AL1 LED Card 25 - 10
25.2.4 Optional Cards 25 - 10
25.2.4.1 RS232 Serial Interface Card 25 - 10
25.2.4.2 DAC Card (analogue outputs) 25 - 11
25.3 Maintenance - Alarms 25 - 14
25.3.1 Clearing Stored Alarms 25 - 15
25.3.2 UAC Module - Status LEDs 25 - 16
25.3.3 UAC Module - Software Alarm
Indications 25 - 16
25.3.4 UAC Module - Hardware Alarm
Indications 25 - 17

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25 - 2 en-938979/0
UAC Servo-Drives

25.1 Technical Characteristics

UAC servo-drives (Universal AC Controllers) use the same hardware to control brushless axis motors and
asynchronous spindle motors.
Only two memory modules (one REPROM containing the software and one RAM or EEPROM containing the
parameters) customise a servo-drive as axis or spindle servo-drive.

Technical Characteristics

UAC servo-drive Unit 3UACM5030I 3UACL5050I 3UACL5075I 3UACG50100II 3UACG50150I 3UACX50200I 3UACX50300I

Rated current (rms) A 14 24 35 47 70 94 141

Maximum current (rms) A 21 35 53 70 106 141 212
No-load dissipation W 30 30 30 30 30 30 30
Dissipation at nominal load W 215 280 350 450 680 900 1360
Control technique Fully digital with flux vector control
Logic input signals V + 15/24 V DC
Command reference V Analogue +/- 10 VDC
Auxiliary voltages V + 24 VDC 0.4 A – + 10 / – 10 VDC 7mA
Protection class IP 10
Operating temperature 0°C to +40°C
°C
range
Storage temperature range °C -25°C to +70°C
Relative humidity max 90 %
Module dimensions mm 62x348x353 105x348x353 105x348x353 190x348x353 190x348x353 190x581x353 190x581x353
Weight Kg 6.5 10 10 20 20 33 33

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25.2 Hardware Implementation
The servo-drive includes:
- A power module containing:
. The IGBT power stage with short-circuit, overvoltage, overcurrent and overheating protection
. A power transistor driver card
. An auxiliary power supply card.
In case of failure of any of these items, it is necessary to replace the complete power module.
- Three basic plug-in cards.
The front panel of the servo-drive is removable by removing the four attaching screws.
A failed card can be replaced individually. In this case, it is not necessary to replace the complete servo-drive.
- A number of optional cards: RS232, DAC, Indexing, Relay, Encoder Simulation, Backlash Compensation, etc.

DAC card or
Led card RS232 Card

Indexing card or
encoder card

ACQ card

Relay card or
encoder card
IP card

! CAUTION
Always power down the module before removing cards.

25 - 4 en-938979/0
UAC Servo-Drives

25.2.1 ACQ Card

The ACQ card is in the leftmost position in the module. It contains two microprocessors, the resolver signal acquisition
circuits, the REPROM containing the software and RAM (or EEPROM) containing the customisation parameter file
called Technical Specification (ST).
The following information is noted on the RAM∗:
- The type of motor for which it is configured
- The ST number (name of the parameter file)
- The maximum current rating of the module, which must be equal to that mentioned on the setting card (CT350) of
the IP card.
When replacing the ACQ card, recover the memories from the failed card and install them on the new card.
In case of a problem with the memories, the NUM spare parts department will need to know the information noted on
the memories (software version on the REPROM, ST on the RAM).
∗ Note: The lithium battery (inside the RAM) life does not exceed 3 years for modules in stock.
The battery cannot be recharged, but it is disconnected when the UAC module is powered by the mains.
When the battery is flat, an alarm is indicated on the servo-drive (OVS LED flashing).
To solve this problem, NUM recently replaced the RAMs by EEPROMs.

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Axis or Spindle RAM

Microprocessor Axis Spindle

Axis Spindle

Axis or Spindle EPROM

Microprocessor

The shielded cables from the sensor are connected to connector mb of the ACQ card.

25 - 6 en-938979/0
UAC Servo-Drives

25.2.1.1 Replacing the RAM

If you have a backup copy of the parameter file and the PC Set Link (SPM) software tool, it is recommended to restore
the file by the SPM pLoad command.
If not, specify the ST number to NUM who will configure the memory before shipping it out.

! CAUTION
The file created by NUM is the standard file for a given motor/servo-drive association. The
OEM may have modified some parameters to adapt them to the machine or to optimise the
feedback. These new parameter settings are not included in NUM’s supply.

- Replacing with a RAM of the same type

Reference ARA002C08J02JT P/N 410728025
- eplacing with an EEPROM
Reference XICORX2816CP20 P/N 410728016
This operation also requires replacing the UAC servo-drive software (see equivalence table)

Software description Software for RAM Software for RAM and EEPROM
2.5 kHz axis A 3.10 A 3.21
5 kHz axis A 4.02 A 4.10
2.5 kHz resolver spindle A 1.28 S 1.31
5 kHz cog wheel resolver spindle A 3.00 S 3.10
5 kHz resolver spindle S 3.82 S 3.90
For equivalent software, the ST number is the same for an EEPROM and a RAM. To be able to communicate with
a PC, SPM Release 2.20 is required as a minimum.

25.2.1.2 Different Types of ACQ Cards

- Basic 2.5 kHz ACQ card:
Reference 2UACLACQF356 P/N 418200356
- 2.5 kHz ACQ card with options:
Reference 2UACLACQF356P P/N 418220356
Various optional daughterboards can be provided for this card:
25
- Master or slave backlash compensation (axes), option:
Reference 2UACANT385 P/N 418400385
- High resolution sensor processor (spindle): 2UACCAXIS411
- High resolution sensor + encoder simulator (spindle): 2UACHR411
- 5 kHz ACQ card
Reference 2UACLACQF356 P/N 418250356
By comparison with the above cards, this card increases the PWM system frequency from 2.5 kHz to 5 kHz. This
modification decreases the heat and noise generated by the motor. It is mainly used with asynchronous spindle
motors.
This card can also be fitted with the above optional daughterboards.
If used, the UAC module reference becomes 3UACx50xx151

en-938979/0 25 - 7
25.2.1.3 Compatibility of ACQ Cards with Software Versions
Compatibilities between ACQ Cards and UAC Software Versions

ACQ Cards SOFTWARE

Type NUM SpA reference NUM A 3.10 A 4.02 S 1.28 S 2.52 S 2.00 to S 2.08 S 3.82 S 3.00
Part No. and < and < S 2.06

2.5 kHz 2UACLACQF356 418 200 356 Yes Rel 3.0 Yes Yes Rel 3.0 No Rel 3.0 Rel 3.0
Standard and above and above and above and above

2.5 kHz 2UACLACQF356P 418 220 356 Yes Rel 3.0 Yes Yes Rel 3.0 No Rel 3.0 Rel 3.0
Options and above and above and above and above

5 kHz 2UACLACQF356V 418 250 356 No Yes No No No Yes Yes Yes

Compatibilities between ACQ Cards and UAC Options

ACQ Cards OPTIONS

Type NUM SpA reference NUM Backlash C Axis High

Part No. compen- resolution
sation

2.5 kHz 2UACLACQF356 418 200 356 No No No

Standard

2.5 kHz 2UACLACQF356P 418 220 356 Yes Yes Yes

Options

5 kHz 2UACLACQF356V 418 250 356 Yes Yes Yes

25 - 8 en-938979/0
UAC Servo-Drives

25.2.1.4 Connector mb (ACQ card)

ACQ card

ACQ card connector

Resolver connector
on motor

Resolver

Green
Black
Black
White
Red
Black
25

The cable supplied by NUM (RSC AWG 22x8) connects the resolver to the connector mb.
Refer to the CAT wiring diagram for connection of the shielding.
To prevent interference in the signal due to the resolver, make sure when installing the cables in the
cabinet to keep the resolver cable and power cables at least 300 mm apart.

en-938979/0 25 - 9
25.2.2 IP1 Card
Reference: 2UACLIPF349 P/N 418201349
(UAC Manual 783E003/C, page 19)
Connections (see UAC manual, pages 34, 35, 36).

25.2.3 AL1 LED Card

Référence: 2UACLF353 P/N 418200353
The AL1 card is located at the top of the module, to the right of the ACQ card.
It includes the UAC servo-drive status and alarm LEDs (see Maintenance below) as well as the regulators for the
auxiliary outputs (+5 V, +15 V, -15 V, +24 V).

25.2.4 Optional Cards

Optional cards can be placed to the right of the IP card (bottom) and the LED card (top).
Two slots (for UAC 5030) or four slots (for other modules) are available for optional cards.
There are no predefined slots for the optional cards.
The following optional cards are available:
- Standard relay card: 2UACG14 P/N 418414386
- Relay + current limiting card: 2UACG15 P/N 418415386
- Indexing card: 2UACPOS1 P/N 418400386
- Encoder card: 2UACENC387x
x specifies the card resolution:
x = A: 768 pulses per revolution P/N 418401387
= B: 3072 pulses per revolution P/N 418400387 (standard)
= C: 12,288 pulses per revolution P/N 418402387
= D: 49,152 pulses per revolution P/N 418403387
These cards are described in detail in the UAC Installation and Maintenance Manual 738E003/C, pages 38-51.
They are not detailed further herein.
However, two optional cards are required for maintenance of the UAC servo-drives.

25.2.4.1 RS232 Serial Interface Card

Reference: 2AUC232 P/N 418400372
This card interfaces the UAC servo-drive with a PC.
It also allows connection of the PC Set Link servo-drive setup software (SPM software) running under DOS.
This software is described in detail in the PC Set Link Manual 738E0.
The SPM software is used to set up the servo-drive and optimise the customisation parameters (ST): servo-drive
configuration, optimisation of the speed loop, adaptation of the options.
It is also used to control the motor from the PC and provides an internal oscilloscope function.
This software is essential for setup and can also be useful for maintenance.

25 - 10 en-938979/0
UAC Servo-Drives

The SPM Info command displays the servo-drive alarm history.

A table in the parameter memory can contain up to 128 servo-drive alarms. This table indicates the type of alarm as
well as the date and time of occurrence (time-date function available only with a RAM but not with an EEPROM).

25.2.4.2 DAC Card (analogue outputs)

Reference: 2UACDAC1374 P/N 418400374
The DAC card converts internal digital quantities to analogue signals available for display on Test Points (TP) and the
terminals of md. Maximum output current 6 mA.
Each card can display two quantities.
The signed value (+ or -) and absolute value are available for each quantity. Two DAC cards can be used together
(if two free slots are available). When two DAC cards are used together, the address dipswitches must be set as
follows:

Switch DAC card 1 DAC card 2

setting (S1)

1 OFF ON

2 OFF OFF

3 OFF OFF

Use PC Set Link to select the parameters to be displayed. The following default quantities are selected in the servo-
drive as delivered:
Spindle TP1: Veldb (speed) 0.444 V = 1000 rpm
TP2: Load 5 V = nominal load
Axis TP1: Velfil (speed) 1.33 V = 1000 rpm for kvelf = 32
TP2: Iq (torque current) 3.93 V = maximum module current
The table below shows the terminal and test point numbers where the quantities are available.
PC Set Link DAC DAC card Signal
software hardware output type
test point test point terminal

TP1 78 0 / +10 V
TP 1
TP2 79 –10 / +10 V 25
DAC
card 1 TP 3 80 –10 / +10 V
TP 2
TP 4 81 0 / +10 V

TP 5 82 GND

TP 1 78 0 / +10 V
TP 3
TP 2 79 –10 / +10 V
DAC
card 2 TP 3 80 –10 / +10 V
TP 4
TP 4 81 0 / +10 V

TP 5 82 GND

en-938979/0 25 - 11
DAC Card (Test Point Selection with PC Set Link)

DAC Card address dipswitch

DAC card 1 DAC card 2

Dip switch

RS232
serial interface card

RS232
serial port DAC card

PC Set Link

25 - 12 en-938979/0
UAC Servo-Drives

With the SPM software, you can modify the assignments of the test points measured on the cards.
The quantities selected can be displayed on the DAC card, on the internal oscilloscope of SPM and dynamically on
the SPM software (command dtEp).
The standard quantities (current, axis speed, power and spindle speed) are used to check the behaviour of an axis.
However, other quantities can be selected during maintenance to check the resolver (e-cos-r, e-sin-r, e-gain) or its
angular setting (Vd) (see the section on axis motors for the setting procedure).
Most of the other quantities that can be tested are for use by NUM S.A. for servo-drive design.

en-938979/0 25 - 13
25.3 Maintenance - Alarms

! CAUTION
The alarm LEDs can be lit in two ways:
LED lit steady —> hardware alarm
LED flashing —> software alarm

UAC

Status DOK Green LED Servo-drive OK, no error

ENB Yellow LED Servo-drive enabled

DES Red LED Current spike in a transistor

THP Red LED Heat sink overheating
Hardware alarm, EXP Red LED External protection triggered
LED lit steady RSL Red LED Connection to resolver cut or incorrect
PWF Red LED Current leakage to earth
OVS Red LED Motor overspeed
MOT Red LED Motor overheating I2t
TOT Red LED Transistor overheating

Software alarm, RSL Red LED RAM battery flat

LED flashing TOT Red LED RAM parameters incompatible
THP Red LED Remote KO (only for servo-drive with backlash compen-
sation)

25 - 14 en-938979/0
UAC Servo-Drives

25.3.1 Clearing Stored Alarms

When an fault triggering an alarm occurs:
- The green DOK (drive OK) and yellow ENB (drive enabled) LEDs go out
- The DOK contact on terminals 1 and 2 of connector ma on the IP card opens
- The alarm LED comes on
- The alarm is stored
- The motor stops by inertia.
To start operation, proceed as follows:
- Power down and wait for around 30 seconds
- Power up (the DOK and alarm LED concerned are lit)
- Check the type of alarm stored
- Correct the problem
- Clear the alarm by enabling then disabling the servo-drive. (The alarm can also be cleared by applying power to
and removing it from terminal 20 of the IP card).
If the alarm disappears and DOK remains lit, the drive is OK. Otherwise, the alarm persists.

en-938979/0 25 - 15
25.3.2 UAC Module - Status LEDs

The green DOK LED is lit when the module is operating correctly.
It goes out when one of the alarm LEDs comes on.

The yellow ENB LED is lit when the servo-drive is enabled and current
is flowing through the motor.

25.3.3 UAC Module - Software Alarm Indications

Cause Corrective action

RAM battery flat Replace the RAM and reload the

parameters with PC Set Link

Incorrect parameters with Reload the correct parameters

incompatible format loaded. with PC Set Link
e.g. axis parameters loaded
in a spindle servo-drive

Operational problems on the other Check the alarms on the other

module operating with backlash backlash compensation module
compensation

Communication problems between Check the link between

master and slave cards the master and slave cards

If one of the above LEDs starts flashing, replace the ACQ card to solve the problem.

25 - 16 en-938979/0
UAC Servo-Drives

25.3.4 UAC Module - Hardware Alarm Indications

Cause Corrective action

Power wiring error, - Check the wiring

e.g. incorrect wiring of - Check the motor insulation
electrical gear change and winding impedance
Error on power - Replace the power module
(motor or servo-drive)

A The rack fan is not running A Check that the fan slide-in
unit is correctly engaged
(see Sec. 23.2, Rack)

B The temperature inside the rack B Check with the machine

is too high (> 45°C) manufacturer for correct
heat exchange

No 24 V across terminals 21 and 6 of Check the wiring

IP card connector ma

Short circuit between resolver cables

Leakage to earth
Check the wiring between
the resolver and ACQ card
25
Connections reversed

en-938979/0 25 - 17
Cause Corrective action

Leakage to earth from Check the wiring of the power part

a power cable (terminal M/motor)

Maximum speed set is higher Check the speed setting on

than that specified potentiometer S1 or S2 of
the setting card on the IP card

A Wiring error between motor A Check the wiring

and servo-drive

B Motor seizure. B Check the mechanical parts

The motor has been running Check the duty cycle

too long in overload

25 - 18 en-938979/0

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