P. Ingold
Electronics Manual CNC97/98
All machines for construction glass and automobile glass
Maschinen AG Industriestrasse5
INC.
CH-4922Bützberg
30,CommerceDrive Hauppauge,NY,11788
Telephone+41629587777 Telefax+41629587700
Phone+15162311212 Fax+15162311040
E-Mail
[email protected] http:/www.bystronic.ch ELEKTRONIK.CNC.BA.V2.USA
email
[email protected]
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Electronics Manual CNC 97/98 Copyright of the edition © 1999 Bystronic Maschinen AG
The work, including all its parts, is protected by copyright. Any use outside the narrow limits ofthe copyright law is not permitted without Bystronic’s consent.
Information on operating instructions Author:P.Ingold
Date:2.2.1999
Initials:PI
Version: 2.0 Order-No.: ELEKTRONIK.CNC.BA.V2.USA
Checked & Approved Technology:Th.Plüss Documentation:R.Fankhauser
Date:29.1.1999 Date:5.2.1999
Initials:TP Initials:rf
When reordering, always state the above order number and version of this Manual. Information concerning errors and proposals for changes should be sent to: Bystronic Maschinen AG Abt. Dokumentation Industriestrasse 5 CH-4922 Bützberg Telefax +4162-958 77 00 E-Mail
[email protected]
Trade marks: Bystronic would like to draw attention to the fact that the company names and trade names mentioned and product designations may be protected by patent and trade mark law.
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ELEKTRONIK.CNC.BA.V2.USA
Using this Manual
Page organization
The pages of the operating instructions have the following structure.
Information on structure of the operating instructions
1 2 3 4
5 6 7 8 9 10 11
The header contains the name of Title 1 Title1 Brief summary of the present chapter Contents of the chapter contains threestages 1st stage Main title, this appears only in the contents at the beginning of the Manual and in the contents of the chapter. 2nd stage Title 1, these chapters deal with a topic on a certain machine or assembly. 3rd stage Title 2, this subsection always deals with a topic which is discussed in the corresponding Title 1. Order number of the operating instructions. This number reveals the machine type, the typeof instructions, the version of the operating instructions and the language. Page numbering of the current chapter. Table caption and brief explanation. Figure caption and brief explanation. Information with preceding pictogram must be complied with. Refers to pages with moredetailed information. Explanation of a technical word used or of an abbreviation.
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Important information Before you begin working on the machine, it is essential to read the general safety requirements in the maintenance instructions. This Electronics Manual is designed for service personnel with a thorough knowledge of industrial electronics. It is t herefore not necessarily suitable for t he operator.
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ELEKTRONIK.CNC.BA.V2.USA
Table of Contents
1
Block diagra m 1-1
2
Electronics rack
3
Stepping motor rack
4
Peripheral cards
5
Panel PC
6
Drive system
7
Drive supply module
8
Drive module 8-1
9
Pressure controller 9-1
2-1 3-1
4-1
5-1 6-1 7-1
10 Positioning module UNIPOS 11
Adjustment instructions
10-1
11-1
12 Appendix 12-1
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Contents of Chapter 1
Block diagram 1.1 Block diagram ................. ................. ................ ................. ..... 1-2 1.1.1 XYZ97/98 1.1.2 XYZF97/98 1.1.3 XYZF97/98R 1.1.4 XYZF97/98DS 1.1.5 PSM-XYZF98 1.1.6 KSM97/98 1.1.7 KSBM97/98 1.1.8 PSM97/98 (Stand alone) 1.1.9 PSM97/98 Compact 1.1.10 PBM98
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Block diagram XYZ97/98
1-2
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Block diagram XYZF97/98
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Block diagram XYZF97/98R
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Block diagram XYZF97/98DS
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Block diagram PSM-XYZF98
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Block diagram KSM97/98
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Block diagram KSBM97/98
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Block diagram VSM97/98
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Block diagram PSM97/98 (Stand alone)
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Block diagram PSM97/98 Compact
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Block diagram PBM98
1-12
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For your notes
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For your notes
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Contents of Chapter
Electronics rack 2.1 The CNC Rack ..................................................................... 2-2 2.1.1 RACK SUPPLY 2
2.2 CPU ....................................................................................... 2-8 2.2.1 CPU 386SX 2.2.2 Light emitting diodes on CPU 2.2.3 CPU switches 2.2.4 CPU Jumpers
2.3 ROM/RAM2 ...................................................................... 2-12 2.3.1 ROM/RAM2 Jumper
2.4 CUTCON2 2.5 IMPGEN ................... .......................................................... 2-18 2.5.1 Impgen switches 2.6 POSCON ........................................................................... 2-22 2.7 SERCOM2 .......................................................................... 2-28 2.7.1 Adapter cards for SERCOM2
2.8 DIOCOM ........................................................................... 2-36 2.8.1 Adapter cards for DIOCOM
2.9 POSCAD ............................................................................ 2-44 2.9.1 POSCAD switches
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2.1 CNC rack
2.1 The CNC Rack cards for The " CNC rack has space for the power supply, a CPU card and peripherals.
Electrostatic discharge
The card guides() are equipped with spring contacts which provide optimal protection from ESD. As soon asthe peripheral cards havebeen inserted, the ESD protection compone nts of the peripheral cards are connected to groundand can thus eliminate any static charges before the bus connection is made. Electrostatic discharge The discharge of static electricity from an external source, e.g. as a result of touching with the hands, often leads to destruction of the circuit Themetallic plug fa stening rail () at the back of the rack permits extensive contact with the cable screens via the plug hous i ng of the incoming and outgoing cables. The back panel ) (makes the connection between power supply, CPU and the other peripheral cards used. A slot number for addressing is available for every slot. The back panel (NCBUS) is in the form of a multilayer circuit board with 3 signal layers and 5 supply layers. A signal layer is enclosed between every two supply layers. The screening effect of the supply layers results in optimal attenuation of the cross-talk of betwee n the signa l line It is also pos way to ada pt the impedance the signal lines to s. the driver ICssible on in thethis peripheral cards.
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2.1 CNC Rack
Fig. 2.1a (Electronics rack)
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2.1 CNC rack
2.1.1 RACK SUPPLY 2
The RACK SUPPLY 2 provides the rack wit h the stabilized volt ages, 5 V/20 A digital part, ± 12 V⁄1.5 A analogue part, and the unstabilized voltage14 V/6 A of the encoder supply. Computer Numerical Control
To ensure satisfactory operation of the CNC control, all voltages are monitored. If the mains voltagefails, an AC powe rfail is generated after two half-waves (one period, 20 ms). The CNC control detects this and can save the most important data a nd bring the system to a safe state before the DC volt agefails. The RACK SUPPLY 2 isequipped with 3 signal inputs. The inputs ALARM A and ALARM B() are managed by the watchdog of the CPU, which is activated by the machine software. The third signal RESET is triggered by the reset switch on the CPU. If oneof the 3 signals responds, the relay K3 (in the CNC cabinet, NC Ready) will drop out. The relay K3 is used for communicating the failure of the supply voltage (in the CNC rack) to a superior control (NC Ready). The presenceof the four volt ages is indicated by means of LEDs,( , , ) on the front panel and can additi onally bemeasured via 5 VDC(), ± 12 VDC (, ) and 14 VDC () test jacks. If one of the controlled DC voltages falls below its minimum reference value, a DC powerfail is generated. The situation currently leads to a system reset. At the same time, the relay K3 (in the CNC cabinet) will drop out. The RACK SUPPLY 2 requires 4 different input voltages. These voltages are supplied by a mains transformer which is electrically isolated from the mains input. The four inputs are protected by fuses ). ( The hous i ng of the RACKSUPPLY 2 contains four reserve fuses)( which, if ). fuses ( required, can be used as a replacement for the faulty
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2.1 CNC rack
Fig. 2.1b (RACK SUPPLY 2)
Legend: 1R eserve fuses 2 Fuses 3 +5 VDC LED 4 +5VDCtestjack 5 +12 VDC LED 6 +12 VDC test jack
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-12 VDC LED
8 -12 VDC test jack 9 10 11
14 VDC LED 14 VDC test jack Alarm A + B LED
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2.1 CNC rack
Fig. 2.1c (Block diagram of RACK SUPPLY 2)
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For your notes
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2.2 CPU
2.2 CPU 2.2.1 CPU 386SX
Abbreviation for millions of instructions per second
The CPU card is equipped with an 80386 SX microprocessor from Intel. The processor is operated ta20 MHz clock frequency . The system thus achieves a processing speed of approx. 5 MIPS. The processor loses little power and therefore needs no cooling system. Owing to the intensive computational use in calculation and for working through the NC program, the CPU card is equipped with an 80387SL coprocessor from Intel. The efficiency of the system is greatly increased especially in floating point calculations. The CPU card is equipped with a universal port module. 2 indepe ndentports are thusavailable, channelA and cha nnelB. Channel Ais connected as an RS232C port and is used for connection of a CMR terminal (Console Monitor). This port serves for program development and testing and is used exclusively by the Bystronic Development Department. Channel B can be operated as an RS 232C or as a fibreoptic port (TOS link). When configured as an RS232C port, channel B conne ctsthe AT terminal to the older (CNC89/92) machines. When configured as a TOS link (Opto port), channel B connects the CNC by mea ns of a fibreoptic cable to the operator terminal (Panel PC) of the CNC 97/98 machine generation. The 2 ports are electrically isolated from the rack and from one another. The transmission rate is 115.2 kbit/s.
Fig. 2.2a (CPU 386SX)
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2.2 CPU
2.2.2 Light emitting diodes on CPU LED H1 yellow
BUSY indicates by means of its luminous intensity the level of utilization of the processor. LED H2 green
IDLE indicates by meansof its luminousintensity the time for which the processor has been waiting in a queue for work. LED H3 red
HALT indicates that the processor has encountered aHALT instruction when executing theprogram and cannot continueperforming the current task. This error can be eliminated only by a cold system start or by an interrupt. LED H4 red
SHUTDOWN indicates that a serious error has occurred during execution of the program. Possible causes are the interrupt 8, 13 or a stack overflow. The system can berecovered from the situation only by an NMI N( on M askable I nterrupt) or a cold start. LED H5 yellow
Bus timeout. The proce ssor hasunsuccessfully wait ed for a ready signalfrom an
addressed interface card andfurther has itself terminated the bus cycle after thewithout maximum waiting time. In this situation, execution of the program is possible problems, but this is a warning that an interface card is not present in the system or is faulty. LED H6 red
INT ERRUPT REQUES T lights up during execution of an interrupt routine. It is activated by the INTA signal of the processor and si cleared again by the software at the end of the interrupt routine.
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2.2 CPU
2.2.3 CPU switches S1 The CPU performs a cold start and triggers a system reset. S2 Position of the memory on the CPU card. (Standard setting: No. 1 at ON/No. 2 at OFF applies to all machines.) S3 Serves for switching channel B from RS 232C to the fibreoptic (Opto). Position 1: Fibreoptic(Tos link) Position 2: RS 232C
2.2.4 CPU Jumpers J5 Configuration of external interrupts:
Pin 1 with 8 Pin 2 with 7
external N on M askableInterrupt (NMI) connected to internal NMI external AC powerfail (ACPF) connected to internal NMI
Pin 4 3 with with 56 Pin
external IN ACT9 powerfail (ACPF) connected external connected to internal IN T9to INT9
Factory settings for all machines Pin 1 connected to 8 Pin 4 connected to 5
Fig. 2.2b (CPU 386SX)
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2.2 CPU
Fig. 2.2c (Block diagram of CPU 386SX)
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2.3 ROM/RAM2
2.3 ROM/RAM2 Read Only Memory/RRead Access Memory
The ROM/RAM2 is the main memory and progra m memory card of the CN control. The card is equipped with 1 MB memory chips . It is divided into 4 memory banks(bank 0 to bank 3). Thefirst bank (bank 0) is equipped with RAM. The 4thbank (bank 3) is equipped with flash EPROM and thus serves as a readonly memory for holding the CNC software. The 2nd and 3rd banks (bank 1 and bank 2) are not used at present and thus serve for later memory extension. The RAM section, bank 0 to bank 2, is protected with a lithium battery to prevent data loss. The battery capacity is sufficient for maintaining the data for about 5 years. 2.3.1 ROM/RAM2 Jumper J1 The RAM section of the card is connected to the lithium battery() by jumper J1 (). When the card is stored, jumper J1 must be removed to protect the battery.
Fig. 2.3a (ROM/RAM2)
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2.3 ROM/RAM2
Fig. 2.3b (Block diagram of ROM/RAM2)
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2.4 CUTCON2
2.4 CUTCON2 Cut Cutting Con Controller
The CUTCON2 generates path-depe ndent real-timecontrol signals for thevarious working processes. The card contains four RS422 outputs and one 16 bit TTL output and one analogue (0-10 VDC) input and output. With the PLD CUT2-A, the switches SW1, SW2 and SW3 are inactive.
Information! In the glass machines, the 3 switches (SW1, SW2 and SW3) are never used. T he switch settings are therefore unimportant.
LED`s The four LEDs (1, 2, 3 and 4) are not actuated and thus have no function as error or status indicators.
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2.4 Cutcon2
Fig. 2.4a (Cutcon2)
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2.4 Cutcon2
Fig. 2.4b (Block diagram of CUTCON2)
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For your notes
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2.5 IMPGEN
2.5 IMPGEN Im Impuls Gen Generator Master card for controlling the POSCON cards
The feed pulse generator card IMPGEN generates all feed frequencies required for the axis system and controls the connected axis cards (CUTCON2/ POSCON). A green light emitting diode shows when the IM PGEN actuates the cards connected to it. The red LEDindicates that the maximum acceleration hasbeen reached. The pulse generatorcard can control up to max. 7 axe s.
2.5.1 IMPGEN switches Interrupt: The switch block SW1 defines the interrupt address of the card. The default setting (SW1) of the third switch on all machines is ON (switched on). The remaining switches must be set to OFF (switched off ). Master frequency: The switch block (SW2) defines the divider ratio of the master frequency. The default setting of all switches is OFF (switched off ). The more switches set to ON (switched on), the slower the axes of the machine travel sincethe frequency for actuating the Poscon is lower. Encoder input: The switch block (SW3) defines the multiplication factor with which the encoder inputs of the hand wheel on the remote control are multiplied. This option is not used at present in the glass machines.
Tab. 2.5a (IMPGEN)
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2.5 IMPGEN
Overview of the switches according to machine type:
Tab. 2.5b (IMPGEN switch settings) LED 1:
The IMPGEN actuates one or more POSCONs. LED 2:
The maximum acceleration was reached.
Fig. 2.5a (IMPGEN) ELEKTRONIK.CNC.BA.V2.USA
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2.5 Impgen
Fig. 2.5b (Block diagram of IMPGEN)
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For your notes
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2.6 POSCON
2.6 POSCON Pos Position Con Controller
The position control card POSCON controls a complete servo axis. The required analoguevalueof ± 10 Vis output via a 12 bit D/A conve rter to thespeed controller (drive module). While working through the CNC code (cutting, drilling or grinding plan), the path is interpolated under IMPGEN control. The approach to the reference and movement by means of the hand keysis performed independently by the POSCON; these actions are indicated by means of the green light emitting diode (RUN). When the axis is exactly on the zero mark of the encoder, the red LED lights up. If the maximum required value of ± 10 VDC is present, the red LED also lights up. Potentiometer P2: The potentiometer P2 is used for symmetrical adjustment of the ± 10 volt required value. LED 1: Red
• The maximum required value is present (overflow) • The axis is exactly on the zero mark of the encoder LED 2: Green
• The con actuates the axis without Impgen control (approach to reference and Pos manual movement)
Fig. 2.6a (Output voltage POSCON)
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2.6 POSCON
Fig. 2.6b (POSCON)
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2.6 POSCON
Switch block SW1: The multiplication factor of the encoder channels is set with switch block S W1.
Tab. 2.6a (POSCON switch positions)
Information! T he encoder chan nels A + B are rotated (interchanged) electronically w ith switch 9. This changes the counting direction of the channel (±). The procedure for correct setting of switch 9 is described in the instructions for commissioning.
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2.6 POSCON
Wire wrap configuration
Tab. 2.6b (Wire wrap configuration)
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2.6 POSCON
Key to wire wrap configuration
Fig. 2.6c (Wire wrap connections)
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2.6 POSCON
Fig. 2.6d (Block diagram of POSCON )
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2.7 SERCOM2
2.7 SERCOM2 Ser Serial Com Communication Card
The SERCOM2 board is a serial interfacecard. It has four indepe ndent ports which are electrically isolated from the rack and from one another. These four ports can be adapted to the port required in each case by mounting different interface adapters (SER232, SER422, SERCUL, SERCOPT). The parameters of the ports (baud rate, parit y ...) are configured on the panel PC in the MMC program (hardware config.). The transmission rate is determined by the interface adapter. The upper limit of the transmission rate limits the USART 16C552 on the SERCOM2 board. It is 1.5 Mbit/s. There is only oneconfiguration switch on the SERCOM2 card. It fixes the address for the master interrupt controller. Interrupt: Switch block SW1 defines the interrupt address of the card. The default setting of theseventh switch is ON (switched on) for all machines. The remaining switches must be at OFF (switched off).
Tab. 2.7a (SERCOM2 switch positions)
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2.7 SERCOM2
Fig. 2.7a (SERCOM2)
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2.7 SERCOM2
Fig. 2.7b (Block diagram of SERCOM2 )
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For your notes
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2.7 SERCOM2
2.7.1 Adapter cards for SERCOM2
Ser Serial Opt Optical Adapter Card
SEROPT The SEROPT moduleis a bidirectional optical port. It is capable of transmitting data at a rate of upto 60 Mbit/s, over a maximum transmission distance of 1 km.
The data transmission takes place optically in a optical fibre. This method of transmission is insensitive to electromagnetic and electrostatic interference. This method of data transmission is very suitable for achieving a fast and safe link in an environment with strong electrical disturbances. Another advantage is the complete electrical isolating of the communicating devices, since no screen connection is required. However, the fibreoptic cables are not so resistant to any mechanical stress. It is advisable to handle the fibreoptic cables carefully, i.e. notto bend them excessively and especially not to buckle them. There are no configuration facilities (switches) on the SEROPT module.
Fig. 2.7c (SEROPT)
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2.7 SERCOM2
Ser Serial 232 Adapter Card
Abbreviation for picofarad
Ser232 The SER232 module is a bidirectional interfacewith a V24 port referred to 0 V (ground). The module is capable of transmitting data at a rate of max. 115,200 bit/s. The line length is dependent on the cable characteristics. The capacitive load may not be greater than 2500 pF with a maximum load of 3000 ohm. This corresponds a pproximately to a cable length of 30 metres. richt ungefähr einer Kabellängevon 30 Metern.
The module supports the port specifications according to DIN 66020. There are no configuration facilities (switches) on the Ser232 module.
Fig. 2.7d (Ser232)
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2.7 SERCOM2
Ser Serial RS 422 Adapter Card
SER422 The SER422 module is a bidirectional interface with a symmetrical port which is not referred to ground. The module is capable of transmitting data at a rate of up to 100 kbit/s over a maximum transmission distance of approx. 1 km. With shorter links, the maximum rate increases. At a length of 100 m, it is thus possible to communicate at a transmission rate of up to 1 Mbit/s. However, these values can be achieved only if the impedance of the transmission line is 120 ohm and the data lines are terminated at both ends with the corresponding end-of-line resistor.
Fig. 2.7e (Ser422)
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2.7 SERCOM2
Ser Serial Cu Current Loop Adapter Card
SERCUL The SERCUL module is a bidirectional interface between the DUART 16C552 and an external device. The module is capable of transmitting data at a rate of max. 19200bit/s over a maximum transmission distanceof 1 km. However, these values can be achieved only in an optimal environment (no interfering electrical fields).
The interface is in the form of a current loop. Signal state 1 is indicated by a current of 20 mA. If no current flows in the loop, the signal state is 0. The transmission circuit can be configured as an active or passive signal source using switch S1. The receiving circuit, too, can be selected as active or passive with switch S2. The 2 loops are in the form of a constant current source or constant current drain and are thus short-circuit-proof. The two green LEDs indicate whether the current is flowing in the transmission circuit and/or in the receiving circuit. The LED H1 indicates the current in the transmission circuit and LED H2 that in the receiving circuit.
Tab. 2.7a (SERCUL switch position)
Fig. 2.7f (SERCUL)
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2.8 DIOCOM
2.8 DIOCOM Digital Input Output Com Communications Card
The DIOCOM board is an interface card for the Bystronic CN control. It serves as a basis for the input/output communication of the CNC. Variouscommunication modules can be mounted in the 4 slots (DIOPORT 14). The 16-bit DIOCAN module permits communication with a CAN field bus (SELECAN protocol). With the 16-bit DIOSSI module, external devices, such as the manual control, the cutting pres sure control, etc.,are actuated. The DIOPAR module esrves for communication with PARCOM-compatible devices. Interrupt: Switch block SW1 defines the interrupt address of the card. The default setting of the 4th switch (SW1) is ON (switched on) in all machines. The remaining switches must be at OFF (switched off ).
DIOCOM slot STD
DIOCOM slot STE
Tab. 2.8a (DIOCOM switch positions)
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2.8 DIOCOM
Fig. 2.8a (DIOCOM)
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2.8 DIOCOM
Fig. 2.8b (Block diagram of DIOCOM)
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For your notes
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2.8 DIOCOM
2.8.1 Interface boards for DIOCOM
Digital Input O utput Par Parallel Adapter
DIOPAR The DIOPAR moduleis a simulation of a PARCOM port. It makes it possible to actuatePARCOM-compatible terminals of the CNC89 generation via the DIOCOM board.
The DIOCOM is used exclusively for actuating the auxiliary keyboard (manual control keysX+/X-). Information! The DIOPAR module contains no switches or LEDs.
Fig. 2.8c (DIOPAR)
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2.8 DIOCOM
Digital Input Output Synchronous Serial Interface
DIOSSI TheDIOSSI moduletransmits two 16 bit ports (port 1&2). TheDIOSSI module is used as a connection to the pressure controller and to the input/output assemblies (MODULE RAIL S3, I/O M ODULE SSI).
The settings of jumper block J1 are determined by the board layout (cannot be changed) and relate to the following parameters: • Data inverted (e.g. with open collector actuation) • Transmission rate (250 kbit /s or 500kbit/s) • Master/slaveconfiguration (timing line) • OE (Output Enable). Determines whether the data are to bewritten directly to the output after reception. The output module rail should, for example, output the received data immediately; however, the input module rail may not write its input signals directly to the bus. The data are scanned by the CPU.
Fig. 8.2d (DIOSSI)
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2.8 DIOCOM
Digital Input Output Controller Area Network
DIOCAN The DIOCAN module transmits and receives data from a SELECAN network and is thusthe connection between the CN control and a Selectron PLCcontrol. The communication to the CAN bus is achieved on the DIOCAN module by a microproce ssor in conjunction with a CAN controller. The nodeaddress of the DIOCAN in the CAN network is set together with other properties of the node on configuration switch S1. Owing to its size, the DIOCAN module can be used only in the slots DIOPORT 1 and 2 on the DIOCOM. The green LED lights up briefly to confirm that the initialization procedure after a restart has been
successfully completed. The red LED lights up if a communication error has occurred on the CAN bus.
Information! The DIOCAN module is currently (October 1998) not used in the glass machines.
Fig. 8.2e (DIOCAN)
Fig. 2.8b (Switch 1)
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For youe notes
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2.9 POSCAD
2.9 POSCAD Pos Position Controller Acceleration Deceleration
The position controller card POSCAD serves for movement of CNC auxiliary axes. Through the various configuration possibilities, the POSCAD card can be used for the following drive concepts: • 2 stepping motorswithout actual value recycling • 1 stepping motor with actual value recycling • 1 servo motor 2.9.1 POSCAD switch Frequency: The switch block (SW1) defines the divider ratio of the master frequency. The more switches at ON (switched on), the slower the down circuit auxiliary axes (motor) travel sincethe freque ncy for actuating the stepping motor cards is smaller. Encoder input: The switch block (SW2) defines the multiplication factor with which the encoder pulses are multiplied. 2.9.1 (POSCAD switches)
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2.9 POSCAD
Fig. 2.9b (POSCAD switch positions)
*) With switch 9, the encoder channels A and B arerotated (interchanged) electronically. This causes a changein the counting direction of the channel (±). The procedure forcorrect setting of switch 9 is described in the commissioning instructions.
Fig. 2.9a (POSCAD)
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2.9 POSCAD
Fig. 2.9c (POSCAD configuration)
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2.9 POSCAD
Fig. 2.9b (Block diagram of POSCAD)
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For your notes
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Contents of Chapter
Stepping motor rack 3.1 Stepping motor rack .......................................................... 3-2 3.2 Stepping motor cards D900 ............................................ 3-4
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3.1 Stepping motor rack
3.1 Stepping motor rack The stepping motor rack is a 19" sub-rack provided with a Bystronic back panel. It permits the integration of the Berger-Lahr stepping motor control cards of Series D550 and D900 in the Bystronic CN controls.
The stepping motor rack can hold one voltage supply module ) and up( to o f ur stepping motorcontrol cards (). The required supply voltage (3 x 85 VAC) is delivered by an external transformer which is connected to plug X1 (POWER IN) on the stepping motor rack.
Fig. 3.1a (Front view of Berger stepping motor rack)
Fig. 3.1b (Back of Berger stepping motor rack)
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3.1 Stepping motor rack
Control signals: The control signals of the CNC drivecards (POSCAD) areconnected to the 25pin D-SUB jacks. X8: Stepping motor control card 1 X9: Stepping motor control card 2 X10: Stepping motor control card 3 X11: Stepping motor control card 4 Power output:
The stepping motors(power output) are connected to the 4-pin jacks. X12: MOTOR 1 X13: MOTOR 2 X14: MOTOR 3 X15: MOTOR 4 Error messages: The 3-pin plug X2: ERROR is connected to a potential-free changeover contact relay on each control card. In the event of a fault, the relay on the relevant card will pick up or drop outand thusshort-circuit or open the ERROR bus. Voltage supply module: The3 x 85 VAC (POWER N) I arerectified to 120 VDC and filtered by the o v ltage ) protects supply module () in the stepping motor rack. A fuse ( the DC voltage
circuit from The output voltage can be asure d at thevoltage ) lights test jack (, ).short-circuit. The light emitting diode ( (120 upVDC) as soon asme the AC-side is min. 10 V.
Information! T he LED ( ) provides no information about the level and quality of the voltage. It serves merely for indicating that a voltage is present.
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3.2 Stepping motor cards D900
3.2 Stepping motor cards D900 The Berger card D900 se rves for actuating 3-phas e stepping motors. They are us ed in the following applications: • Positioning stops (KSM/VSM/KSBM/PSM) • Spindle height adjustment (PSM) • Drill feed (PBM)Spindelhöhenverstellung (PSM) The card is actuated with the pulse, direction, door, current zeroing and micro step signals by a superior control (POSCAD). With these control signals and the (120VDC) supply voltage, the card drives a 3-phase stepping motor with a current consumption (adjustable) between 1.35 A and 5.5 A. Light emitting diodes:
LED 1 (green) LED 2(red) LED 3(red) LED 4(red) LED 5(red) LED 2, 3, 4, 5
= = = = = =
Ready (the supply voltage is above 80 VDC) Short-circuit between 2 phases Excess temperature (> 75°C) at heat sink Overvoltage (> 140 V) Undervoltage (< 80 V) Pulse frequency too high or interfering pulses.
Attention! In the event of a fault (LED 2 to LED 5), the current to the motor is cut off and the card reports „Not ready“ 1 goes out). This can lead to A currentless motor no longer has a (LED holding moment. undesired reactions.
Fig. 3.2a (Dip switch settings on Berger card D900)
Factory setting: S teps: C urrent lowering:
3-4
1O FF2O N(500steps) 3 OF F current lowering on
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3.2 Stepping motor cards D900
Rotary switch for motor phase current
Tab. 3.2b (Rotary switch for motor phase current)
Information! The value printed in bold Table factory The set phase current mustinbethe equal to corresponds or less than to thethe rated phasesetting. current shown on the motor rating plate.
Fig. 3.2a (Stepping motor card D900) ELEKTRONIK.CNC.BA.V2.USA
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For your notes
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Contents of Chapter
Peripheral cards 4.1 TERMIF ................................................................................. 4-2 4.1.1 TERMIF plugs
4.2 PARAN ............................................................................... 4-4 4.2.1 PARAN plugs
4.3 Speed limit monitor SLIM ................................................. 4-6 4.4 SSI module bus S3 ........................................................... 4-10 4.5 I/O Module SSI ................................................................ 4-12 4.5.1 Light emitting diodes SSI 4.5.2 Plugs on module SSI
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4.1 TERMIF
4.1 TERMIF Ter minal Interffface Adapter erm
The TERMIF is an interface between the hand terminal (HANDTERM) and the CN/PLC control. On the TERMIF, the variousHANDTERM signals are divided and are transmitted to the corresponding superior controls (IMPGEN, DIOCOM and PLC). The two channels A/B of the handwheel incremental encoder are transmitted to the IMPGEN card. The key channels1 and 2 and the timing of the SSI link areconnected to the DIOCOM card. The contacts of the emergency stop switch are looped in the safety circuit of the line control. In addition, detection of whether a function key ha s been pressed is performed on the key channel 2 of the SSI link. This information is additionally fed into the safety circuit via a relay contact. This permissive function is possible only wit h HANDTERM2 since HANDTERM3 transmits the key to channel 1 (howe ver, only channel 2 si monitored).
Fig. 2.10a (TERMIF)
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2.10 TERMIF
4.1.1 TERMIF plugs X1 Terminal 1 Terminal 2 Terminal 3
+24 VDC 0 VDC (ground) PE (ground)
X2 Plug for connection to hand terminal (HANDTERM). X3 Plug for connection to DIOCOM card (DIOSSI module on Dioport 1). X4 Plug for connection to IMPGEN card. X5 Function keys contact These lines are only looped on theTERMIF. The contact is on the HANDTERM. X6 Permissive contact These lines are only looped on theTERMIF. The contact is on the HANDTERM. X7 Not-Aus Emergency stop These lines are only looped on theTERMIF. The contact is on the HANDTERM.
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4.2 PARAN
4.2 PARAN Par Parallel An Analogue Converter
The PARAN board provides two isolated analogue voltages (0 VDC - 10 VDC) at plug X3. The voltages are generated by a digital input signal which is 2 x 8 bits wide (plug X1).
Fig. 2.11a (PARAN electronics card)
4.2.1 PARAN plugs X1 Plug X1 connects PARAN to the DIOPAR card on the DIOCOM board. X2 Power supply input for the PARAN board: Terminal 1 24 VDC Terminal 2 0 VDC X3 Analogue voltage output: Reference value1 Terminal 1 0-10 VDC Terminal 2 Ground
Reference value2
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Terminal 3 0-10 VDC Terminal 4 Ground
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For your notes
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4.3 Speed limit monitor SLIM
4.3 Speed limit monitor SLIM Speed Lim Limit
The speed limit monit or SLIM monit orsthe grinding disc speed as a function of the grinding disc diameter and detects whether or not the spindle is rotating. LE D s
H1 = H2 = H3 =
V max, theset speed has not been exceeded Stop, spindle is stationary Coding switch B active
H4 H5 H6 H7
Coding switch A active V1 low speed V2 high speed Thespeed limit indicator of thespindlelightsup if theswitch (S1 speed monitor) in the spindle is operated.
= = = =
P1: Frequency oscillator of this potentiometer is set at the factory and may not be changed. Speed setting Switch S12(50 mm) and S2 (150 mm) coding switches A + B
Information! T he value printed in boldin the Table corresponds to the factoryetting. s
Tab. 4.3a (Speed setting)
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4.3 Speed limit monitor SLIM
X 1.1 X1.2 X 2.1 X 2.2 X 2.3 X 3.1 X3.3 X 4.1 X 4.2
= = = = = = = = =
+24 VDC supply 0V +24 VDC from coding switch A +24 VDC from coding switch B Signal from thespindle +24 VDC Enable 0V Output Limit / K1 contact closed if Output Limit / n
