num 1000 Maintenance Manual

NUM 1000 FAMILY

CNC - NUM DRIVE

MAINTENANCE

MANUAL

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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.

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.

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.

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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

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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

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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

DOCUMENT REVISIONS

Date Revision Reason for Revision

07 - 98 0 Document creation

Record of Revisions

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Part 1

CNC

General

1 General

1.1 Main Rack 1 - 3

1.2 Differences Between Versions 1 - 5

1.3 Panels 1 - 9

1.4 Additional Components 1 - 11

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1.1 Main Rack

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

General

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

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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 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

System Bus

Graphic

processor

Memory

CNC

processor

Axes

Special

interfaces

Machine

processor

Serial link

Speed reference Measurement Origin switch

Serial Bus

Serial bus/fibre

Inputs

Outputs

optic

adapter

Optional keyboark

∗

Remote

inputs

Remote

outputs

Interrupts Analogue inputs/outputs Serial link

∗

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

Machine

panel

Machine

panel

extension (I/O)

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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 ∗

System Bus

CNC/graphic

processor

Memory

Axes

Special

interfaces

Machine

processor

Speed reference Measurement

Origin switch

Outputs

Serial Bus

Serial bus/fibre

adapter

Inputs

optic

Optional keyboard

Machine

panel

Interrupts Analogue inputs/outputs

Serial link

∗

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

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Machine

panel

extension (I/O)

UCSII Systems

General

Such systems general include only one processor unless the PCNC option is present. In a standard system, the single 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

U C

Graphic function

Memory

CNC

function

PLC

function

Compact panel

Optional keyboard

RS 232 serial interface Interrupt

∗

Analogue inputs/outputs

Serial

bus/fibre

optic adapter

System Bus

Inputs

Machine

panel

Machine

panel

extension (I/O)

Serial Bus

Outputs

Speed reference

Axes

Dedicated

interfaces

∗

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

Measurement Origin switch

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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

Memory

Communication

function

Axes

CNC

function

Communication

function

(PCMCIA card)

Modbus Plus

RS 232E serial interface

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

Speed reference Measurement Origin switch

PLC

CPU

Memory

Status RAM

I/O register

Discrete I/O

I/O processor

Communication processor

User logic

Ladder logic networks

and segments

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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 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.

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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.

5.5

320 mm

5.5

320 mm

8 holes diameter 4.5

15 minimum

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.

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1.4 Additional Components

Machine Panel

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.

General

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.

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32-Input Interface Panel with Cable

24-Output Relay Panel with Cable

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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 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.

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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

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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.

Minimum fibre-optic

cable curve

radius: 50 mm

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 + 5 V 10 A 25 A + 15 V 250 mA 500 mA

- 15 V 250 mA 500 mA + 24 V (bus) N/A 2 A + 24 V (external) N/A 2 A

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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

+15V

+5V

+24VE

-15V Pw Fail

RaZ

F/O

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24 VE

0 VE

Rec

Alim

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

123

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

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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.

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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+ 292 hidden pages

num 1000 Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual