num 1020, 1040 User Manual

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NUM 1020/1040

INST ALLATION AND

COMMISSIONING

MANUAL

0101938938/2-E1

11-97 en-938938/2-E1

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 1997. 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 1997 software CNC 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.

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Table of Contents

This executive summary includes only the level 1 and 2 titles. A complete table of contents is given at the beginning of each chapter.

Part One: INSTALLATION

1 General Installation Instructions 1 - 1

1.1 Operating Conditions 1 - 3

1.2 System Power Consumption 1 - 4

1.3 System Cooling 1 - 5

1.4 Interconnections 1 - 6

1.5 NUM Operator Panel Colours 1 - 14

1.6 Screen Saver 1 - 14

2 General System Description 2 - 1

2.1 System Components 2 - 3

2.2 Basic Configuration 2 - 6

2.3 System Architecture 2 - 7

3 Overall Dimensions - Installation 3 - 1

3.1 NUM 1020 and 1040 CPUs 3 - 3

3.2 Compact Panel 3 - 5

3.3 9" Monochrome and 10" Colour 3 - 8

3.4 14" Colour QWERTY Panels 3 - 11

3.5 Machine Panel 3 - 14

3.6 Additional Components 3 - 16

4 Component Preparation 4 - 1

4.1 Preparing the CPU 4 - 3

4.2 Preparing the Compact Panel 4 - 11

4.3 Preparing the Machine Panel 4 - 14

4.4 General Operations 4 - 20

5 Interconnections 5 - 1

5.1 CNC/Peripheral Interconnections 5 - 3

5.2 NUM 1020 and 1040 CPUs 5 - 4

5.3 Compact Panel 5 - 36

5.4 CNC Panels 5 - 38

5.5 Machine Panel 5 - 40

5.6 NUM Diskette Drive 5 - 45

6 Cable Diagrams 6 - 1

6.1 Communication Cables 6 - 3

6.2 Axis Cables 6 - 12

6.3 Analogue I/O and Interrupt Cable 6 - 39

6.4 Input and Output Cables 6 - 42

6.5 Power Cables 6 - 51

6.6 Video/Panel Cable 6 - 55

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Part Two: COMMISSIONING

7 Initial Operation 7 - 1 8 Load and Check of the PLC Programme 8 - 1

8.1 Load Procedures 8 - 3

8.2 Checking the PLC Programme: Test of the Safety Systems 8 - 3

8.3 PLC Programming Supplements 8 - 3

9 Integration of the Machine Parameters (by UT5) 9 - 1

9.1 Maximum Time Allocated to the PLC Application: P99 9 - 3

9.2 Sampling Period: P50 9 - 3

9.3 Minimum Block Execution Time: P51 9 - 4

9.4 Assignment of Serial Lines: N0 of P110, P111 and P112 9 - 5

9.5 Axis Assignment to a Group: P9 9 - 5

10 Axis Calibration (by UT2) 10 - 1

10.1 General 10 - 3

10.2 Record of Corrections to Be Made 10 - 5

10.3 Operations on Axis Measurement Correction Tables 10 - 6

11 Interaxis Calibration 11 - 1

11.1 General Description of Interaxis Calibration 11 - 3

11.2 Interaxis Calibration by Utility 20 11 - 7

11.3 Dynamic Interaxis Calibration 11 - 13

12 Final Inspection 12 - 1

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Date Index Description

06 - 95 0 Document creation

07 - 95 1 Miscellaneous corrections

09 - 96 2 Additions and miscellaneous corrections

11 - 97 2 - E1 Additional information on operating conditions

Modified system cooling design data

Record of Revisions

Modified cable shielding connection to connector plug covers Miscellaneous corrections

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NUM 1020 / 1040 Documentation Structure

User Documents

These documents are designed for use of the CNC.

Foreword

OPERATOR

MANUAL

M / W

938821

OPERATOR

MANUAL

T / G

938822

PROGRAMMING

MANUAL

938819

Integrator Documents

These documents are designed for setting up the CNC on a machine.

NUM 1020 / 1040

INSTALLATION

AND

COMMISSIONING

MANUAL

938838

PARAMETER

MANUAL

938818

AUTOMATIC

CONTROL

FUNCTION

PROGRAMMING

MANUAL LADDER

LANGUAGE

938846

PROGRAMMING

MANUAL

938820

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List of NUM 1060 and NUM 1060-7 Utilities

A series of utilities are available for the NUM 1060 and NUM 1060-7 CNCs for integration and use of the systems. These utilities may be included in the basic version or available as options. Depending on the function performed by each utility, its use is described in the integration manual or operator manual,

as appropriate. The table below lists the utilities and gives the references of the document describing them:

Utility Name Manual Chapter

UT2 axis calibration installation and commissioning manuals (938938) 10 UT3 resident macros operator manuals (938821 or 938822) 8 UT5 parameter integration parameter manual (938818) 12 UT7 programme debugging automatic control function programming 16

manual - Ladder Language (938846) UT12 option locking operator manuals (938821 or 938822) 8 UT20 interaxis calibration Installation and Commissioning Manual (938938) 11 UT22 integration of axis parameters SETTOOL Manual (938924) 8

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Installation and Commissioning Manual

This manual includes two parts:

- installation: physical integration of the numerical control with the machine and its environment,

- commissioning: adaptation of the CNC to the machine configuration.

Part One: Installation

General requirements concerning the CNC environment:

- Applicable standards,

- Power consumption,

CHAPTER 1

GENERAL

INSTALLATION

INSTRUCTIONS

- Heat dissipation,

- Electrical specifications,

- Equipment colours.

Foreword

CHAPTER 2

GENERAL

SYSTEM

DESCRIPTION

CHAPTER 3

OVERALL

DIMENSIONS

—

INSTALLATION

Detailed explanation of the various possible configurations. Overview of the system architecture.

Data used for installation of the components:

- detailed configuration,

- overall dimensions,

- mounting dimensions.

Preparing the CPU. Preparing the compact panel.

CHAPTER 4

COMPONENT

PREPARATION

Preparing the machine panel. Replacing fuses. Wiring the watchdog.

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CHAPTER 5

INTER-

CONNECTIONS

CHAPTER 6

CABLE

DIAGRAMS

General interconnection diagram. General data and connections:

- CPU

- Compact panel

- CNC panels

- Machine panel

- NUM diskette drive.

Wiring diagrams for the following cables:

- Communication

- Axes

- Analogue inputs/output and interrupt

- Inputs and outputs

- Power supply

- Video/panel.

Part Two: Commissioning

CHAPTER 7

INITIAL

OPERATION

CHAPTER 8

LOAD AND CHECK

OF THE PLC

PROGRAMME

Initial operating procedure.

Reference to the PLC Function Programming Manual. Checking instructions. Supplements to PLC programming.

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CHAPTER 9

INTEGRATION OF

THE MACHINE PARAMETERS

CHAPTER 10

Foreword

Reference to the Parameter Manual. Special settings related to the NUM 1020 and 1040 CPUs.

Correction of the axis position measurement read by the coupler according to the real position on the axis.

AXIS

CALIBRATION

CHAPTER 11

INTERAXIS

CALIBRATION

CHAPTER 12

FINAL

INSPECTION

Correction of the offsets on a slave axis according to the position on a master axis.

Recommended inspection by machining of a reference part.

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Use of the Installation and Commissioning Manual

Procedures

The manual includes procedures (in particular in Chapters 10 and 11). The actions required are presented as follows:

Reset the system. ☞

On the right are indicated the keys to be pressed in two possible forms:

Square keys: correspond to keys on the operator panel.

EXIT

Rectangular keys: correspond to software keys located in the bottom part of the screen and actuated by function keys (F2-F11) located under the screen.

Dealers

The list of NUM dealers is given at the end of the manual.

Questionnaire

To help us improve the quality of our documentation, we request you return to us the questionnaire at the end of this manual.

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Part One

INSTALLATION

General Installation Instructions

1 General Installation Instructions

1.1 Operating Conditions 1 - 3

1.2 System Power Consumption 1 - 4

1.3 System Cooling 1 - 5

1.4 Interconnections 1 - 6

1.4.1 Frame Earth and Operational Earth 1 - 6

1.4.2 Signal Earth 1 - 6

1.4.2.1 Equipment Operating at Relatively Low Frequency and Low Signal Levels 1 - 6

1.4.2.2 Modern Equipment Operating at High Frequency and High Signal Levels 1 - 7

1.4.3 Equipment Immunity 1 - 9

1.4.3.1 Attenuation at the Source (Interference Suppression) 1 - 9

1.4.3.2 Reduction of Couplings 1 - 10

1.4.3.3 Equipment Hardening 1 - 12

1.4.4 Diagram of the 0 V, Frame Earth and Operational Earth 1 - 13

1.5 NUM Operator Panel Colours 1 - 14

1.6 Screen Saver 1 - 14

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General Installation Instructions

1.1 Operating Conditions

Do not unplug any subassemblies (cards, circuits) with the system live.

Do not use measuring instruments whose output voltage is ≥ 5 VDC.

NUM equipment complies with the following standards:

Reference standard Level Temperatures IEC 1131 Mechanical stresses IEC1131 Mains variation IEC1131 Mains brownouts IEC1131 Electrostatic discharge (ESD) IEC 1000-4-2 Level 3 Electromagnetic field IEC 1000-4-3 Level 3 (excluding video) Fast electric transients IEC 1000-4-4 Level 3 Electric shock IEC 1000-4-5 Level 4 Damped ripple IEC 1000-4-12 Electromagnetic emissions EN 55022

CAUTION

Operating temperature range: Minimum 5 °C, maximum 55 °C. Cooling: See Sec. 1.3. The systems must always be installed in power cabinets equipped with:

- efficient door seals,

- air filters or air/air exchangers,

- possibly, air conditioning.

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1.2 System Power Consumption

The table below specifies the power consumption of each system component: Component Power consumption

NUM 1020/1040 CPU (24 VDC) 40 W Compact panel (230 VAC)

• Panel with 10" colour CRT 60 W

• Panel with 9" monochrome CRT 30 W 50-key panels (230 VAC)

• Panel with 10" colour CRT 60 W

• Panel with 9" monochrome CRT 30 W QWERTY panel with 14" colour CRT (230 VAC) 100 W Machine panel (24 VDC)

• Single panel 3,8 W

• 32 inputs/24 outputs extension 9,8 W Additional components (24 VDC)

• 32-inputs interface module 24 W

• 24-output relay module 19,2 W

• NUM diskette drive 3,5 W The system power consumption is obtained by summing the power consumptions of the system components.

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General Installation Instructions

1.3 System Cooling

The life cycle of electronic equipment is closely related to its operating temperature.

Compliance with the following recommendations will ensure optimal product reliability.

Determining the Air Flow Rate

The heat to be dissipated is a maximum of 40 W for the CPU and 100 W for the panel. The dissipation can be calculated more accurately by adding together the power consumptions of the individual

components (see Sec. 1.2). The cabinet and pendant must be designed such that the temperature difference between the ambient air of the

components (CNC, CRT) and the ambient air in the shop is less than 10 °C or such that the average annual temperature of the ambient air of the components does not exceed 40 °C.

CAUTION

The air flow rate required for correct heat dissipation is Q = 0.4 x P where: Q = air flow rate (l/s) P = heat to be dissipated.

Example For a 50-key panel with 10" colour CRT in a pendant: P = 60 W Q = 0.4 x 60 = 24 l/s.

REMARK This calculation should be confirmed by temperature measurements.

Recommendations

Use efficient filters on the cabinet or pendant air intakes. Do not allow the fans to blow air directly onto the equipment.

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1.4 Interconnections

1.4.1 Frame Earth and Operational Earth

Definition of the concepts of frame earth and operational earth:

- frame earth: low impedance, low frequency path used in case of failure between the electric circuit and the earth,

- operational earth: low impedance path used for equipotentiality between electric circuits. The purpose of the

operational earth is to attenuate all interference and spurious voltages that may exist between units over a very wide

frequency band. These two concepts do not always require different circuits. The frame earth earth system is provided by interconnecting all metal parts (building structure, pipework, cable trays,

equipment enclosures and equipment). The operational earth is the physical connection point (earth rod, earthing mat, building earth) to which all the frame

earths must be connected.

1.4.2 Signal Earth

A distinction is made between two types of electronic equipment:

- equipment operating at relatively low frequency (a few kHz to a few hundred kHz) and low signal level,

- equipment operating at high frequency (a few tens of MHz to a few hundred MHz) and high signal levels.

1.4.2.1 Equipment Operating at Relatively Low Frequency and Low Signal Levels

Such equipment mainly includes «analogue» systems sensitive to a few mV (or µV). The most troublesome interference is generated by low or medium frequency electromagnetic fields captured mainly

by the interconnections between units. High frequency interference is eliminated by the bandwidth of the circuits themselves or by low-pass filters.

Apply the following rules to attenuate interference:

- provide a wye connection for the signal earths and a wye connection for the frame earths with a single

interconnection between the two earthing systems,

- when a sensitive wire must be protected against EMI by shielding, the shielding is considered a screen and is only

earthed at one end so as not to create a loop with circulation of interference in the shielding. Wrong: Loops between units due to interconnection of the earths and common wires

Voltage generated (U = ZI)

I : Current generated

Alternating

magnetic

field

Unit 1 Unit 2

Z: Impedance of link AB

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Right: Wye connection of frame earths and 0 V (signal earths)

General Installation Instructions

Unit 1

: frame earth

Unit 2

: operational earth

: zero V

1.4.2.2 Modern Equipment Operating at High Frequency and High Signal Levels

Such equipment includes modern «logic» equipment with electronic gates whose switching times are around 1 ns and whose signal levels are high (static switching margin from 400 mV to 10 V).

The most critical interference is electromagnetic interference at a frequency between 30 and 300 MHz. Such interference originates in coil switching (relays, contactors, transformers, motors, transformer-supplied indicator

lights, etc.), circuit breaker trip arcs, drive switching power supplies, HF systems located nearby, and electrostatic discharges generated by the operators, etc.

Unit 3

Unit 4

At such frequencies, the earths must be at the same potential. However, the impedance of an earthing wire becomes high at high frequencies (Z = Lω). For instance, for a 2.5 mm2 wire 1 m long whose inductance is L ≈ 1.4x10-6 H, the impedance, which is only 0.09 Ω at 10 kHz becomes 90 Ω at 10 MHz - and the earthing wires are not suitable for creating a good signal earth.

It is necessary to use a meshed system to decrease interference. This means interconnecting the units with one another by the largest possible number of the shortest possible links.

This is achieved best by using metal parts interconnected by many attachment points ensuring good electrical conduction (zinc- or cadmium-plated steel, stainless steel, removal of paint, use of claws on aluminum).

If electrical continuity is not correctly provided by the mechanical link, the link must be shunted by at least two short, wide bonding braids (length/width ratio ≤ 5 with length < 20 cm).

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Example of Meshed System

Compact panel with zinc-plated

seal enclosure

(to be placed on a conductive

surface or connected by shunts)

Zinc- or cadmium-plated

metal cable trays

Metal frame equipment with

good electrical conductivity of

the attachment points

Protective

earthing wire

Structural beam

Electrical continuity

ensured

Pendant

Conductive hinges

or 2 bonding braids

Metal conduit with

conductive attachment

(recommended)

Cabinet attachment

points providing good

electrical continuity

Earth

I V E

RELAY

Metal power cabinet

1 0 4 0

Earthing terminal

Isolating

switch

RELAY

Door hinges

RELAY

Rear view of a lathe

In the units, the concepts of logical 0 V and protective earth coincide, i.e. the logical 0 V is connected in many points to the frame earth.

to be shunted

The shieldings of logical signal cables are earthed at both ends. This contributes to the mesh and in addition, the internal electronic circuitry and the enclosure are at the same potential.

To attenuate the loop effects thus created (the captured field depends on the loop area), the cables must be attached against the conduit or metal walls. This is called cabling with "reduction effect".

In the case of separate power supply for the logical inputs and outputs, the 0 V lines of these power supplies must be earthed and the wiring must be made with "reduction effect".

REMARK: Meshing the earths does not provide a protective system. The earthing terminals

on the units must be connected to the general earth electrode of the building.

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1.4.3 Equipment Immunity

General Installation Instructions

Equipment immunity to electromagnetic interference is guaranteed by:

- attenuating the interference generated by the sources,

- reducing the coupling between source and sink,

- increasing the immunity (hardening) of the equipment. The three methods are complementary and should be applied together.

1.4.3.1 Attenuation at the Source (Interference Suppression)

To limit the interference generated by components outside the system, make sure that:

- all the connections on terminal boards are securely attached,

- all the interference sources (relays, solenoid valves, motors, etc.) are provided with a suitable protection system.

Examples

Low power AC contactor

Medium and high power AC contactor

Low power DC contactor

220 Ω

0,47 µF

+–

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Three-phase motor

1.4.3.2 Reduction of Couplings

Provide a suitable earth meshing system (see Sec. 1.4.2.2) using metal parts with a conductive surface interconnected (bolted) together.

Wire with a reduction effect (low area loops):

- cables supplied against conduits and metal parts forming the frame earth,

- forward and backward travel of a signal in the same cable (twisted pair). Earth the shielding of logic signal cables at both ends. Earth the cable shielding over 360 degrees:

- with a conductive gland to penetrate through a bulkhead,

- by pinching the shielding in metal covers that are suitably earthed for connector plugs. Connection of shielding to frame earth

WRONG

ACCEPTABLE

Earthing rail

IDEAL, CONTACT

RIGHT

Frame Frame

OVER 360 degrees

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Connection of cable shielding to the cover of a connector plug

General Installation Instructions

Earth the cable shielding over 360 degrees: fold the shielding back onto the cable over a length of 1 cm and clamp it in the cover clamp.

Attaching

screw

Sub.D connector

Wiring

location

Clamp

Half-cover

Cables

Cable

shieldings

Low level circuits must be separated from power circuits and circuits with interference:

- by physical separation of the cables (recommended minimum 30 cm),

- by routing in separate conduit or cable trays,

- by crossings at 90 degrees. Analogue inputs (such as servo-drives) must be differential (common mode rejection).

Special case of servo-drive wiring Servo-drives are low level (microvolt sensitivity), low frequency systems. It is therefore recommended to protect the

link by a screen earthed only on the CNC side (see Sec. 1.4.2.1) and to provide double shielding on the cable earthed at both ends to serve for bonding.

When these recommendations cannot be applied (unavailability of cable with double shielding, etc.), bonding must be given precedence by using a cable with single shielding earthed at both ends.

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1.4.3.3 Equipment Hardening

Hardening is a feature integrated in the equipment design. Special care was taken with equipment immunity:

- multilayer cards with internal ground plane,

- stainless steel enclosure around the system and front panels in good contact with the enclosure so that the assembly forms an excellent Faraday cage,

- metal connector receptacles electrically connected to the front panels and provided with metal covers on which the shielding is earthed over 360 degrees,

- high level mains filtering on the power supply input,

- optoisolated binary inputs and outputs with physical separation from interference circuits.

All these measures give the equipment excellent immunity to electromagnetic interference.

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General Installation Instructions

1.4.4 Diagram of the 0 V, Frame Earth and Operational Earth

Peripheral

Screen

(not mandatory)

24 VDC

Shielding

230 VAC

STORAGE

UNIT

Axes

Shielding

(not mandatory)

Screen

KEY

Shielding not earthed at this end

Shielded earthed at this end

Twisted wires 0 V

Frame earth

Operational earth

SERVO-DRIVE

Axis or spindle

POWER CABINET

Video / Operator

panel

CAUTION

Op. panel

PENDANT

The 0 V lines of the 24 VDC power supplies must mandatorily be

connected to the frame earth.

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1.5 NUM Operator Panel Colours

The colours used for the NUM 1020 / 1040 operator panels are from standard colour ranges:

Colour Use Standard Dark grey Background RAL 7021 Medium grey Keys RAL 7036 Light grey Keys RAL 7032 Red Side trim PANTONE WARM RED C

1.6 Screen Saver

The CNC has a screen saver designed to extend the screen life. When it is activated by the PLC programme, the screen saver clears the screen after 5 minutes of no action on the keyboard. Pressing any key redisplays the previously active page.

It is recommended to activate the screen saver by the PLC programme. This is done by setting the SC_SAVE bit (%W5.7).

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General System Description

2 General System Description

2.1 System Components 2 - 3

2.1.1 Operator Panels 2 - 3

2.1.1.1 Compact Panels 2 - 3

2.1.1.2 50-Key Panels 2 - 3

2.1.1.3 QWERTY Panels 2 - 3

2.1.2 1020 or 1040 Rack 2 - 4

2.1.4 Machine Panel 2 - 4

2.1.5 Additional Components 2 - 4

2.2 Basic Configuration 2 - 6

2.2.1 Basic 1020 Configuration 2 - 6

2.2.2 Basic 1040 Configuration 2 - 6

2.3 System Architecture 2 - 7

2.3.1 1020 or 1040 System with Compact Panel 2 - 7

2.3.2 1040 System with CNC Panel 2 - 8

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2.1 System Components

2.1.1 Operator Panels

2.1.1.1 Compact Panels

10" Colour and 9" Monochrome Compacts Operator Panels

Subassemblies Weight (kg) Panel 11 Video cable

General System Description

2.1.1.2 50-Key Panels

2.1.1.3 QWERTY Panel

10" Colour and 9" Monochrome Operator Panels

Subassemblies Weight (kg) Panel 10,7 Video cable

14" Colour Operator Panel

Subassemblies Weight (kg) Panel 16,5 Vidéo cable

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2.1.2 1020 or 1040 Rack

Weight: 6 kg

2.1.4 Machine Panel

Subassemblies Weight (kg) Machine panel 2.200 Optical fibres Machine panel extension (optional) 0.300 Handwheel (optional) 0.515

2.1.5 Additional Components

32-Input Interface Module

Subassemblies Weight (kg) Interface module 0.300

Input/output card connecting cable

24-Output Relay Module

Subassemblies Weight (kg) Relay module 1.050

Input/output card connecting cable

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General System Description

Axis Interface Module

Subassemblies Weight (kg) Axis interface module 0.230

AXE N°

Axis interface connecting cable

Handwheel

Weight: 0.615 kg

NUM Diskette Drive

Subassemblies Diskette drive Serial interface cable

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2.2 Basic Configuration

2.2.1 Basic 1020 Configuration

NUM 1020 CPU Compact panel + video cable

2.2.2 Basic 1040 Configuration

NUM 1040 CPU Panel (compact, 50-key or QWERTY) + video cable Machine panel (optional)

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2.3 System Architecture

2.3.1 1020 or 1040 System with Compact Panel

Compact panel

Graphic function

Memory

General System Description

Communication

function

Axes

CNC

function

PLC

function

Optional keyboard

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

Speed reference Measurement

Origin switch

Inputs

Outputs

Interrupt Analogue inputs/output

REMARK A machine panel cannot be used with the compact panel.

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2.3.2 1040 System with CNC Panel

Graphic function

Memory

Panel

Communication

function

Axes

CNC

function

PLC

function

Optical fibre

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

Speed reference Measurement Origin switch

Inputs

Outputs

Machine

panel

Machine

panel extension

(I/O)

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Interrupt Analogue inputs/output

Overall Dimensions - Installation

3 Overall Dimensions - Installation

3.1 NUM 1020 and 1040 CPUs 3 - 3

3.1.1 CPU Mounting Parts 3 - 3

3.1.2 Overall Dimensions and Attachments of the CPU 3 - 4

3.2 Compact Panel 3 - 5

3.2.1 Panel Mounting Parts 3 - 5

3.2.2 Overall Dimensions of the Compact Panel 3 - 6

3.2.3 Cutouts for Compact Panel Mounting 3 - 7

3.3 9" Monochrome and 10" Colour 3 - 8

3.3.1 Panel Mounting Parts 3 - 8

3.3.2 Overall Dimensions of the Panels 3 - 9

3.3.3 Cutouts for Panel Mounting 3 - 10

3.4 14" Colour QWERTY Panels 3 - 11

3.4.1 Panel Mounting Parts 3 - 11

3.4.2 Overall Dimensions of the Panel 3 - 12

3.4.3 Cutouts for Panel Mounting 3 - 13

3.5 Machine Panel 3 - 14

3.5.1 Machine Panel Mounting Parts 3 - 14

3.5.2 Overall Dimensions of the Machine Panel 3 - 15

3.5.3 Cutouts for Machine Panel Mounting 3 - 15

3.6 Additional Components 3 - 16

3.6.1 Mounting of the 32-Input Interfacing Module 3 - 16

3.6.2 Mounting of the 24-Output Relay Module 3 - 16

3.6.3 Mounting of the Axis Connection Module 3 - 17

3.6.4 Handwheel Mounting 3 - 18

3.6.5 Mounting of the NUM Diskette Drive 3 - 19

3.6.6 Overall Dimensions of the Sub.D Connector Covers (Cables) 3 - 20

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3.1 NUM 1020 and 1040 CPUs

,,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,

,,,,,,,,,,,,,

,,,,,,,,,,,

,,,,,,,,,

,,,,,,,

,,,,,

,,,

Weight: 6 kg.

3.1.1 CPU Mounting Parts

Overall Dimensions - Installation

24V

POWER

SUPPLY

1 - CPU 2 - Attaching screw and washer (3)

Output

Input

Reset

Pwr

Fail

Def

m S e

1 r i

Axis

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3.1.2 Overall Dimensions and Attachments of the CPU

380

Output

Input

6.5

R e c

E m

DefL3Pwr

Axis

100

air flow

Clearance for

Reset

Fail

I t

/ A n a

276

Clearance

354100

P a n e

for door opening

Contact surface

,,,,,,,,,,,,

24V

POWER

SUPPLY

285100

cables

6.5 6.5 =

40 =

21.5 28.5 air flow

110

Clearance for

Front view Top view

REMARK It is not necessary to open the door except to add axis cards or an SRAM memory

chip or adjust the transmit power of the optical fibre line.

CAUTION

For correct ventilation, the CPU must be installed vertically.

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3.2 Compact Panel

Weight: 11 kg.

3.2.1 Panel Mounting Parts

Overall Dimensions - Installation

ESC ?

F10

F11

F12

INSER

DEL END

1 - Panel 2 - Panel attaching screw and washer (6)

CAUTION

The panel is not sealed unless the cover is installed over the front panel connectors.

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3.2.2 Overall Dimensions of the Compact Panel

220

483

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

271

ESC ?

G%ME/

7N8S9 4X5Y6 1A2B3

DP0

INSER

DEL END

Q.R

T-=

Z+!

308 (for 10") 37

202

266 (for 9")

180

Clearance

for cables

3 - 6 en-938938/2

150

3.2.3 Cutouts for Compact Panel Mounting

Overall Dimensions - Installation

=202=

Cutout

211.6

6 M4 holes

211.5==

451

211.5

REMARK The cutout dimensions are the same as for the 50-key panels. Only the

attachment holes differ between the two types of panels.

CAUTION

It is recommended to make sure the enclosure over the rear part of the

panel provides IP65 insulation.

en-938938/2 3 - 7

3.3 9" Monochrome and 10" Colour

Weight: 10.7 kg.

3.3.1 Panel Mounting Parts

3 - 8 en-938938/2

1 - Panel 2 - Edge trim 3 - Panel attaching screw and washer (4)

3.3.2 Overall Dimensions of the Panels

Overall Dimensions - Installation

220

252

483

MACHINING PRESET

N%GHF

{

YBV(J)T

}

DPQ

SHIFT

Ctrl

HELP

MODE

294 (for 10") 30

1060

PROGRAM

EDIT

I;U:X

xoff

]

.>K[WZ

SPACE

TOOL

JOG

7&8 9

4$5 6

=/0-+

INS/

OVER

ENTER

LINE

DEL

CHAR

\ ~0

3#2@1

HOME

PgUp

END

PgDn

197

253 (for 9")

Clearance for cables

183

en-938938/2 3 - 9

3.3.3 Cutouts for Panel Mounting

2630

4 M6 holes

Cutout

4 dia. 10 mm holes

451= = 466

=180=

202

13 9

REMARK The cutout dimensions are the same as for the compact panel. Only the

attachment holes differ between the two types of panels.

CAUTION

It is recommended to make sure the enclosure over the rear part of the panel

3 - 10 en-938938/2

provides IP65 insulation.

3.4 14" Colour QWERTY Panels

Weight: 16.5 kg.

3.4.1 Panel Mounting Parts

Overall Dimensions - Installation

1 - Panel 2 - Edge trim 3 - Panel attaching screw and washer (8)

en-938938/2 3 - 11

3.4.2 Overall Dimensions of the Panel

483

F3F2

!1@2#3$4%

ESC Q W E R T Y U I O P

CTRL A D F G HJKL

5^6&7*8(9)0_-+=+

x off

ALT

F8F7F6F5F4

MNBVCXZSHIFT SPACE

340

,<.>/

F10

{ [}]

`";

F11 F12

` ?

400

290

JOGTOOL

MODE

M01

HELP

line

DEL

INS

char

ALL

home Pg Up

CAPS

VALID

Pg Dnend

399

3 - 12 en-938938/2

Clearance for cables

3.4.3 Cutouts for Panel Mounting

Cutout

Overall Dimensions - Installation

=235=

89 89 32.532.5

389

4 dia. 10 mm holes

8 M6 holes

451= =

466

CAUTION

It is recommended to make sure the enclosure over the rear part of the panel

provides IP65 insulation.

en-938938/2 3 - 13

3.5 Machine Panel

Weight: 2.200 kg unequipped (add 0.300 kg for the extension and 0.515 kg for the handwheel).

3.5.1 Machine Panel Mounting Parts

3 - 14 en-938938/2

1 - Machine panel 2 - Machine panel attaching screw (4)

3.5.2 Overall Dimensions of the Machine Panel

483

Overall Dimensions - Installation

177

280

122

3.5.3 Cutouts for Machine Panel Mounting

4 M6 holes

Overall dimensions with the extension connecting cable

Overall dimensions without extension

= 101.6

167

451 466

CAUTION

It is recommended to make sure the enclosure over the rear part of the panel

provides IP65 insulation.

en-938938/2 3 - 15

3.6 Additional Components

3.6.1 Mounting of the 32-Input Interfacing Module

Weight: 0.300 kg.

MOD. INTERFACE 32 E

183

Mounted by snapping to extrusions complying with standards EN 50022 (or NF C 63-015) and EN 50035 (or NF C 63-018).

3.6.2 Mounting of the 24-Output Relay Module

Weight: 1.050 kg.

MOD. RELAYAGE 24 S

376

Mounted by snapping to extrusions complying with standards EN 50022 (or NF C 63-015) and EN 50035 (or NF C 63-

018).

3 - 16 en-938938/2

3.6.3 Mounting of the Axis Connection Module

Weight: 0.230 kg.

ALIM

0 1

ADRESSE

PRESENCE TENSION

ECLK

RCLK

/ECLK

Z.DATA

/Z.DATA

CAPTEUR REF VIT. BUTEE

/RCLK

ALIM CAPTEUR

700/800

BROCHE 2

PFD

PCH

MANIVE

BROCHE 1

/BUTEE

700/800 1000 INT. 5V EXT.

A/AB

SPFD

SPCH

SALIS.

AXE

N°

AXE ANALOG.

INTERDIT

Overall Dimensions - Installation

1000

MANIVE

BROCHE

ALIM.EXT.

BUT

0VBUT

0V BUT

5..24V

160

Mounted by snapping to extrusions complying with standards EN 50022 (or NF C 63-015) and EN 50035 (or NF C 63-018).

en-938938/2 3 - 17

3.6.4 Handwheel Mounting

Overall dimensions

46.5

108

Holes and cutout

4 M5 holes

ø 63.5

52 62 60

3 - 18 en-938938/2

dia. 67 mm

7.5

3.6.5 Mounting of the NUM Diskette Drive

Overall dimensions

Overall Dimensions - Installation

147

Clearance for cables and switch

Holes and cutout

123 115= =

174

4 M4 holes

4313

Cutout

en-938938/2 3 - 19

3.6.6 Overall Dimensions of the Sub.D Connector Covers (Cables)

Number of contacts A B C

9311641 15 53 16 38 25 53 16 45 37 70 24 51

REMARK The dimensions given in the table are rounded off and correspond to the product

line of a particular supplier. They could differ slightly for other suppliers.

3 - 20 en-938938/2

Component Preparation

4 Component Preparation

4.1 Preparing the CPU 4 - 3

4.1.1 Opening the Fuse/Battery Cover 4 - 3

4.1.2 Opening the Cover Plate 4 - 4

4.1.3 Adding Axis Cards 4 - 6

4.1.4 Adding an SRAM Memory Module 4 - 9

4.1.5 Adjusting the Optical Fibre Transmit Power 4 - 10

4.1.6 Replacing or Installing the Battery 4 - 10

4.2 Preparing the Compact Panel 4 - 11

4.2.1 Removing the Rear Cover 4 - 11

4.2.2 Relocating the Keyboard Connector 4 - 12

4.2.3 Installing the Key Customisation Label 4 - 13

4.3 Preparing the Machine Panel 4 - 14

4.3.1 Assigning an Address to the Panel 4 - 14

4.3.2 Installing the Handwheel 4 - 15

4.3.3 Installing the Machine Panel Extension 4 - 16

4.3.4 Setting the Optical Fibre Transmit Power 4 - 17

4.3.5 Installing the Key Labels 4 - 18

4.4 General Operations 4 - 20

4.4.1 Replacing Fuses 4 - 20

4.4.1.1 1020/1040 CPU Fuses 4 - 20

4.4.1.2 10" Compact Panel Fuse 4 - 20

4.4.1.3 10" 50-Key Panel Fuse 4 - 20

4.4.1.4 Machine Panel Fuse 4 - 21

4.4.2 Wiring of the Watchdog, Safety Daisy Chain 4 - 22

en-938938/2 4 - 1

4 - 2 en-938938/2

Component Preparation

4.1 Preparing the CPU

Operations that can be performed on the CPU:

- Adding axis cards (see Sec. 4.1.3),

- Adding an SRAM memory module (see Sec. 4.1.4),

- Adjusting the optical fibre transmit power (see Sec. 4.1.5),

- Replacing or installing the battery (see Sec. 4.1.6). The first three operations require opening the cover plate (see Sec. 4.1.2) and the last requires opening the fuse/battery

cover (see Sec. 4.1.1).

4.1.1 Opening the Fuse/Battery Cover

Remove the screw and take off the cover.

Location of the fuse and battery:

Reset

DefL3Pwr

Fail

S e

DefL3Pwr

Screw

C o

Reset

Fail

Cover

1 - Battery 2 - Fuse 3 - Battery connector

en-938938/2 4 - 3

4.1.2 Opening the Cover Plate

Remove the two screws and swing open the cover plate.

Screws

4 - 4 en-938938/2

Location of the items concerned by the work:

Component Preparation

1123

1 - Slot for SRAM memory module 2 - Optical fibre transmit power adjustment switches 3 - Axis cards

en-938938/2 4 - 5

4.1.3 Adding Axis Cards

,,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,

,,,,,,,,,,,,,

,,,,,,,,,,,

,,,,,,,,,

,,,,,,,

,,,,,

,,,

,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,

,,,,,,,,,,,,

,,,,,,,,,,

,,,,,,,,

,,,,,,

,,,,

Refer to the layout diagram (see Sec. 4.1.2).

Remove the two screws and take off the card retaining bar.

24V

POWER

SUPPLY

Reset

Pwr

Fail

Def

C o

m S e

r i

/ A n a

Screw

Bar

Axis

P a n e

Screw

4 - 6 en-938938/2

Remove the screw and remove the card slot blanking plate.

Install the new card and tighten the screw.

Component Preparation

Screw

Blanking plate

Axis card

CAUTION

When inserting a new card, push it straight into the connector so as not to damage the

connector pins.

en-938938/2 4 - 7

Install the bar and tighten the screws.

,,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,

,,,,,,,,,,,,,

,,,,,,,,,,,

,,,,,,,,,

,,,,,,,

,,,,,

,,,

,,,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,,,

,,,,,,,,,,,,,,

,,,,,,,,,,,,

,,,,,,,,,,

,,,,,,,,

,,,,,,

,,,,

24V

POWER

SUPPLY

Reset

Pwr

Fail

Def

C o

m S e

1 r i

t / A n a

Axis

4 - 8 en-938938/2

4.1.4 Adding an SRAM Memory Module

Refer to the layout diagram (see Sec. 4.1.2).

Position the module at a slant into the connector with the polarising slot located on the right (1).

Swing the module up to a vertical position until it snaps in place (2).

Component Preparation

Polarising slot

en-938938/2 4 - 9

4.1.5 Adjusting the Optical Fibre Transmit Power

The adjustment is made on switches (see Sec. 4.1.2) according to the length of the optical fibre cable:

Optical fibre cable length Switch setting

L ≤ 15 m

123

15 m < L ≤ 30 m

123

L > 30 m

123

4.1.6 Replacing or Installing the Battery

Refer to the layout diagram (see Sec. 4.1.1).

CAUTION

The battery must be replaced within 15 minutes so as not to lose the data present in the

RAM. A special capacitor powers the SRAM modules while the battery is being replaced.

Remove the battery from its housing and take off the connector. Connect the new battery, making sure the connector is correctly installed,

and install the battery.

4 - 10 en-938938/2

4.2 Preparing the Compact Panel

Operations that can be performed on the compact panel:

- Relocation of the DIN connector (see Sec. 4.2.2),

- Installation of the key customisation label (see Sec. 4.2.3). These operations require removing the rear cover (see Sec. 4.2.1).

4.2.1 Removing the Rear Cover

Remove the three screws and take off the cover.

Component Preparation

Screws

Location of the items concerned by the operations:

Cover

Rear view

Label installation slot

DIN connector support

en-938938/2 4 - 11

4.2.2 Relocating the Keyboard Connector

The compact panel is equipped with a keyboard connector (5-contact DIN connector) accessible on the front after removing the cover.

This location of the DIN connector corresponds to occasional use of a PC type keyboard (seal not ensured when the cover is removed).

For permanent connection of a PC type keyboard, the DIN connector can be moved to the back of the panel:

DIN connector support attaching nuts

DIN connector located on the front DIN connector relocated on the back of the panel

Unscrew the two DIN connector support attaching nuts. Turn over the support and reinstall the nuts.

4 - 12 en-938938/2

Component Preparation

4.2.3 Installing the Key Customisation Label

The compact panel has six cutomisable keys. The key assignments are identified by a label at the rear of the panel.

Customising the Label Supplied with the Compact Panel:

Marking areas

The label can be customised by transfers (Letraset type), Universe 54 font, pitch 12.

Installing the Label on the Rear of the Compact Panel:

en-938938/2 4 - 13

4.3 Preparing the Machine Panel

4.3.1 Assigning an Address to the Panel

Set the address on the thumbwheel: address 1 to 4, different for each panel.

4 - 14 en-938938/2

Component Preparation

4.3.2 Installing the Handwheel

The handwheel is installed on the machine panel without its bezel (remove the cap by cutting the plastic pins with cutting pliers):

1 - Handwheel body 2 - Attaching screw (3) 3 - Bezel attached by two screws

CAUTION

The handwheel could interfere with installation of the key labels.

It is therefore recommended to install the labels (see Sec. 4.3.5) before the handwheel.

en-938938/2 4 - 15

4.3.3 Installing the Machine Panel Extension

The machine panel extension is installed at the rear of the machine panel. It requires removing the enclosure.

4 - 16 en-938938/2

1 - Machine panel 2 - Machine panel extension 3 - Enclosure 4 - Screws (8) 5 - Spacers (5)

Component Preparation

4.3.4 Setting the Optical Fibre Transmit Power

The setting is made on the rear of the machine panel according to the optical fibre cable length:

Optical fibre cable length Switch settings

L ≤ 15 m

15 m < L ≤ 30 m

L > 30 m

2 1

3 2 1

en-938938/2 4 - 17

4.3.5 Installing the Key Labels

The keys on the machine panel are not engraved. Their assignment is specified by installing a set of labels in windows 1 to 7 at the rear of the machine panel.

These labels can be:

- The standard labels provided by NUM

- Labels customised for the user.

Set of Labels Supplied with the Machine Panel

ILL10 0001 000100101

Window 1

JOG label

Window 1 customisable

M01

Window 2

Window 3 turning

Window 4 turning

Window 5 turning

Window 3 milling

Window 4 milling

Window 5 milling

Axis control labels

4 - 18 en-938938/2

Windows 2 to 5 customisable

Window 6 customisable

Window 7

Window 7 customisable

Machine function label

Mode label

Installing the Labels at the Rear of the Machine Panel:

Component Preparation

Customising the Labels

The labels can be customised by transfers (Letraset type), Universe 54 font pitch 12.

en-938938/2 4 - 19

4.4 General Operations

4.4.1 Replacing Fuses

Accessible fuses:

Location Characteristics 1020/1040 CPU Slow-blow 2 A, 5 x 20 glass fuses 10" compact panel Fast-blow 2 A, 250 V, 5 x 20 glass fuse 10" 50-key panel Fast-blow 2 A, 250 V, 5 x 20 glass fuse Machine panel Fast-blow 500 mA, 250 V, 5 x 20 glass fuse

4.4.1.1 1020/1040 CPU Fuses

Refer to the layout diagram (see Sec. 4.1.1)

Unscrew the fuse-holder cover (quarter-turn fastener). Replace the blown fuse. Install and screw on the fuse-holder cover.

4.4.1.2 10" Compact Panel Fuse

Unscrew the fuse-holder cover (quarter-turn fastener). Replace the blown fuse. Install and screw on the fuse-holder cover.

4.4.1.3 10" 50-Key Panel Fuse

Unscrew the fuse-holder cover (quarter-turn fastener). Replace the blown fuse. Install and screw on the fuse-holder cover.

INSER

4 - 20 en-938938/2

4.4.1.4 Machine Panel Fuse

Replace the blown fuse.

Component Preparation

Rear view

en-938938/2 4 - 21

4.4.2 Wiring of the Watchdog, Safety Daisy Chain

The watchdog (WD) is the machine processor status signal. When WD = 0, the machine processor is faulty and the programmed safety devices are therefore triggered.

The watchdog output is set by PLC programming: WD is the first output (OUT.0) of the CPU or machine panel extension.

CAUTION

The CNC may continue to control the axes when WD = 0, which could cause problems

(collisions, etc.).

The WD output must therefore be wired in the safety chain so that when WD = 0, power

supply to the axes is cut off.

The system should remain on, to allow troubleshooting and setting of certain logic inputs

(which are not the only possible cause of failure).

Recommended safety daisy chain:

CNC ready WD CNC on

CNCr monitor WD monitor CNC on Power supply

CNCr: CNC ready

Off pushbutton

On pushbutton Power supply

WD monitor CNC on

CNCr monitor WD monitor

CNCr monitor

4 - 22 en-938938/2

Component Preparation

This diagram is used to check that the WD and CNCr relays are not operated at power on. No timeoutre used. Powering up of the CNC is not enabled unless the watchdog and CNCr relay are deenergised. When the CNC is on, the PLC programme closes the CNCr relay. Power application is determined by the presence of WD and CNCr.

en-938938/2 4 - 23

4 - 24 en-938938/2

Interconnections

5 Interconnections

5.1 CNC/Peripheral Interconnections 5 - 3

5.2 NUM 1020 and 1040 CPUs 5 - 4

5.2.1 Power Supply 5 - 5

5.2.2 Connection to the Compact or CNC Panels 5 - 6

5.2.3 Optical Fibre Connecting Cable to the Machine Panels 5 - 7

5.2.4 Analogue Inputs/Output and Interrupt 5 - 8

5.2.4.1 General 5 - 8

5.2.4.2 Analogue/IT Link Connecting Diagram 5 - 9

5.2.5 Communications 5 - 10

5.2.5.1 General 5 - 10

5.2.5.2 Serial Line Connection Diagram 5 - 10

5.2.6 Incremental and Absolute Axis Encoder Cards 5 - 11

5.2.6.1 General 5 - 11

5.2.6.2 Voltage Across the Sensor 5 - 12

5.2.6.3 Maximum Incremental Sensor Channel Output Frequency (Incremental or Combined Sensors) 5 - 13

5.2.6.4 Setting the Reference Signal (Rules with Encoded Distance Reference Marks) 5 - 13

5.2.6.5 Synchronous Serial Interface Timing Diagram 5 - 14

5.2.6.6 Maximum Available Current per Axis 5 - 14

5.2.6.7 Setting the Origin Switch 5 - 15

5.2.6.8 Setting the Origin Switch (SSI or Combined Sensor with semiabsolute Measurement) 5 - 16

5.2.6.9 Homing of SSI or Combined Sensors with Absolute Measurement 5 - 16

5.2.6.10 Axis Connection Diagram 5 - 17

5.2.6.11 Handwheel Connection Diagram 5 - 18

5.2.7 Discrete Inputs 5 - 19

5.2.7.1 Input Characteristics 5 - 19

5.2.7.2 Connection Diagram for Inputs with Interface Module 5 - 21

5.2.7.3 Interface Module Connections and Customisation 5 - 23

5.2.7.4 Connection Diagram for Inputs without Interface Module 5 - 25

5.2.8 Outputs 5 - 27

5.2.8.1 Output Characteristics 5 - 27

5.2.8.2 Output Connection Diagram with Relay Module 5 - 30

5.2.8.3 Relay Module Connections and Customisation 5 - 32

5.2.8.4 Connection Diagram for Outputs without Relay Module 5 - 34

en-938938/0 5 - 1

5.3 Compact Panel 5 - 36

5.3.1 General 5 - 36

5.3.2 Compact Panel Connection Diagram 5 - 37

5.4 CNC Panels 5 - 38

5.4.1 General 5 - 38

5.4.2 Panel Connection Diagram 5 - 39

5.5 Machine Panel 5 - 40

5.5.1 General 5 - 40

5.5.2 Machine Panel Connection Diagram 5 - 41

5.5.3 Machine Panel Extension 5 - 42

5.5.3.1 General 5 - 42

5.5.3.2 Connection Diagram of the Machine Panel Extension with Remote Modules 5 - 43

5.5.3.3 Machine Panel Extension Connection Diagram without Remote Modules 5 - 44

5.6 NUM Diskette Drive 5 - 45

5.6.1 General 5 - 45

5.6.2 Connections of the NUM Diskette Drive 5 - 45

5.6.2.1 Connection of the NUM Diskette Drive to an RS 232E Line 5 - 45

5.6.2.2 Connection of the NUM Diskette Drive with a Remote RS 232E Line 5 - 46

5.6.2.3 Connection of the NUM Diskette Drive to an RS 422A Line 5 - 46

5.6.2.4 Connection of the NUM Diskette Drive with a Remote RS 422A Line 5 - 47

5 - 2 en-938938/2

5.1 CNC/Peripheral Interconnections

Interconnections

PC or PS

FIPWAY network

Machine panels*

I/O extension*

Machine tool

Power cabinet

Automatic controls

Output

Input

R e c

DefL3Pwr

S e r i a l

Axis

Reset

Fail

Diskette

drive

C o m

I t / A n a

Analogue

inputs/outputs

Printer

External interrupt

Motor

P a n e l

Servodrive

Sensor or

rule

Handwheel

Compact panel

50-key panel*QWERTY panel*

∗ Not available on NUM 1020

REMARK A machine panel cannot be used with the compact panel.

en-938938/0 5 - 3

5.2 NUM 1020 and 1040 CPUs

The NUM 1020 and 1040 CPUs are 68020 microprocessor-based 32-bit processors. Communication function

The NUM 1020 and 1040 CPUs can communicate with peripherals via the Com 1 serial (RS 232E) and Serial (RS 232E, RS 422A or RS 485) lines.

PLC function The NUM 1020 and 1040 CPUs manage the machine environment via inputs and outputs:

- 32 inputs and 24 outputs with the 32-24 I/O card, or

- 64 inputs and 48 outputs with the 64-48 I/O card. The machine panel extension can manage an additional number of 32 inputs and 24 outputs (1040 only). An analogue I/O connector allows connection of the NUM 1020 and 1040 CPUs to:

- one interrupt input

- one analogue output

- two analogue inputs. CNC function

The NUM 1020 and 1040 CPUs use the CNC software to manage part programmes and machining data, compute paths and speeds and monitor axis movements.

Panel management function The NUM 1020 and 1040 CPUs manage the VDU and keyboard.

Mass memory function The NUM 1020 and 1040 CPUs store the operating programmes in REPROM, and the machine processor

programmes and user files in RAM with backup. Backup for the files in RAM is provided by a battery with an operating time of 18 months.

CAUTION

The battery must mandatorily be replaced (see Secs. 4.1.1 and 4.1.6) after 18 months of

use (connected).

5 - 4 en-938938/2

5.2.1 Power Supply

Power supply voltage 24 VDC nominal (19.2-30 VDC) Maximum power 40 W

24 VDC

power supply

Interconnections

,,,,,,,,,,,,

24V

POWER

SUPPLY

M5 holes

1 - Power cable (see Sec. 6.5.1)

Top view

en-938938/0 5 - 5

5.2.2 Connection to the Compact or CNC Panels

1 2

1 - Video/panel cable (for lengths, see tables)

2 - Compact of CNC panel The minimum video cable curve radius is 110 mm. The video/panel cables are available in two versions:

- video interconnection kit (for wiring, see Sec. 6.6),

- video cable assembled. Video interconnection kits:

Length P/N Length P/N 5 m ∗ 206203223 30 m 206203231

10 m ∗ 206203225 40 m 206203233 15 m 206203227 to order 206203235 20 m 206203229

∗ Only the 5 and 10 m cables can be used to the compact panel.

Assembled video cables: Length P/N Length P/N

5 m 206202394 10 m 206202395

5 - 6 en-938938/2

5.2.3 Optical Fibre Connecting Cable to the Machine Panels

The CPU is connected to the machine panels by an optical fibre ring as shown below:

Interconnections

Rec

Em Rec

1 - Optical fibre The minimum optical fibre cable curve radius is 50 mm. The transmit power must be set according to the length of the optical fibre connecting the transmitter of an item to the

receiver of the next item (see Sec. 4.1.5 for the CPU and Sec. 4.3.4 for the machine panels). The machine panel addresses are set on a thumbwheel (see Sec. 4.3.1).

Rec

When the optical fibre link is not used (CPU with optical fibre function), the transmitter must be connected to the receiver by an optical fibre shunt:

Rec

en-938938/0 5 - 7

5.2.4 Analogue Inputs/Output and Interrupt

5.2.4.1 General

Analogue Inputs

Two inputs can be dedicated to connection of resistive potentiometers Typical potentiometer rating 10 kΩ Resolution 0.4 percent full scale Power supply + 5 V

Analogue output

Output voltage - 10 / + 10 V Minimum load 2 kΩ Resolution 20 mV

External Interrupt

Maximum current draw 20 mA Minimum current required 10 mA Input on 5 V Logic "0" between 0 and 1 V

Logic "1" between 3.5 and 5.5 V Input on 24 V Logic "0" between 0 and 4.7 V

Logic "1" between 18 and 27 V IT time Programmable: T1 = 0,5/250/500/2220/4440 ms Masking between two ITs Programmable: T2 = 1/500/1000/4000/8000 ms

Interrupt timing diagram:

Rising edge active

Falling edge active

t ≥ T1 t ≥ T2

IT Masking

5 - 8 en-938938/2-E1

5.2.4.2 Analogue/IT Link Connecting Diagram

Analogue data:

spindle speed

and feed rate

override

potentiometers,

temperature probe

Analogue

process

control:

spindle,

flow control

Interconnections

Interrupt

1 - Analogue I/O - interrupt cable (see Sec. 6.3)

en-938938/0 5 - 9

5.2.5 Communications

5.2.5.1 General

Serial line RS 232E (Com 1) Multistandard serial line RS 232E, RS 422A or RS 485 (Serial) Data rate 300 to 38.400 bauds (the data rate is limited to 19,200 bauds if two serial lines

are used) The serial lines allow the CPU to exchange data with peripherals such as a PC or PS, a diskette drive and/or printer.

5.2.5.2 Serial Line Connection Diagram

applications

1 - Serial interface cable

- RS 232E (Com 1 or Serial: see Sec. 6.1.1)

- RS 422A (Serial only: see Sec. 6.1.2)

- RS 485 (Serial only: see Sec. 6.1.3)

NUM

user

Peripheral

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Interconnections

5.2.6 Incremental and Absolute Axis Encoder Cards

5.2.6.1 General

Number of axes controlled Maximum 6 Servo-drive analogue output 1 -10 V/+10 V 14-bit + sign output per axis Switch contact 1 24 V input per axis (19.2 to 30 V including 5% ripple) Switch input impedance 2.15 kΩ∗ (2 to 2.4 kΩ) Switch input current 11 mA minimum ∗ (7.5 mA on the old interface models)

∗ for interfaces with index E or above (interface P/N 204 203 382)

The axis interfaces allow the CNC to control the axes: control of the servo-drives and processing of the encoder data. There are three types of axis measurements:

- Incremental measurement,

- absolute measurement by SSI (serial synchronous interface) link,

- measurement by rule with encoded distance reference marks.

Position Sensors Approved by NUM

Incremental sensors: ROD 428B (HEIDENHAIN, DG 60L (STEGMANN), ENH 2E7C55 (CODECHAMP) and C315805 (MCB).

Incremental rule with encoded distance reference marks: LS 706C + EXE 612 (HEIDENHAIN). Absolute single- or multiturn SSI (Synchronous Serial Interface) sensors: ROC 424 (HEIDENHAIN), AG 66 and AG

661 (STEGMANN). Combined sensors (SSI + incremental): ECN 1313 + IBV 610, EQN 1325 + IBV 650, ROC 412 + IBV 610 and RCN

619 (HEIDENHAIN).

Requirements Concerning Sensors and Their Power Supply

The installation of a sensor is subjected to several requirements:

- minimum sensor power supply voltage (see Sec. 5.2.6.2),

- maximum frequency above which the signals provided by the sensor are no longer counted with accuracy by the

system (incremental channels, see Sec. 5.2.6.3),

- maximum available current for supply of the sensors (see Sec. 5.2.6.6). These requirements determine:

- the minimum power cable size,

- the maximum cable lengths,

- the need or not for an external power supply. In the case of incremental and semiabsolute sensors, the origin switch must be set after installation.

Consumption of the Axis Interface Module

The specific consumption of the axis interface module is:

- 14 mA maximum on the sensor power supply ("Power on" LED),

- 7 mA maximum on the switch power supply ("/SWITCH" LED)

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5.2.6.2 Voltage Across the Sensor

When installing a position sensor, it is necessary to provide the minimum power supply voltage related to the type of sensor used.

5 VDC Sensors

When the NUM power supply is used, the voltage across the sensor is given by the equation: Vs = 4.95 - (0.45 + 36.8 x 10-3 x L/S) x I where:

- Vs (in V) is the voltage across the sensor,

- L (in m) is the cable length (one way only),

- S (in mm2) is the power conductor cross-sectional area,

- I (in A) is the current through the sensor. The minimum wire size of the power supply conductors is calculated from the maximum current through the sensor,

the minimum voltage across the sensor and the required wire length. It is recommended not to use wires with a cross-sectional area above 2.624 mm2. If a larger size is required, the use

of an external power supply located near the sensor can reduce the required wire size. Example of a 5 V ± 5 percent sensor, current rating 220 mA

The computed voltage (Vs) must not be less than 4.75 V. The table below gives the calculation results obtained for different cable lengths using the NUM power supply:

Cable length Minimum cross-sectional area Voltage across the sensor 20 m 1.65 mm 30 m 2.624 mm

4.753 V

4.758 V

Above 30 m, the wire size required would be above 2.624 mm2. In this case, use an external power supply whose characteristics provide a minimum voltage of 4.75 V across the sensor while preserving a reasonable wire size.

Sensors Requiring a Power Supply Voltage Above 5 VDC

The use of an external power supply is mandatory.

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Interconnections

5.2.6.3 Maximum Incremental Sensor Channel Output Frequency (Incremental or Combined

Sensors)

The diagram below shows the waveform of the signal on sensor channels A and B:

Channel A

Channel B

Pulses

Te : signal period on one of the channels a : time between two edges The sensor channel output frequency fe = 1 / T

Extreme values allowing correct signal detection by the system:

- Maximum frequency: f

- Minimum time between two edges: a

= 1.8 MHz

e max

= 138 ns.

min

The minimum time between two edges allowing correct signal detection by the system depends on the length and type of cable used. The table below gives the results of tests conducted with [4 x (2 x 0.14 mm2)] shielded cables connecting the sensor to the axis encoder card and using an external power supply:

Cable length Minimum time between two edges 10 m 147 ns 20 m 156 ns 50 m 250 ns

5.2.6.4 Setting the Reference Signal (Rules with Encoded Distance Reference Marks)

The reference signal (Z pulse) must be set for an electrical angle of 90 degrees. This setting can be made on the EXE or IBV units.

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5.2.6.5 Synchronous Serial Interface Timing Diagram

Sensor clock

Data channel

New sensor

data available

= 1/T: minimum 100 kHz, maximum 2 MHz

clock

Tv: minimum 50 ns, maximum T synchronisation and data bits: maximum 32 bits status bits: maximum 4 bits parity bit: maximum 1 bit.

REMARK The synchronisation bits are leading 0’s in the frame (not present in mode

encoders).

Depending on the clock frequency and sensor cable length L, the clock output is connected to the clock input on the interface or the sensor:

Sensor clock frequency Connection to interface Connection to sensor 100 kHz L < 400 m L < 400 m 200 kHz L < 200 m L < 250 m 400 kHz L < 60 m L < 150 m 500 kHz L < 50 m L < 100 m 800 kHz L < 30 m L < 85 m 1 MHz L < 20 m L < 75 m

1.6 MHz L < 5 m L < 60 m 2 MHz ---- L < 50 m

5.2.6.6 Maximum Available Current per Axis

Each axis interface can supply a maximum of 350 mA. The current draw of all the sensors connected cannot exceed 1.5 A. Above these values, an external power supply should be used.

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5.2.6.7 Setting the Origin Switch

Homing is carried out on the zero pulse following opening of the origin switch:

Homing direction

Contact closed Contact open

Interconnections

Sensor zero pulse

1 / 4 1 / 4

The switch must be set so that the contact opens between one-quarter and three-quarters of the distance separating two zero pulses. This is to avoid coincidence between switch operation and the zero pulse, which could cause a random shift by a distance equal to that separating two zero pulses.

The switch size should be such that the contact opens before detection of the sensor zero pulse and remains open until the axis stops after detection of the zero pulse.

Useful area

1 sensor revolution

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5.2.6.8 Setting the Origin Switch (SSI or Combined Sensor with semiabsolute Measurement)

The axis travel exceeds the sensor measurement travel. Homing is carried out on opening of the origin switch. It is used to identify the sensor revolution on which the switch operates:

Homing direction

Contact closed Contact open

Sensor zero pulse

1 / 4 1 / 4

Useful area

1 sensor revolution

The electrical contact opening signal must be clean, without bounce. The switch must be set so that the contact opens between one-quarter and three-quarters of the distance separating

two zero pulses. This is to avoid coincidence between switch operation and the zero pulse, which could cause a random shift by a distance equal to that separating two zero pulses.

The switch size should be such that the contact opens before detection of the sensor zero pulse and remains open until the axis stops after detection of the open contact on the switch input.

5.2.6.9 Homing of SSI or Combined Sensors with Absolute Measurement

The axis travel is less than the sensor measurement travel. Homing is made at any point of the axis travel at power on or after a reset of the CNC.

The axis connector switch input should not be wired.

REMARK The sensor zero pulse must be outside the axis travel.

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5.2.6.10 Axis Connection Diagram

Interconnections

Sensor

Servo-drive

External

power supply

Switch

Servo-drive

Switch

External

power supply

Sensor

Connection of an axis to an axis interface

1 - Axis cable (see table)

Connection of an axis via an axis interface module

2 - Axis cables (see table)

3 - Axis interface module (P/N 263900000) and cable 1.5 m long

(P/N 260900000)

Axis type Power supply Cable alone Cable with interface

(see Sec.) module (see Sec.)

Encoded supplied by the interface 6.2.1.1 6.2.1.2 and 6.2.7

external 6.2.1.1 and 6.2.6 same as cable alone Absolute SSI measurement supplied by the interface 6.2.2.1 6.2.2.2 and 6.2.7

external 6.2.2.1 and 6.2.6 same as cable alone Semiabsolute SSI supplied by the interface 6.2.3.1 6.2.3.2 and 6.2.7

measurement external 6.2.3.1 and 6.2.6 same as cable alone Combined: SSI + incremental supplied by the interface 6.2.4.1 6.2.4.2 and 6.2.7

Sinusoidal pulses external 6.2.4.1 and 6.2.6 same as cable alone Combined: SSI + incremental supplied by the interface 6.2.5.1 6.2.5.2 and 6.2.7

Square pulses external 6.2.5.1 and 6.2.6 same as cable alone

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5.2.6.11 Handwheel Connection Diagram

Handwheel

1 - Handwheel cable

- with nondifferential outputs (see Sec. 6.2.8)

- with differential outputs (see Sec. 6.2.9)

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Interconnections

5.2.7 Discrete Inputs

The NUM 1020 and 1040 CPUs receive input signals via the front panel Input connector. There can be 32 inputs (3224 I/O card) or 64 inputs (64-48 I/O card). The inputs can be wired via an interface module (see Sec. 5.2.7.2) or directly on the connector (see Sec. 5.2.7.4).

5.2.7.1 Input Characteristics

32-24 I/O card 32 inputs: I 00.0 to I 03.7 64-48 I/O card 64 inputs: I 00.0 to I 07.7

Input characteristics via the 32-input interface module

MOD. INTERFACE 32 E

32 discrete inputs Complying with IEC 1131 type 2 Power consumption 30 W maximum (all inputs switched) Input ratings

Nominal voltage 24 VDC Maximum current 30 mA per input

Operating ranges low level: 0 to 5 V

high level: 11 to 30 V Delay 5 ms ± 10 % Wire size 0.2 to 2.5 mm2 multistrand or 0.2 to 4 mm2 single strand Display 32 LEDs (LED lit: high level)

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Characteristics of the inputs wired to the connector

Input

Inputs

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

With 32-24 I/O card

Discrete inputs Complying with IEC 1131 type 1 Input interface

Nominal voltage 24 VDC (external power supply) Voltage limits 15-30 VDC Internal consumption Maximum 30 mA

Input ratings Nominal voltage 24 VDC Maximum current 8 mA per input

Operating ranges low level: 0-9 (current < 2 mA)

high level: 12-30 V (current > 4 mA) Input impedance 4.7 kohms Reverse voltage withstand 30 VDC continuous Response time 4.7 ms Scanning time 2.6 ms Sensor common Positive power supply terminal Logic Positive (current sink)

Input

Inputs I 04.0 to I 04.7

I 05.0 to I 05.7 I 06.0 to I 06.7 I 07.0 to I 07.7

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

With 64-48 I/O card

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5.2.7.2 Connection Diagram for Inputs with Interface Module

With 32-24 I/O Card

1 2 3

Interconnections

MOD. INTERFACE 32 E

1 - 32-input interface module (P/N 263900001)

See Sec. 5.2.7.3: Interface module connections and customisation

2 - Card/Interface module connecting cable

- Length 1 m (P/N 263203077)

- Length 2 m (P/N 263203078)

- Length 5 m (P/N 263203611) See Sec. 6.4.3: Customising the input and output cables

3 - Leave the cover in place on the top part of the connector

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num 1020, 1040 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual