num 1020, 1040 User Manual

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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+ 198 hidden pages

num 1020, 1040 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual