num 1060 User Manual

NUM 1060
INST ALLATION AND
COMMISSIONING
MANUAL
0101938816/5-E1
10-97 en-938816/5-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 1060. 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
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 Colours of the NUM 1060 Operator Panels 1 - 15
1.6 Screen Saver 1 - 15
2 General System Description 2 - 1
2.1 System Components 2 - 3
2.2 Basic Configuration 2 - 8
2.3 Multipanel Configuration 2 - 8
2.4 Multi-CNC Configuration 2 - 9
2.5 Multirack Configurations 2 - 9
2.6 System Architecture 2 - 10
3 Overall Dimensions - Installation 3 - 1
3.1 QWERTY 14" Colour Operator Panel 3 - 3
3.2 50-Key Panels 3 - 6
3.3 Compact Panel 3 - 12
3.4 Multiplexer Module 3 - 15
3.5 Card Racks 3 - 18
3.6 Machine Panel 3 - 24
3.7 Additional Components 3 - 26
4 System Component Preparation 4 - 1
4.1 Rack Preparation 4 - 3
4.2 Preparing the Compact Panel 4 - 12
4.3 Machine Panel Preparation 4 - 15
4.4 General Operations 4 - 20
5 Interconnections 5 - 1
5.1 CNC/Peripheral Interconnections 5 - 3
5.2 Operator Panel 5 - 8
5.3 Multiplexer Module 5 - 15
5.4 Rack Interconnections 5 - 16
5.5 Machine Panel Interconnections 5 - 22
5.6 NUM Diskette Drive 5 - 28
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6 Cards 6 - 1
6.1 Power Supply Cards 6 - 5
6.2 1060 Series II CPU 6 - 7
6.3 1060 Series I Processor 6 - 11
6.4 CPU Cards 6 - 12
6.5 Incremental and Absolute Axis Measurement Card 6 - 24
6.6 IT/Serial Line Card 6 - 32
6.7 Analogue Input/Output Card 6 - 34
6.8 32-24 I/O and 64-48 I/O Cards 6 - 36
6.9 32-Input/24-Output Card 6 - 42
6.10 32-Input Interface Modules 6 - 46
6.11 24-Output Relay Modules 6 - 50
6.12 32-Input Card 6 - 56
6.13 32-Output Card 6 - 59
7 Cables 7 - 1
7.1 Communication Cables 7 - 5
7.2 Axis Cables 7 - 17
7.3 Analogue I/O, Interrupt and Timer Cables 7 - 44
7.4 Input and Output Cables 7 - 56
7.5 Power Cables 7 - 72
7.6 Video Cable 7 - 76
Part Two: Commissioning
8 Initial Operation 8 - 1 9 Load and Check of the PLC Programme 9 - 1
9.1 Load Procedures 9 - 1
9.2 Checking the PLC Programme: Test of the Safety Systems 9 - 1
10 Integration of the Machine Parameters (by UT5) 10 - 1 11 Axis Calibration (by UT2) 11 - 1
11.1 General 11 - 3
11.2 Record of Corrections to Be Made 11 - 5
11.3 Operations on Axis Measurement Correction Tables 11 - 6
12 Interaxis Calibration 12 - 1
12.1 General Description of Interaxis Calibration 12 - 3
12.2 Interaxis Calibration by Utility 20 12 - 7
12.3 Dynamic Interaxis Calibration 12 - 13
13 Final Inspection 13 - 1
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Revisions of the Documentation
Date Index Description
12 - 91 0 Document creation
12 - 92 1 Inclusion of Series II
Inclusion of new components:
- 9" and 10" operator panels
- machine panel
- 2-slot extension rack
- 32-input interfacing module
- 24-output relay module
- IT card - Serial lines
Record of Revisions
03 - 94 2 Inclusion of the analogue 8-input/8-output card
Miscellaneous corrections
08 - 94 3 Inclusion of utility 20
Miscellaneous corrections
04 - 96 4 Inclusion of new components:
- version 2 machine processor
- UC SII CPU
- 32-24 and 64-48 I/O cards
- 32-input or 32-output cards with LMI connectors
- compact panel
- new 32-input interfacing module
- new 24-output relay module
- axis interface module
- NUM diskette drive Inclusion of axes with absolute measurement
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Date Index Description
04 - 97 5 Inclusion of new components:
- version 2 CNC processor
- NUM keyboard
- 50-key keyboard with LCD screen Improvement of existing components Miscellaneous corrections and additional information.
10 - 97 5 - E1 Additional information on operating conditions
Modified cable shielding connection to connector plug covers Modified multiplexer module mounting recommendations Modified 50-key LCD panel power cable
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NUM 1060 Documentation Structure
User Documents
These documents are designed for use of the CNC.
Foreword
Foreword
NUM
OPERATOR
MANUAL
M / W
938821
NUM
OPERATOR
MANUAL
T / G
938822
NUM
PROGRAMMING
MANUAL
M
938819
Integrator Documents
These documents are designed for setting up the CNC on a machine.
NUM 1060
INSTALLATION
AND
COMMISSIONING
MANUAL
NUM
PARAMETER
MANUAL
NUM
AUTOMATIC
CONTROL
FUNCTION
PROGRAMMING
MANUAL
LADDER LANGUAGE
NUM
PROGRAMMING
MANUAL
T
938820
938816
938818
938846
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List of NUM 1060 Utilities
A series of utilities are available for the NUM 1060 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 (938 816) 10 UT3 resident macros operator manuals (938 821 and 938 822) 8 UT5 parameter integration parameter manual (938 818) 12 UT7 programme debugging automatic control function programming manual - 16
Ladder Language (938 946) UT12 option locking operator manuals (938 821 and 938 822) 8 UT20 interaxis calibration installation and commissioning manual (938 816) 11 UT22 integration of axis parameters SETTOOL Manual (938 924) 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:
- operating conditions
- power consumption
Chapter 1
General
Installation
Instructions
- heat dissipation
- electrical specifications
- equipment colour.
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.
Card layout in racks. Rack addresses.
Chapter 4
System Component Preparation
Temperature probe wiring. Operations on the UC SII CPU. Preparing the compact panel. Preparing the machine panel. Replacing fuses. Wiring the watchdog.
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Chapter 5
Interconnections
Chapter 6
Cards
Chapter 7
Cables
Wiring diagram for the different configurations. General data and connections:
- CNC panels
- compact panel
- multiplex module
- racks
- machine panels
- NUM diskette drive.
General data and interconnection of the cards comprising the system.
Wiring diagrams for the following cables:
- communication
- axes
- analogue inputs/outputs, interrupts and timer
- inputs and outputs
- power supply
- video/panel.
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Part Two: Commissioning
Chapter 8
Initial
Operation
Foreword
Initial operation procedure.
Reference to the PLC Function Programming Manual and checking instructions. Specific features of the compact panel.
Chapter 9
Load and Check
of the PLC
Programme
Chapter 10
Integration
of the Machine
Parameters
Chapter 11
Axis
Calibration
Reference to the Parameter manual.
Correction of the axis position measurement read by the coupler according to the real position on the axis.
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Chapter 12
Interaxis
Calibration
Chapter 13
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 11 and 12). The actions required are presented as follows:
Foreword
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.
Y
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.
en-938816/4 13
14 en-938816/4
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 Mains 1 - 6
1.4.2 Protective and Signal Earth 1 - 6
1.4.3 Functional Earth 1 - 7
1.4.3.1 Equipment Operating at Relatively Low Frequency and Low Signal Levels 1 - 7
1.4.3.2 Modern Equipment Operating at High Frequency and High Signal Levels 1 - 8
1.4.4 Equipment Immunity 1 - 10
1.4.4.1 Reduction at the Source (interference suppression) 1 - 10
1.4.4.2 Reduction of Couplings 1 - 11
1.4.4.3 Equipment Hardening 1 - 12
1.4.5 Diagram of the 0 V, Frame and Protective Earth Links 1 - 13
1.5 Colours of the NUM 1060 Operator Panels 1 - 15
1.6 Screen Saver 1 - 15
1
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1 - 2 en-938816/4
General Installation Instructions
1.1 Operating Conditions
!
Do not unplug any subassemblies (cards, circuits) with the system live.
Do not solder the equipment when live.
Use earthed soldering irons.
Do not use testers with an output voltage 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 3
IEC 1000-4-12 Electromagnetic emissions EN 55022
CAUTION
1
Operating temperature range: Minimum 5 °C, maximum 55 °C. Cooling: See Sec. 1.3. The systems must mandatorily be located in power cabinets equipped with:
- efficient door seals,
- air cleaners or air/air heat exchangers,
- possibly air-conditioning units.
en-938816/5-E1 1 - 3
1.2 System Power Consumption
The system power consumption is calculated by adding the system component power consumptions.
Component Power consumption CNC racks and cards (230 VAC)
Power supply cards (includes rack consumption)
- 130 W power supply card 45 W
- 60 W power supply card 28 W
Two-card extension rack 8 W
CPUs
- UC SII CPU 11 W
- CNC/graphic processor 10.2 W
- graphic processor 10.2 W
- memory card 1.27 W
- machine processor 6.85 W
- version 2 CNC processor 5 W
-optional daughterboard for high-speed line 5 W
- version 1 CNC processor 5.55 W
Axis card 6.85 W
IT/serial line card 2 W
Analogue I/O card 6.7 W
Input/output cards
- 32/24 I/O card 4 W
- 64-48 I/O card 4 W
- 32-input/24-output card 4 W
- 32-input card 8.44 W
- 32-output card 6.4 W
Panels (230 VAC)
QWERTY operator panel with 14" CRT 100 W
50-key or compact panel with 10" colour CRT 60 W
50-key or compact panel with 9" black and white CRT 30 W
50-key panel with LCD screen (24 VDC) 20 W (monitor) Machine panels (24 VDC)
Machine panel alone 3.8 W
32-input/24-output extension 9.8 W
Additional components (24 VDC)
32-input interface module 24 W
24-output relay module 19.2 W
Multiplexer module 25 W
NUM diskette drive 3.5 W
1 - 4 en-938816/5
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 at most 175 W for a rack and 100 W for the operator panel. A more detailed calculation can be made by summing the individual power consumptions of the system components
(see 1.2).
CAUTION
1
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.
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 Mains
Supply of the system by the single-phase 230 V mains does not require an isolation transformer but must:
- be independent of disturbed systems: connection as far upstream as possible on the general system, routing away
from power, high interference or low level cables,
- include the supervision, protection and cutout components specific to the system. The installed power must be approximately twice the power rating (For the power consumptions of the system
components, see 1.2) to cater for transient overloads (peaks of around 10 times the rated value for a few cycles). On mains that may be subject to interference such as:
- voltage or frequency variations,
- microbreaks due to mains equipment switching,
- power failures that are short (a few seconds) or long, the installer must provide devices allowing the system to operate with in the limits defined by the tolerances.
Always earth the neutral of the 230 VAC power supply.
REMARK In the event of problems due to the mains, call in a specialised contractor authorised
to investigate the problem and recommend a suitable power supply source.
1.4.2 Protective and Signal Earth
Definition of the concepts of protective and signal earth:
- protective earth: low impedance, low frequency path between the circuit and earth used in the case of a fault,
- functional earth: low impedance path used between electric circuits for equipotentiality. The purpose of this earth
is the attenuation of all the spurious and accidental voltages that can exist between equipment items over a very
wide frequency band. These two concepts do not correspond to different circuits. The frame earth is provided by interconnecting all metal components (building structure, piping, cable trays, equipment
enclosures and equipment). The earth is the physical connection (earthing well, earthing mat, building earthing system) to which the frame earth
must be connected.
1 - 6 en-938816/5
1.4.3 Functional Earth
q
General Installation Instructions
A distinction is made between two types of electronic equipment:
- relatively low frequency equipment (a few kHz to a few hundred kHz) operating at low signal levels,
- equipment operating at high frequency (a few tens of MHz to a few hundred MHz) and high signal levels.
1.4.3.1 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 and medium frequency electromagnetic fields injected in
particular in the loops between equipment items. High frequency interference is rejected by the natural bandwidth of the circuit or by low-pass filters.
The following rules must be applied to decrease interference:
- star connection of the common circuits and star connection of the frame earth with a single interconnection between
the two systems,
- when a sensitive wire must be protected against electromagnetic interference by shielding, the shielding is
considered a screen and only one end is connected to the earth so as not to create a loop with an interference current
flow in the shielding. Wrong: loops between equipment items due to interconnection of the earth and common wires
Voltage generated (U = ZI)
I : Current generated
A
B
AC
magnetic
field
Z: impedance of link AB
1
uipment item 1 Equipment item 2
E
Right: star connection of earth and common wires
Equ. 1
: frame earth
: protective earth
: 0 V
Equ. 4
Equ. 2
Equ. 3
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1.4.3.2 Modern Equipment Operating at High Frequency and High Signal Levels
Such equipment includes modern logic systems with electronic gates whose switching time are around 1 ns and whose signal levels are high (static switching margin from 400 mV to 1 V).
The most critical interference is electromagnetic interference at frequencies between 30 and 300 MHz. Such interference originates in all open coil circuits (relays, contactors, transformers, motors, transformer-driven
lights, etc.), arcing of circuit breakers when tripping, servo-drive switching devices, HF systems located nearby, electrostatic discharges generated by the operators, etc.
At such frequencies, the earths must be equipotential. However, the impedance of an earthing wire is high at high frequency (Z=Lω). For instance, for a 2.5 mm2 wire 1 metre long with an inductance L = 1.4 x 10-6 H, the impedance, which is 0.09 at 10 kHz, becomes 90 at 10 MHz - and the earthing wires do not allow creation of a good frame earth.
An "earth grid" is used to reduce interference: the equipment items are interconnected by the largest possible number of links as short as possible.
This is best achieved by using metal parts interconnected by a large number of mounting points ensuring good electrical conduction (zinc-plated or cadmium-plated steel, stainless steel, removal of paint, use of cleats on aluminum, etc.).
If the electrical continuity is not sufficiently assured by the mechanical interfacing, the link must be shunted by at least two short wide bonding braids (length/width ratio 5 and length < 20 cm).
1 - 8 en-938816/4
Example of Meshing
General Installation Instructions
NUM operator panel made
of zinc-plated steel
(to be mounted on a conductive
surface or connected by shunts)
Conductive seals
or 2 bonding braids
JOGTOOL
MODE
M01
HELP
F11 F12
F3F2
5^6&7*8(9)0_-+=+
S
x off
/
F10F9F8F7F6F5F4
{ [}]
:
`";
MNBVCXZSHIFT SPACE
,<.>/
line
line
DEL
INS
char
char
ALL
home Pg Up
CAPS
VALID ` ?
Pg Dnend
F1
!1@2#3$4%
ESC Q W E R T Y U I O P
CTRL A D F G HJKL
Pendant
Zinc- or cadmium-plated
metal cable trays
Metal frame equipment
with good electrical conduction
of the mounting points
Metal ducts
with conductive mounting
(recommended)
Cabinet mounting points
ensuring good
electrical conductivity
Protective
earthing wire
Earthing terminal
NUM CNC
RELAYS
RELAYS
Structural metal
building beam
Isolating
switch
Earth
DRIVE 1
DRIVE 2
DRIVE 3
Electrical continuity
provided
Earthing terminal
Door hinges
to be shunted
1
Metal power cabinet
Rear view of a lathe
The concepts of signal earth and protective earth coincide for the equipment, i.e. the logical 0 V is connected to the frame earth in many points.
The logic circuit connecting cable shielding is earthed at both ends, which contributes to the mesh. In addition, the internal electronics and the enclosure must be at the same potential.
To reduce the loop effects thus created (the field captured depends on the loop surface area), the cables must be attached to ducts or metal surfaces. This type of wiring has a reductive effect "reductive effect".
In the case of separate power supplies for the logic inputs/outputs, the 0 V of these power supplies must be earthed and the wiring must be made with "reductive effect".
REMARK The earthing grid is not a protective system. The earthing terminals of the equipment
items must be connected to the general system earthing terminal.
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1.4.4 Equipment Immunity
EMI immunity of the equipment is achieved by:
- reducing the interference generated by the sources,
- reducing the couplings between source and circuit with interference,
- ensuring high immunity of the equipment. The three approaches are complementary and are used simultaneously.
1.4.4.1 Reduction 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 tight,
- 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
1W
0.47 µF
1 - 10 en-938816/4
Three-phase motor
General Installation Instructions
1
M
1.4.4.2 Reduction of Couplings
For correct meshing of the earths (see 1.4.3.2), use metal cards with a conductive surface interconnected (bolted) together.
Wire with a reductive effect (low surface area loops):
- cables applied against the ducts and metal parts forming the frame earth,
- signal forward and return path in the same cable (twisted pair). Earth the shieldings of the logic signal cables at both ends. Interconnect the cable shielding to the earth on 360 degrees:
- with a conductive gland to penetrate through a bulkhead,
- by pinching the shielding with metal covers themselves in contact with the earth for connector plugs. Connection of a shielding to a frame earth
IDEAL 360-degree
PROHIBITED
ACCEPTABLE
Earthing
rail
CORRECT
Frame Frame
CONTACT
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Interconnection of a Shielding to a Connector Plug Cover Earth the cable shieldings over 360 degrees: fold the shieldings onto the cables over a length of 1 cm and clamp them
in the cover clamp.
Attachment
screw
SUB D
CONNECTOR
Separate the low-level cables from the power circuits or circuits with interference:
- by physical separation between the cables (at least 30 cm desirable),
- by routing in ducts with separate, distant cable trays,
- by 90-degree crossings. The analogue inputs (for the servo-drives, for instance) must be differential (common mode rejection).
Particular Case of Servo-Drive Wiring
Location
of the wiring
Cable clamp
Half-cover
Cables
Cable
shielding
The systems are low level (sensitive to microvolt levels) and low frequency. The link must therefore be protected by a screen earthed on the CNC side only (see 1.4.3.1) and overshielding on the cable, earthed at both ends for the mesh.
When these recommendations are not applicable (unavailability of cables with double shielding, etc), preference shall be given to the earthing mesh using a cable with single shielding earthed at both ends.
1.4.4.3 Equipment Hardening
This is related to the equipment design. Particular care was taken to ensure equipment immunity:
- multilayer cards with internal grounding plane,
- stainless steel enclosure of the system and front panels ensuring good contact with the enclosure, with the assembly forming an excellent Faraday cage,
- metal connectors ensuring continuity with the front panels, provided with metal covers with 360 degree shielding connection,
- high level of mains filtering at the power supply input,
- opto-isolated binary inputs/outputs with physical separation of circuits with interference.
All these measures make the equipment highly resistant to electromagnetic interference.
1 - 12 en-938816/5-E1
General Installation Instructions
1.4.5 Diagram of the 0 V, Frame and Protective Earth Links
230 VAC
VIDEO/OPERATOR PANEL
AXES
Shielding
SEE DETAIL 2
Screening
(not compulsory)
POWER CABINET
SERVO-DRIVE Axis or Spindle
1
SEE DETAIL 1
PENDANT
STORAGE UNIT
!
CAUTION
LEGEND
PERIPHERAL
or
or
Shielding not connected at this end
Shielding connected at this end
Twisted wires 0 V
Frame earth
Protective earth
The 0 V of the 24 VDC power supplies must mandatorily be connected to the frame earth
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Detail 1
230 VAC
Detail 2
Axis card
Op. panel
5V
Operator panel
Graphic display
processor
CNC processor or
machine processor card
5V
Video /
1 - 14 en-938816/4
Axes
Screening not compulsory
Power supply
Shielding
Peripheral
Video / Operator
panel
General Installation Instructions
1.5 Colours of the NUM 1060 Operator Panels
The colours used on the NUM 1060 operator panels are standard colours:
Colour Used on 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 system designed to extend the screen life. When the screen saver is activated by the PLC programme, it turns off the screen after five minutes of keyboard inactivity. Pressing any key redisplays the previously active page.
1
It is recommended to activate the screen saver by the PLC programme. This is done by setting bit SC_SAVE (%W5.7).
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