Yaskawa PC NC User Manual

YASNAC PC NC Operating Manual
Version: Beta 1.0
YASNAC PCNC Operating Manual Introduction
SAFETY INFORMATION
PRECAUTIONS
1. Read this instruction manual in its en ti rety before using the op era ti ng functions availabl e in the YASNAC PCNC.
even fatal injury and damage to pro duc ts or related equipment or systems.
WARNING
WARNING
WARNING
This sym b ol indica tes the pre s en ce of a potentially hazardous condition which, if not avoided, could result in serious personal injury or death.
This precautionary symbol appears in labels attached to YASNAC products to alert the user to conditions requiri ng concern for safety.
SPECIAL SAFETY NOTE: This symbol indicates that ELECTRICAL SHOCK HAZARD condition exists. DO NOT TOUCH any electrical connection terminals when the power is on, and for at least 5 minutes after switching off the power supply. Warning label is located on the PCNC
PCNC Unit
xxxxxxxxx xxxxxxxxx xxxxxxxxx xxxxxxxxx xxxxxxxxx
WARNING LABEL
NOTICE
Printed _______. 1999. The informatio n contained within thi s doc ument is the proprietary property of Yasakawa Electric America, I nc. , and ma y not be c opied, reproduced or tra nsm it te d t o other parties without the expressed wr itte n authorization of Yasakawa Electric America, Inc.
No pattent liability is assumed with respect to the uses of the information contained herein. Moreover, becaus e Yaskawa is constantly improving i ts high quality product, the informati o n contained in this manual is subject to chan ge without notice. Every precaution h as be en taken in the prepa ra ti on of this document .
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YASNAC PCNC Operating Manual Introduction
INFORMATION INDICATORS
The following symbols are used in this operating manual to empha siz e particular inform at ion to the user:
Indicates important information to be remembered, i.e., precautionary alarm
POINT
displays to prevent damaging devices.
SUPPLEMENT
TERMS
Indicates supplementary material.
Indicates definitions of terminology that has not been explained before.
NOTES REGARDING SAFE OPERATION
It is important that the user should read this manual before inst al li ng, operating, perfor mi ng any mainten ance or ins p ecting th e
<$61$&3&1&
Also, the functions and performance of a NC machine tool are not determine d by t he CNC unit itself, therefore thoroughly read and familiarize yourself with the machine builder’s documentation conc erning the safe an d mo st effic ie nt wa ys to u se the machine too l. Nevertheless, Yasa kawa assumes no responsibility for da ma ge s resulting from the use of the informat io n contained within this publication.
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YASNAC PCNC Operating Manual Introduction
TABLE OF CONTENTS
1. OUTLINE OF THE PRODUCT
1.1 OUTLINE of the YASNAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -2
1.1.1 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.2 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.3 Machine Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.4 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2 PROTECTIVE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.2.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.2.2 Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.2.3 Stored St roke Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.2.4 Interlock Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
2. BASIC OPERATION OF YASN AC PCNC
2.1 GENERAL OPERATION FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 INSECTION BEFORE TURNING THE POWER ON . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Inspection of the PCNC unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.2 Prepartion before Turning the Power ON. . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3 TURNING THE POWER ON/OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
AND INSPECTION AFTER POWER ON/OFF . . . . . . . . . . . . . . . . . . . . . . . .2-8
2.3.1 Procedure for Turning the Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.2 Checking the Motors for Abnormalities. . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Procedure for Turning the Power OFF. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.4 Inspection of the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
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YASNAC PCNC Operating Manual Introduction
2.4 MANUAL OPERATION (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.1 Manual Rapid Traverse (RAPID). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.2 Jog Feed (JOG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.3 Step Feed (STEP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.4 Handle Feed (HANDLE)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 MANUAL OPERATION(2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.1 Simultaneous 2- o r 3-axis Handle Feed* . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.2 Manual Reference Point Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5.3 Manual Reference Point Ret urn t o the Second Reference Point l . . . . . 2-18
2.5.4 1-line MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.6 AUTOMATIC OPERATION (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.1 Preparation of Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.6.2 Memory Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.6.3 MDI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.6.4 Feed Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.6.5 Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.7 AUTOMATIC OPERATION (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.1 Optional Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.2 Optional Block Skip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7.3 Dry Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.4 Display Lock and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.5 Auxiliary Function Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.6 Z-axis Command Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.7 4th-axis Command Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.7.8 5th-axis Command Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
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YASNAC PCNC Operating Manual Introduction
2.8 OPERATION INTERVENTION (during automatic operation) . . . . . . . . . . . . 2-29
2.8.1 Manual Operation Intervention (during automati c ope ra ti on) . . . . . . . . 2-3 0
2.8.2 MDI Operation Intervention ( duri ng automatic operation) . . . . . . . . . . 2-30
2.8.3 Automatic Handle Mode Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.8.4 Manual Absolute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
3. BASICS OF DISPLAY AND WRITING OPERATION
3.1 USER INTERFACE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.0 User InterfaceOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.1 Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.2 Battery Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.3 NC Execution Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.4 Motion Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.1.5 Alarm Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.1.6 Warning Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.1.7 Time/Dat e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.1.8 Mode / MDI / Tool Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.1.9 Mode Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.1.10 Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.2 RECURRING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.2.1 Positioning the Cursor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.2.2 Nest Level Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.2.3 Shortcuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.2.4 Number Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.2.5 File Browser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
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3.3 RUN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.3.1 Production Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.3.2 Proveout Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.3.3 NC Switch Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.3.4 Timers Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.4 PROGRAM MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.4.1 File Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.4.2 Editor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.4.3 List Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3.4.4 Macro Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.5 TOOL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.5.1 Offset Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.5.2 Magazine Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3.6 SETUP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.6.1 Workshift Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3.6.2 Four (4) Position Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.6.3 One (1) Position Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.7 UTILITIES MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.7.1 Log in Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.7.2 System Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.7.3 Maintenance Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.7.4 Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.7.5 Backup and Restore Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3.7.6 CPU Monitor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.7.7 Setting Parameters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
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3.7.8 NC Parameters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.7.9 Machine Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.7.10 Pitch Error Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.7.11 Torque Ripple Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.7.12 Parameter Search Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.7.13 High Speed Cutting Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.7.14 User Install Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3.7.15 MTB Install Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3.7.16 PLC Parameters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3.7.17 PLC Diagnosis Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3.7.18 Ladder Monitor Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3.7.19 Switch Label Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3.8 ALARM MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.8.1 NC Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.8.2 PLC Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.8.3 Alarm History Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.9 Help Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.10 MMI Map Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.11 Manual Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.12 Offline Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3.13 Offline Mode Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
4. MAINTENANCE
4.1 MAINTENANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.1 Checking the Status of Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.1.2 Checking the NC Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.1.3 Display of Alarm Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.1.4 Cause of Alarm and Corrective Action. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
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4.1.5 Troubleshooting (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.1.6 Troubleshooting (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4.1.7 Alarms Not Indicated by Alarm Numbers . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4.1.8 PCNC Alarms Not Indicated by Alarm Numbers . . . . . . . . . . . . . . . . . . .4-28
4.1.9 Touch Screen Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4.1.10 Mode of PCNC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4.1.11 Self-D i a gnosi s Func ti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
4.1.12 Hard Drive Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
APPENDIX 1. LIST OF PCNC INPUT/OUTPUT SIGNALS
1.1 INPUT SIGNALS ( PLC > NC ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-2
1.2 OUTPUT SIGNALS ( NC > PLC ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1-9
APPENDIX 2. ALARM TABLE
2.1 CLASSSIFICATION OF ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-2
2.2 ALARM TABLE ( PCNC ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-3
2.3 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2-21
APPENDIX 3. PARAMETER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3-1
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YASNAC PCNC Operating Manual Introduction
USING THIS MANUAL
This manual decribes the procedures for operating the
<$61$&3&1&
RELAT ED INFORMATION SOURCES
For additonal information, refer to the follow in g ma nuals:
TITLE OF DOCUMENT CONTENTS
YASNAC PCNC Programming Manual
(YEA-SIE-C844-2.2)
YASNAC PCNC/PLC Programming Manual
(YEA-SIE-C844-0.1)
YASNAC PCNC I/O Signal Manual
(YEA-SIE-C844-2.3)
YASNAC PCNC Connection Manual
(YEA-SIE-C844-0.2)
YASNAC PCNC Maintenance Manual
(YEA-SIE-C844-2.9)
.
PCNC Program creation instructions
PLC Program creation instructions
Describes functions between PCNC and PLC
Instructions for connecting PCNC with machines,
machine interface and peripheral equipment
Describes service and maintenance procedures.
ix
YASNAC PCNC Operating Manual Introduction
CAUTIONS
This manual describes all the option functions (identified by the “*” sym bol ) but some of these may not be available with your YASNAC PCNC. T o determine the option functions installed in your PCNC, refer to the specification docume nt or manuals publishe d by t he machine tool buil der.
Unless otherwise specified, the follow i ng conditions apply in prog ramming explan ations and programm i ng examples.
l
Metric system for input and metric system for output / movement
l
Zero point in the base coo rdi nate system
l
Reference point
Yaskawa has made every effort to de scribe individual func ti ons a nd their relationships to oth er fun ct ions as accurate ly a s possible. However, there are many things that cannot or must not be performed and it is not possible to describe al l of th ese . Accordingly, readers are requested to understand that un le ss it is specifically stat ed that something can be pe rformed, it should be assumed that it cannot be perfor med.
Also, bear in mind that the performanc e a nd functions of an PCNC m a chine tool are not de te rm ined solely by the PCNC unit. The entire contr ol system consists of the mechanical system, then machine operatio n pa nel and other machine related equ ip ment in addition to the PCNC. Therefore, read the manuals publ ished by the machine tool builder for detailed information rela ti ng t o the ma chine.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
1

Outline of the YASNAC System

Chapter 1 describes the outline of the YASNAC system and the operating features and func­tions that should be thoroughly understood for the safe and efficient operation of the system.
1.1 Outline of the YASNAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.1.1 System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.1.2 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.1.3 Machine Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.1.4 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.2 Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.2.1 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.2.2 Overtravel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.2.3 Stored St roke Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.2.4 Interlock Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System

1.1 Outline of the YASNAC System

1.1.1 System Configuration

PCNC
Remote Machine Pendant
The configuration of the Y ASNAC PCNC system and the list of components are described below.
Unit
YASNAC PCNC
Unit
FIGURE 1.1.1.1: Standard Configuration of PCNC System

Table 1.1.1.1: List of YASNAC PCNC System Components

COMPONENT NAME MODEL NAME

CPU rack JZNC-JPCRKM-

NC Operation Panel JZNC-JPCOP-

SERVOPACK SGDC-

Spindle drive CIMR-M5

Servomotor SGMo-

Spindle motor UAASKA-

Remote Pendant TBA

o-oooo-oo
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oo
oo
oo
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System

1.1.2 Environmental Requirements

Requirements for the installation of an PCNC unit are indicated below. Install the PCNC unit in a location where only these requirements are satisfied to avoid possible malfunctioning.
CAUTION!
Avoid using it in an environment where it may be subject to high temperatures, high humidity, dust, corrosive gases, vibration or physical impacts that may cause fire, electric shock or malfunction.
Use the product in an environment meeti n g the following conditions:
Free from gases or vapors that create a potentially explosive atmosphere.
Free from oil, organic solvents, et c.
Relative humidity in the range 10 to 90% RH, with no condensation.
Ambient temperature in the 0°C to 55°C with no freezing.
(Installation site must not be exposed to direct sunlight, must be distanced from heat generating devices, and must be indoors.)
2
Vibration not exceeding 4.9 m/s
.
Do not store the product in locations subje ct to rain, w ater droplets, harmful gases or liquid s.
Failure to observe this caution may result in product failure.
Select a storage area indoors that is clean and meets the following temperature and humidity requirements.
Ambient temperature: –15° C to 65° C (–5° F to 149° F) Relative humidity: 10% to 90%
Failure to observe this caution may result in product failure.
(1) Ambient Temperature
For operation:0°C to 55°C For storage and transportation:–15° C to 65° C Install the PC NC unit in a location not subject to direct sunlight, distant from heat sources,
and indoors.
(2) Humidity
Relative humidi ty m ust be in the range of 10 to 90%RH (non -condensing).
(3) Vibration
During operation: Max. 4.9 m/s
2
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
(4) Atmosphere
Avoid the following locations:
Dusty places
Places where concentration of coolant and/or organic solvent mist is ext remely high.
(5) Power Sou rce
Input voltage:AC (single-phase) 180V ~ 264V Frequency:50/60 Hz –2 to +2 Hz

1.1.3 Machine Operation Panel

An example of t h e machine operation panel is indicate d below. Arra ngement and names of switch es and indicator la mps vary according to the mach ine model. For deta ils, refer to the machine tool man ua l.
FIGURE 1.1.3. 1: Example of Mac h i ne Operation Panel
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System

1.1.4 Gene ra l Speci fic ations

(1) Standard Specifications
CATEGORY ITEM AND FUNCTION
Controlled
axes
Input
command
Interpolation
Feed
Storage and
editing of
program
Operation
and
display
Input/Output
function

Number of simultaneously controlled axes

Maximum programmable value

Absolute/incremental programming

Automatic acceleration and deceleration

Controlled axes

Least i nput increment

Least output incre ment

Decimal point input

Input unit 10 times

Tape code

NC tape

Input format

Buffer register

Positioning

Linear interpol ation

Circular interpolation

Rapid traverse

Cutting feed

Dwell

Incremental feed

Program storage capacity

Number of programs

Program editing

Program number search

Sequence number search

Address search

MDI editing

Operation panel

MDI function

l-line MDI

Operation and display

Calendar display

Pop-up menu

Buzzer function

Input/Output interface

OPERATION
MANUAL
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á
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PROGRAMMING
MANUAL
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SECTION
NO.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
CATEGORY ITEM AND FUNCTION

Tool function

Miscellaneous function

Tool offset
Coordinate
system
Operation
support
function
Programming
support
function
Safety
and
maintenance
Environment requirements

Automatic return to reference point

Automa tic return to second reference point

Circular interpolation by R command

Self-diagnostics (always displayed)

Tool length offset

Tool position offset

Number of tool offset data sets

Manual return to reference point

Reference point return check

Return from reference point

Base coordinate system setting

Label sk ip

Single block

Optional stop

Optional block skip

Dry run

Machine lock

Miscellaneous function lock

Display lock

Manual absolute

Numerical value set-up

Break-point function

Operat ion mode

Feed hold

Repetitive circle interpolation

Subprogram

Exact stop check

Exact stop chec k mode

Emergency stop input

Overtravel

Axis interlock

Stored stroke limit

Power supply

Ambient temperature

Humidity

OPERATION
MANUAL
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PROGRAMMING
MANUAL
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SECTION
NO.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
(2) Option Spe cific a tions
CATEGORY ITEM AND FUNCTION
Controlled
axes

Least input/output increment of rotary axis

Input
command
Interpolation Helical interpolation
Feed
Storage and editing of program
Operation
and
display
Input/output
function and
device
Spindle, tool
and
miscellaneous
functions
T ool offset

Automatic third/fourth reference point return

Coordinate
system
Expanded number of workpiece coordinate

Number of controlled axes

Rotary axis cont rol

Inch/metric switching Multi-active reg isters

Synchronized feed (solid tap)

High-speed mode operation

F1-digit

Simultaneous1-axis handle feed Simultaneous 2-axis handle feed Simultaneous 3-axis handle feed

Addition of program storage capaci ty

Addition of number of programs

Playback Internal toggle switch NC program drawing

Comment display func ti on

Tape reader without take-up reels

Tape reader with take-up reels

RS-232C interface T4-digit command

Second miscellaneous function

Tool radius offset

Additi on of tool offset data sets

Manual second reference point return

Workpiece coordinate system setting

systems

Local coordinate system

Rotation of workpiece coordinate system

OPERATION
MANUAL
á á á á
á á á
á á á
á
PROGRAMMING
MANUAL
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SECTION
NO.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
Operation
support
function
Programming
support
function
Accuracy
correction for
mechanical
system
Automation
support
function
Safety and
maintenance

Optional block skip B

Automatic mode handle offset

Program restart

Automa tic tool length measuremen t (TLM)

Manual interruption point return

Canned cycle

Canned cycle B

Circle cutting

Macroprogram

Programmable mirror image

Scaling

Coordinate syst em rotation

Automa tic comer override

Programmable data input

Hole ma chining pattern cycle

Program copy

Stored pitch error compe nsa ti on

Unidirectional approach

Skip function

Tool life control function

Program interruption Stored stroke limit B Stored stroke limit C
á á á á á
á á á á á á á á á á á
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System

1.2 Protective Functions

1.2.1 Emergency Stop

Press the emergency stop button immediately if a problem occurs with the system or line. The execution of all c om m ands stops instantaneously when the emergency stop button is pressed. Servo power supply of the PCNC is shut OFF and dynamic br ake is applied to stop all mechanical movement. In the emergency stop state, the PCNC is in the alarm stat e “3002”. If the emergency stop signal is “opened”, the PCNC stops the en tire operation, and the SVMX and BKX signals are “opened”.
PCNC
This operation is executed by setting the pins on the board. The pins differ between J300M and J100M.

1.2.2 Overtravel

The overtravel function stops axis feed operation when an axis reaches the travel limit; for the detection of travel limit, a limit switch and a dog are used and if an axis reaches the travel limit, the limit switch outputs a signal a nd th e function stops axis feed operati on i n response to this input. The axis rea ched and stopped at the tr avel limit can be moved manually into the axis mov­able range.
When the overtravel input is “opened”, axis movement is stopped in the manner as indicated in Table 1.3. In response to thi s inpu t, the alarm output (ALM) i s “closed” and the corresponding alarm message is di sp la ye d on the screen.

Table 1.2.1. 1: E mergency Related Signals

Signal Name Pin Setting

Emergency Stop Input CN12-19 pin on JZNC-JFC 10 board

SVMX CN12-17 pin on JZNC-JFC 10 board

BKX CN12-16 pin on JZNC-JFC 10 board

Table 1.2.2.1: Axis Stop Direction with Overtravel Input “Opened”
Manual Operation Mode Automatic Operation Mode
*+X to *+5
input is “opened
*-X to *-5
input is “opened
* Normally closed contact
Movement in the *+X to *+5
direction is stopped.
Movement in the *-X to *-5
direction is stopped.
Movement of all axes is
stopped in all directions.
If the overtravel inpu t is “opened”, select the manual mode (jog, pulse handle) and move the axis in the direction opposite to the direction for which the overtravel input is “opened” to “close” the input. After that press the [RESET] key on the NC operation panel, the alarm output and display are canceled.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
1. After the oc currence of an ala r m d ue to the “open” of the overtravel input, the M, S, and T code read output signa ls (MF, SF and TF) are not turned OFF.
2. If it is necessary to in te rrupt the operatio n ca ll ed by M, S and/or T code, set th e i nte rl ock by an external seque nce.
3. The alarm numbers at the occur rence of overtravel are 2001 to 2005. If the overtra v e l alarm occurs, axis move is stopped. Note that the servo is not turned OFF.

1.2.3 Stored Stroke Limit

To ensure improved safety in operation, this function prevents axis from entering the preset entry prohibited are as bo th in manual and autom atic operation.
(
1) Stored Stroke Limit
To use the stored stroke limi t fu nction, the axis movable area is set by parame te rs wit h the
coordinate values in the machine coordinate system. Th e a rea outside the set bou nda ry is established as the entry prohibited area. If an axis enters the entry prohibited area, the function stops axis movement and displays an alarm message. The functi o n is made va lid upon completio n of th e manua l re f er en ce point return after the power is turned ON. In automatic operation, if even o ne axis caus es the alarm, all axis are stopped.
In manual operati on, only the axis tha t caused an alarm is stopped.
FIGURE 1.2.3. 1: Stored Stroke Limit
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System
(2) Stored Stroke Limit B, C (G22, G23) *
The area either outside or in s id e the boundary set by par ameters or by the commands in a
program is established as the entry prohibited area. The boundary is set with the coordi­nate va lues in the m achine coordinate system. W h ether the entry prohibited area is esta b­lished outside or inside the boundary can be determined by the setting for a par ameter. The function is made valid upon completion of the reference point return after turning ON the power.
Table 1.2.3.1: G Code Used to Turn ON/OFF the Stored Stroke Limit B Function
G CODE FUNCTION GROUP
G22 Turning ON the stored stroke limit B 04 G23
Turning OFF the stored stroke limit B
04
FIGURE 1.2.3.2: Stored Stroke Limit B Function
In addition to the stored stroke limit s A and B, stor ed stroke limit C can be added.
With the stored stroke limit C, set the boundary of the area and inside or outside the
boundary by parameters.
Accord in g to the setting for the parameter or the input signal , one of the stor e d str o ke
limit C (third to fifth prohibited area ) ca n be ma de valid.
For details of the stored stroke limit B, C, refer to 4.2. 3 Stored Stroke Limit B and C
(G22, G23) in the PROGRAMMING MANUAL.
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YASNAC PCNC Operating Manual Chapter 1: Outline of YA SNAC System

1.2.4 Interlock Inputs

The interlock input is the signal used to disable axis mov em ent, and is provided for each axis.
When an axis is interlocked during movement, it is stopped after deceleration.
When the interlock is re leased, the axis con tinues mo ving to co mplete th e remainin g com-
mands. Upon com ple tion of the commands, the program advances to the next block.
For simu ltaneous two or three axis interpolation commands, interpolation operation is dis­abled if one of the s e two or three axis is int erlocked.
Fig. 1.6 Interlock Inputs
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC
2

PCNC System Outline

Chapter 2 describes various operations including power ON procedure,
manual operation and automat ic oper ation.
2.1 Gen eral Operation Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Insection before Turning the Power ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.1 Inspection of the PCNC unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.2 Prepartion before Turning the Power ON. . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3 Turning the Power ON/OFF and Inspection after Power ON/OFF . . . . . . . . . . . 2-8
2.3.1 Procedure for Turning the Power ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.2 Checking the Motors for Abnormalities . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Procedure for Turning the Power OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.4 Inspection of the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC
2.4 Manual Operation (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.4.1 Manual Rapid Traverse (RAPID). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.4.2 Jog Feed (JOG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.4.3 Step Feed (STEP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.4.4 Handle Feed (HANDLE)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.5 Manual Operation (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
2.5.1 Simultaneous 2- o r 3-axis Handle Feed* . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
2.5.2 Manual Reference Point Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2.5.3 Manual Reference Point Return to the Second Reference Point . . . . . . . .2-18
2.5.4 1-line MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2.6 Automatic Operation (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2.6.1 Preparation of Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2.6.2 Memory Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.6.3 MDI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
2.6.4 Feed Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
2.6.5 Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.7 Automatic Operation (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.7.1 Optional Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.7.2 Optional Block Skip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2.7.3 Dry Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2.7.4 Display Lock and Machine Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2.7.5 Auxiliary Function Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2.7.6 Z-axis Command Neglect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2.7.7 4th-axis Command Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2.7.8 5th-axis Command Neglect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC
2.8 OPERATION INTERVENTION (during automatic operation). . . . . . . . . . . . . . .2-29
2.8.1 Manual Operation Intervention during automatic ope ra ti on . . . . . . . . . . .2-29
2.8.2 MDI Operation Intervention during automatic operation. . . . . . . . . . . . . .2-30
2.8.3 Automatic Handle Mode Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2.8.4 Manual Absolute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2.9 AUTOMATIC OPERATIONS AT ENHANCED LEVEL. . . . . . . . . . . . . . . . . . .2-34
2.9.1 Tool Length Measurement* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
2.9.2 Return to the Operation Interrupted Point* . . . . . . . . . . . . . . . . . . . . . . . .2-37
2.9.3 Manual Centering Operation* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
2.9.4 Program Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
2.9.5 Playback Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC

2.1 General Operation Flow

The operatio n proc edure usually followed for daily operation is i ndi cated in Figure 2.1. This chapter explains these operation items.
Setting Part Program
Loading NC program from PC by Ethernet or from touch screen and executing the Program numbers
FIGURE 2.1.1: Operation Proc edure
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC

2.2 Inspection Before Turning the Power ON

Before turning the power ON for YASN AC PCN C, it is necessary to carry out inspe c ti on t o Ensure safety. If the power is turned ON while the system has trouble, it could cause malfunc­tioning of the system itself and create a hazards conditions for the operations. Make sure to carry­out daily inspection bef ore turni n g the power ON.
WARNING!
Always turn all power OFF (including the primary power supply) before carrying out daily inspection.
Performing the inspection with the power ON may lead to electric shock.
Wait 5 minutes after turni ng the power (including the primary power supply ) OFF befo re removing or replacing any unit or part.
Failure to observe this warning could lead to electric shock and equipment failure.
Do no t touch any unit, terminals, e tc., while the powe r is ON.
Failure to observe this warning could lead to electric shock or device malfunction.
Immediately after switching the power OFF, the product retains some electric charge. Do not touch any parts (which are live when the power is ON) for 5 mi nutes after switching the po w er OFF.
Failure to observe this warning could lead to electric shock or device malfunction.
Do not damage cables, subject them to exc essive stress, or pinch them.
Excessive load on cables may cause electric shock.
When the equi pment is po w ered ON, never tou ch its rota ting parts.
Failure to observe this warning could result in personal injury.
Ne ver modify the produ ct.
Failure to observe this warning could result in electric shock, fire, or product failure.
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC
CAUTION!
To prevent personnel other than those invo lv ed in maintenance and in spe ct io n w ork from turning the power ON whi l e mai nt ena nc e and i nspe ct io n is in progress, place signs stating DO NOT TURN THE POWER ON or words to that effect at the primary power supplies of related cont rol pan el s and othe r re le va nt l oca t ion s.
Failure to observe this caution could lead to electric shock.
Electronic devices such as CMO S ICs are used on the control boards. If you touch the ICs with your bare fingers, static electrical charge in your body could destroy these ICs, care must be taken when handling these devices. Before handling these devices for maintenance purposes, first discharge the static electricity in your body by touching a gro unded metal device.
Failure to observe this caution could lead to personal injury and product failure.
Do not install or remove boards, wiring, connectors, etc., while the power is ON.
Failure to observe this caution could lead to electric shock, product failure, and malfunction.
Do not let foreign matter such as ele ct ric a l wire scrap enter the unit .
Failure to observe this caution could result in fire, product failure or malfunction.
Be sure to check the follow in g points after comple t ing maintenance and inspection work:
Check that al l fastening bolts are tightened.
Check that no tools or other objects have been left inside the control panel.
Check that the control panel door is closed properly.
Failure to carry out these checks could lead to electric shock, injuries, fire, and malfunction.
Never attem pt to disa ssemble the NC unit modify units/dev ices inside the PC N C unit.
Failure to observe this caution could lead to fire, product failure and malfunction.
Do not change the se t values of the devices, variab le resistors, et c., in the control panel.
Failure to observe this caution could lead to fire, product failure, and malfunction.

2.2.1 Inspection of the NC Unit

In this subsection, the items to be inspected before turning ON the power are indicated for the standard PCNC box supplied by Yaskawa. For the machine tools control box, refer to the machine tool man ua ls.
(1) Inspecting the Machine Cabinet Doors
Make sure that the doors are secu rely closed before turning th e power ON. The PCNC CPU ra ck is not protected against oil mists or ot he r ai rborne foreign matt er. The door of the machine cabinet doors must always be kept closed before powering ON.
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YASNAC PCNC Operating Manual Chapter 2: Basic Operation of YASNAC PCNC
(2) Inspecting the Shielding Parts in the Machine Cabinet
Inspect the shielding parts in the Machine Cabin et eve ry m onth for gaps and/or damag e.
Open the doors and check the packings installed around the door for dama ge.
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Inspect the inside of the Machine Cabinet for abnormal contamination. If the inside is abnormally dirty, clean it immediately after loc a ti ng the cause of contamination.
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Lock the doors secure ly a nd in spect the doors to make sure that th ere are no gaps.
By carrying out th e inspection procedures indicated above at regular int erv als, the YASNAC PCNC can pe rform efficiently for a long time .

2.2.2 Preparation before Turning the Power ON

Before turning the power ON, confirm the following con dit io ns:
Make sure that the front side of the PCNC unit is closed. If the door is open or if there is a gap between the door and the box panels, securely close and loc k t he door.
Carry out the inspection for the machine an d machine related controllers according to the instructions in t h e machine to ol manuals.
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