c

TABLE OF CONTENTS (MELDAS-5000C/51 OOC MAINTENANCE MANUAL)

CHAPTER 1. O U T L I N E O F N C SYSTEM .................................................................................................... 6

1 h

2. N C U N I T C O N F I G U R A T I O N 2.1 Main unit configuration

................................................................................................. .................................................................................................

8 8 8 8 10 13 14

1)
3) 4) 5)

Exterior

...................................................................................................................... ................................................................................................. .................................................................... ...................................................................

2) Interior configuration

Interior configuration (compact cabinet) View of card arrangement in logic board Release of door interlock

..........................................................................................

3. INTERCONNECTIONS 3.1 3.2 3.3

...........................................................................................................

.15 .15 16 18 19 26

Interconnection diagram of the MELDAS 5000C ........................................................... Interconnection diagram of the MELDAS 5100C _ .......................................................... List of input and output signals ...................................................................................... MELDAS 5000C list of input and output signals MELDAS 5100C list of input and output signals ................................................... ...................................................

3.3.1 3.3.2

4. BLOCK DIAGRAM 4.1 4.2 4.3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 .......................................................................................................... .......................................................................................................... ....................................................................................................... .34 .35 .36

Block diagram (1) Block diagram (2) MCU block diagram

5. THE F U N C T I O N A N D T H E H A N D L I N G O F LOGIC CARD (from BNP-A2006) .............. .37 5.1 5.2 5.3 5.4 5.5 5.6 The function of logic card .............................................................................................. .......................................................................... .37 38 .41 .42 47 55

Replacing and handling the logic cards Regular inspection of logic cards Logic card check points

...................................................................................

................................................................................................. ......................................................................

inside setting on the printed circuit board Logic card maintenance parts

........................................................................................

6. F U N C T I O N A N D H A N D L I N G O F S T A N D A R D B O A R D (from BNP-A2007) 6.1 6.2 6.3 6.4 6.5 Standard board and its functions

................... .56 56 .57 57

................................................................................... ...................................................................

Replacing and handling the standard board

Regular inspection of standard board . ............................................................................ Checking and setting the standard boards Parts list of standard board

........................... . .........................................5 7 .57

............................................................................................

7. SETTING AND INDICATION BOARD FUNCTIONS AND HANDLING 7.1 PZ57 board functions and handling (from BNP-A2008) 7.1 .l 7.1.2

............................ .58

................................................. 58 .58 58 59 .59 .60

PZ57 board and its functions ................................................................................... Replacing and handling the PZ57 board .................................................................

7.1.3 Regular inspection of PZ57 board 7.1.4 Checking the PZ57 board 7.1 .5 7.2

...........................................................................

........................................................................................

Patts list of PZ57 board ...........................................................................................

DP51 and DP52 board functions and handling (from BNP-A20091 7.2.1 7.2.2 7.2.3 DP51 and DP52 boards and their functions

................................. 62 ,62 P-

............................................................

Replacing and handling the DP51 and DP52 boards Checking and setting the DP51 and DP52 boards

.............................................. ,62 62 63

...................................................

7.2.4 Parts list of DP51 and DP52 boards 7.3

........................................................................

yb

DP box 62A and 64A functions and their handling (from BNP-A2010) 7.3.1 Functions

...................... .64

&$ ...............................................................................................................
.64

7.3.2 Replacing and handling ............................................................................................

.64 7.3.3 Checking and setting .................................................................................................

7.3.4 Parts list .................................................................................................................... 7.4 DP box 628 and 648 functions and their handling (from BNP-A2011) 7.41 Functions 65

...................... .66 66 .66 .66 66

...............................................................................................................

7.4.2 Replacing and handling ............................................................................................ 7.4.3 Checking and setting ................................................................................................. 7.4.4 Parts list .....................................................................................................................

8. FUNCTIONS AND HANDLING OF PTR-210 TAPE READER (from BNP-A20121 8.1 8.2 8.3 Tape reader and its functions

............ .67 67 .69 70 75 76 ?

.........................................................................................

Replacing and handling the tape reader .......................................................................... Regular maintenance and inspection of tape reader ........................................................ ...........................................................................................

8.4 Tape reader check procedure 8.5 Parts list of tape reader

..................................................................................................

9. PDWER SUPPLY FUNCTIONS AND HANDLING ................................................................. 9.1

77

PD08A power supply functions and handling (from BNP-A2013) ................................ .77 9.1.1 Functions ................................................................................................................ 77

9.2

Functions and handling of PDOSA power supply (from BNP-A2014) Functions

............................ 79 .79 .80 .81 81

9.2.1

...............................................................................................................

9.2.2 Replacement and handling ........................................................................................ 9.2.3 Check procedure ......................................................................................................

9.2.4 Parts list .....................................................................................................................

9.3

PMIOA charger functions and handling (from BNP-A20151

........................................

82 82 83 83 83 84

9.3.1 Functions

.............................................................................................................. .....................................................................................

9.3.2 Replacement and handling 9.3.3 Check procedure 9.3.4 9.3.5

.....................................................................................................

Parts list ................................................................................................................... List of ratings relating to charger ...........................................................................

9.4 Battery handling (from BNP-A20161 9.4.1 Replacement

...............................................................................8 5
85 87

..........................................................................................................

9.4.2 Parts list ...................................................................................................................

i
10. DRIVE AMPLIFIER FUNCTIONS AND HANDLING ...........................................................
i r10.1 Drive amplifier (3SlO/20/4OB) functions and handling (from BNP-A2017) ................. 88 88 88 89 89 90 91 10.1.1 Functions 10.1.2 ............................................................................................................... 88

Replacement and handling ....................................................................................... ................................................................................................... ..............................................................................................

10.1.3 Regular inspection

10.1.4 Checking and setting

10.1.5 Parts list ................................................................................................................... 10.2 Drive amplifier (SA20/40A/B) functions and handling (from BNP-A20181 .................

10.2.1 Functions 10.2.2

............................................................................................................... 91 ?. .......................... 92
92 93 . 94

Replacement and handling ........................................................... .....................................................................

10.2.3 Regular inspection 10.2.4 Checking and setting 10.2.5

........................... \ : ..............................................................................................

Parts list ...................................................................................................................

11. SPINDLE CONTROL DRIVE AMPLIFIER FUNCTIONS AND HANDLING 11.1

Spindle control drive amplifier (S3S50/60A/B) functions and

...................... 95

handling (from BNP-A2019) ..................................................................... 11 .I.1 Functions ...............................................................................................................

95 95 95 97 97 102

11.1.2 Replacement and handling ....................................................................................... 11.1.3 Regular inspection 11.1.4 Checking and setting ................................................................................................. ...............................................................................................

11.1.5 Parts list ...................................................................................................................

11.2

Spindle control drive amplifier (S3S50/60A/B) functions and handling (from BNP-A20201 ...................................................................... 103 103 105 106 106 108

11.2.1 Functions

................................................................................................................

11.2.2 Replacement and handling ........................................................................................ 11.2.3 Regular inspection ....................................................................................................

11.2.4 Checking and setting .................................................................................................. 11.2.5 Parts list ....................................................................................................................

12.

MOTOR HANDLING (from BNP-A20211

................................................................................

109 109 109 109 110 1 10 110 111 r

12.1 Cup motor 12.1.1 12.1.2

........................................................................................................................ .............................................................................. .............................................................

Regular inspection of cup motor

List of commutator brushes for cup motor

1 2 . 2 H D m o t o r ......................................................................................................................... 12.2.1 12.2.2

Regular inspection of I-ID motor ...............................................................................

List of commutator brushes for HD motor .............................................................

12.3 Low inertia motor. .............................................................................................................. 12.3.1 12.3.2

Regular inspection of Low inertia motor ...................................................................1 1 1

List of commutator brushes for Low inertia motor.. ................................................. 111

13. DETECTOR G E A R B O X F U N C T I O N S A N D H A N D L I N G (from BNP-A20221 13.1 Functions

. . . . . . . . . . . . . . . . . . . . 1 12 112 114 114 11 5

......................................................................................................................... .............................................................................................

13.2 Replacement and handling 13.3 Regular inspection 13.4 Parts list

...........................................................................................................

.........................................................................................................................

1 4 . M A N U A L H A N D L E (HD51) FUNCTIONS AND HANDLING (from BNP-A20231 14.1 Functions

.............. 1 1 6 116 118

......................................................................................................................... .............................................................................................

14.2 Replacement and handling

15. ROTARY ENCODER FUNCTIONS AND HANDLING (from BNP-A20241 15.1 Functions

........................ 1 1 9 119 121 124 125

......................................................................................................................... .............................................................................................

15.2 Replacement and handling 15.3 Regular inspection 15.4 Parts list

...........................................................................................................

..........................................................................................................................

16. TAPE HANDLER (TH-400) FUNCTIONS AND HANDLING (from BNP-A20251 16.1 Functions

.............. 1 2 6 126 128 129 129 129

......................................................................................................................... .............................................................................................

16.2 Replacement and handling 16.3 Regular inspection 16.4 Checkpoints 16.5 Parts list

...........................................................................................................

....................................................................................................................

..........................................................................................................................

17. SERVO ADJUSTMENT M E T H O D (from BNP-A20261 17.1 General outline of NC servo

..........................................................

130

130 ............................................................................................. 130 131

17.1.1 17.1.2

NC servo ................................................................................................................... Types of NC servo systems .....................................................................................

17.1.3 MELDAS servo system

136 .............................................................................................

17.2 17.3

NC servo system diagram ................................................................................................. Servo adjustments and regular inspection .....................................................................

138 140

18. PARAMETER SETTINGS 18.1 System parameter tape loading ........................................................................................ 142

19. SELF-DIAGNOSIS ....................................................................................................................

19.1 Alarms and states indication ...........................................................................................

144 144 144

19.2 ALARM contents check 19.3

..................................................................................................

Interface check

...............................................................................................................

144

20. TROUBLE-SHOOTING (from BNP-A20271

...........................................................................

145

21. TROUBLE-SHOOTING WITH SOFTWARE (from BNP-A20281 21.1

21.2 21.3

..........................................

165
165

LC2, LC120, LC23 logic cards ........................................................................................

Action when there is something wrong with LC2, LC120 or LC23 logic card Trouble-shooting

............. ..16 9 170

.............................................................................................................

22. MAINTENANCE PARTS LIST (from BNP-A20291 22.1 22.2 22.3 22.4 22.5 22.6 22.7 22.8 22.9 Spare parts

1 ................................................................. 1 71
..: .................. 171 ,171 172 172 173 173 173 .I 7 3 174 174 175 176

.................................................................................................

Printed circuit board (Logic card) ................................................................................... Board ..............................................................................................................................

Power supply .................................................................................................................... Battery .............................................................................................................................. Tape reader .................................................................................................................... ................................................................................................................

Rotary encoder

Detection gear box .......................................................................................................... Drive amplifier ...............................................................................................................

22.10 Motor 22.1 1

............................................................................................................................. ....................................................................................................................

Motor brush

22.12 Thermal relay ....................................................................................................................

CHAPTER 1. OUTLINE OF NC SYSTEM

The MELDAS51OOC is a numerical control unit which is designed especially for lathes, and the MELDAS-5000C

is a numerical control unit which allows combinations with other machine tools. Figs. 1.1 and 1.2 give the arrangement of systems using the numerical control units.

_---- -- --

M 5oooc main unit

3
X-axis motor Y-axis motor Z-axis motor

r- - -

Operation panel

-Limit- Power switches,etc. controller l -l

L-_______

J
------_Limit
Power controller switches,etc.

-1 i

____.__________J

Connection cables

7 Machine

Fig. 1.1

View of ME LDAS5000C configuration

r - - - - ----c c

---Operation panel

I I I

X-axis motor 7 Z-axis motor -

I
M51ooC main unit

I I I

c
Rotary encoder

\
J

z z ii
J J / -_--__

I I
I

L-_______ 7_-----Connection cables f Machine

Fig. 1.2

View of MELDAS51OOC configuration

The system is composed of the numerical control main unit, the operation panel, the power controller and the main machine unit. The main machine unit is provided with servo motors (also rotary encoder for lathes) for

the X axis up to the 4th axis (X axis and 2 axis for lathes). The construction of the MELDAS 5OOOC/51OOC can be broadly divided into the following five sections.

Power supply section Logic section Paper tape reader section M ELDAS5000C/51 OOC Servo drive section

!
MELDAS F/lPaper tape reader

Setting and indicating section (Spindle motor drive section) (Machine operation setting and indicating section)

Setting and indicating section L (Machina operation setting and indicating section)

.--I I

y-:

I
._J

L.-f

4-k

Logic section Power supply section

S e r v o d r i v e saction _ _ _ (Spindle motor drive section)

Fig. 1.3

MELDAS-5000C/51OOC

CHAPTER 2. NC UNIT CONFIGURATION

2.1 1)
2)

Main unit configuration

Exterior Refer to Fig. 1.2 and Fig. 1.3 of the MELDAS5OOOC/51OOC Instruction Manual

Interior configuration (1) Exterior with front door open

Logic section

Board

D.C. power supply _

Tape
SCR AMP ------&-

reader

3-phrw transformer

_g

Front door

No-fuse breakor

(2) Exterior with rear door oDen

Logic board rear

D.C. powu supply

Exhaust fan

Connecton for external connections

Relay unit

3-phase transformer

b .-

$ c

10

11

,. ._...
Logic section 7--.?.-

.,s..,

I Rear
AC 1OOV line. fuse (lOA) +24V fuse (3A) - Card DC power supply section

view) Logic section

DC power
supply section

Battery box

Frequency se-_ lector switch

Ad--X-axis SCR AMP Z-axis SCR AMP CANNON connectors for ex- ternal connection 1 Z-axis no-fuse breaker Terminal block for tap switchingof control power transformer
r 1 I 1 I I I

I
DCll DC12 *

_
Terminal block for X-axis motor connection

Relay unit ocll

DC12 -1 I

X-axis no-fuse breaker

2 -

3 -

----

12 rGZ - 1

_ Terminal block for Z-axis motor connection

Space for additional axis or spindle AMP

I I I

I I I

Space for power

controller -

I I I I

L _-__-----_ -I

I I
a-phase transformer switch- ing tap

I I I I L__________1

I I I I I I I I

Limit switch for door interlock Limit switch for _ door interlick

(
TB 2 f
Terminal block for input power connection

Fig. 2.5

Main unit interior arrangement (ME LDAS-51OOC)

Supply

\ .

j .

p .Y w

n _.

Uame of card

Name of card LC LC LC LC 22 21 120 10 1 2 3 4

p
h) w a cn 0, 4 co t_-

n _.
N t

Jame of card IF01 LC23 LC LC LC LC LC LC LC LC 1 2 120 21 4-I 4_, 3 10 N w VP m Q, q 00 D

Jame of card LC LC LC LC 23 21 10 1 + N w P

--k
LC LC 4_, cn 3 a LC 10 -a

LC LC LC LC

LC LC LC

120 2 3

m Q, 4

I
LC 1 a, LC 2 I ,a

LC

4_,

03

g =

LC22

5) Release of door interlock MELDAS5000C/51OOC has a door interlock construction for a safety measure. When the front or rear door is opened, the main input no-fuse breaker is opened automatically so that all the power supplies in the N/C controller are cut off for preventing the trouble due to an electric shock. Make sure to close the front and/or rear doors before turning on the main input no-fuse breaker. (If the breaker is turned on while the door is open, the breaker opens immediately.) When it is forced to turn on the N/C power supply while the door is open, release the door interlock system according to Fig. 2.10. (Refer to Fig. 2.1 -Fig. 2.5 as to the locations of the door interlock limit switches for the front and rear doors.)

plate

Limit switch for door interlock

(a) Normal state

Ib) Released state of door interlock Release of door interlock

Fig. 2.10

(1) Loosen the setscrew in the state shown in Fig. 2.10(a). (2) Turn the lock plate 90 degrees as shown in (b) and tighten the setscrew while pushing the limit switch with the lock plate. Then the main input no-fuse breaker can be turned on manually in this state. Note that the door cannot be closed in the (b) state. Be sure to return the lock plate to its original position before closing the door. (3) Since the limit switch for the door interlock is provided each for the front and rear doors, the above procedure should be done for both the limit switches when the power is turned on while both the doors are open.

14

CHAPTER 3. INTERCONNECTIONS
3.1 Interconnection diagram of the MELDAS 5000C
onnector NO. Y,,, HELDIS 5UC

TB2 (M8 screw)

Interconnection diagram of the MELDAS 5000C (for relay output)

15

3.2

Interconnection diagram of the MELDAS 5100C

(InlIe connecte to be to abbs (oppaite skte of NC) we not btcluded In the MELDAS SIOOC. (2) Ihs able8 l d thn conmton Jllll

attuhd

MS3102.\28 -2lSI

:\lSJO57--16.\

(4)Cablu connected to tke control quipmmt halt not be grouped in I swne bundb with the pma cables to tbe machine. WPtew prepare I lapante AC IOOV wppty *hen externll PO* counterr or punchers are innJled. (6)In TB121 and 11122. please connect DC1 PA. and DC12 to NB of the nlota. (7) The abler CNA 3.4 are prosided for the sisnals from the detectors. Pbar cc.ect these able, directly to the NC mntrotler without a junction in the mmhtne. OJAs for the particulara of the EC.nccttons for TB121. TBl22. pteau refer to the instruction Manual. 3 (9) Sidr for the extr. exe, (No. 3 & 4 axes) we shown in the bracket f ).

I to

L16

E---J I--:
VS3lO?\?H 2lS\ \lb31Otili2X 2lI\ \lS3lJ57 I6 \

.\1S31081128 21SX SIS3057-16A , 1 \IS3102A28 2llX -

IS3 1 O&II120 29s I\lS3057- l2A IS3102\2lJ ; 291

I,

handle ked

i r \+i3102\2u

Ys

r T

\Is:~lntill?o 041 YS305i 12\

\lS3102\20

?YS%

us3 I u(i1+20 2Yl% \Is30 Si I ? \ - - -

\L%.l lOti 29s \I53057 1 2 4 /-\lS31lJ2\10/ 291

\Is:!lo2\?o

?YS% \IS3 I Otil120 2 9 s \I53057 12\ as3 102?\20 291'

/ r-

motorside A (A2) or PA

motorside B Al) or Nl

power supply grounding

Interconnection diagram of the MELDAS 51OOC (for relay output)

MS3102A20-29s
MS31O~B20-29P h&33057-12A

r
CNDB

Ms3106826-21s r MS3102A26-21P

MS3057-16A

ground 1-w AC 10 O/l 1 OV asVn/l Axis

- MS3102A20-29% CNA5 l-MS3106H20--29Pz MS3057-12A

f&i3106H20-29s MS3057-12A NS3102A20-29P

No.3 axis motor

otor side ACA2) or PA otor side B(A1) or NE otor side A (A2)or PA otor side B (Al)or NE (M4 screw)

No.4 axis motor

Interconnection diagram between the MELDAS 51OOC and items specified by the optional specifications

17

3.3

List of input and output signals

The meaning of the symbols used in the following lists are: (1)
l

. . . . . . . . . . . . . ...*.. means a normally closed contact.

(2) - - I I - -

. . . . . . . a circuit receiving input signals in the MELDAS 5OOOC/51OOC, as shown in the following drawing.

r __----------

+21v

- - - - - -1

-I-

! I I I I -..---J L _ __ - __-__-----_1 (N/C wx2~

-5

2.2 ,uF

! 4

(3) ---.-jj-- -..- . . . . . . . means a relay contact output from the MELDAS 5OOOC/51OOC. (note) (1) The maximum allowable current for a relay contact is 200 mA for DC24V and 100mA for DC 4SV.

18

3.3.1

MELDAS5000C list of input and output signals

-___

_._

MELDAS 5OOOC CND Cycle start Automatic halt (feed hold)

/
The contact is opened for the feed-hold state ----a CSDf; - :M
- CND3 - iT)

-- -fl- .!i- 0 :;I,,

~iy _. .._ _._

Tape

command select .__. _-__a_ .i_

Manual handle step feed selection _. __.. +. Manual feed selection . .._. Manual data input salact -..__. --I) ..! Manual handle feed axis selectton (X) - ---#-I!

Manual joa feed

The contact is opened for the emergency stop state

Return to the zero select ------I)--!-.

1
1
SII.

HSO JO

i!k.Y p
RT

(\I):, !

<

Feed hold indication - --.

1 FL!-

6-llllf

Cycle start indication - -- -1 /--.-The zero point indication X - -.-.---f ). 1-4 ;I 111

_ _

Manual rapid select

__.{ Automatic operatron 1_ _.__.._..._

,JP,

s _-.-- .- -. 1

OP

mte 1 I If *

marked signal is not used. connect it to grounding.

Interconnection diagram for CNDl of MELDAS 5000C (for relay output)

19

(CNDZ) MELDAS 6OOOC CND 2M function outpot 1 Ml 1 Ml 2 Ml 4 Ml 8 M2 1 M22 M24 M28 MF OM DEN1 DEN2 Sll s12 s14 Sl8 s21 s22 S24 S28 SF OS Tll T12 T14 T18
, ;;
II

;M11
Ml 2 Ml 4 Ml a M2 1 M22 M24 M28

c M command &art MF M function output common Traverse command completed I

S function output S 1 1 I )I I z S command start S function output common / T function output T i i I n

n

s12 s14 S18 521 s22 524 s20

T12 T14 T18 T21 T22 T24 T28

e

I T command start T function output common MST

I,

b <) I, 4,

f 0 g

T21 T22 T24

,, h I, OT28 ,I 1 J k 0 TF

compkted

NC ready completed

Interconnection diagram for CND2 of MELDAS 5000C (for relay output)

20

(CND3 i
MELDAS 5000C CND 3 Pitch error compensation tX

p+x P --x Ps-Y

I, ,, I, Interlock X I, 0
The zero point detection X

.P --Y PfZ P - Z I TX* ITYa ITZ* DECX* DECY* DECZ*

When open, significant

I,

External deceleration +

EDXPf EDYPf EDZP* OJ M30R M02R MOOR OMR

OR

I, I, II
Auxiliary function output M 3

,, I
Output common Input groundng NC reset output

RSTl RST2 ERS

+LX*

I
External reaet output Overtravel + X I,

-Lx* +LY* -LY* +Lz* -Lz* OL

I, 0 I ,I

Tape editing Spindle gear selection input

EDT GRl GR2

Mode selection switch

,I

note) If * marked signal is not used, connect it to grounding.

Interconnection diagrams for CND3 of MELDAS 5000C (for relay output)

21

(CNDI)

Manual

jog

feed

+ 4

--rJ

f4T 4 T

d-7 3 4
Manud handb faad axis selection switch

Manual handk fead axis selection (4 th) Tha zaro point indication (4 th) Pitch error compnsation

H4T

k +24V CN-Dl -c

( f4 th)
(---4th)

Intarlock (4 th) Tha zero point detection External de&oration i- 4 input grounding Overtravel + When open, significant

- 4

q n o t .

I
Input grounding Baxis r&o off

- 4

a ) I f

markedsignalis not used, connect it to grounding.

--L4* OL SVFB*

B3 ( T5 , S4 ) digit

function output common

BF

BF Bll ( T 3 1 , B12(T32, B.14 (T34, Bl 8 (T38, S31) S32) S 3 4 ) S38)

# * I I I I , N N , ,

Bll(T31, B12(T32, B14(T34, B18(T38, B21

S31) S32) S34) S 3 8 )

( T 4 1 , S41) S42) S 4 4 ) S 4 8 )

B21 ( T 4 1 , S41) B22(T42, B24 (T44. S42) S44) S48)

B22(T42, B24 (T44,

B28(T48, B31 (T51)

B28(T48. B31 (T51)

B32(T52) B34(T54) B38(T58)

B32(T52) B34(T54) B38(T58)

lnterconnggtion

diagram for

CND4 of MELDAS 5000C (for relay output)

22

(CNDG) MELDAS 6WOC CND 6 Manwi Jog food spwd selaction 1 I I # I Handk bad rrcodr A phan output B phase output f12V -12v Grounding 2 3 4 6 FSTl FST2 FST3 FSTI FST5 HA HB +12Vh -12Vh Oh MPl MP2 OSP

( rt 12V)
2

Handk food multiple 1 *

Optional stop Input grounding Auxiliiry output MO1

ON
MO 1 R

Feed override 1 H I 2 4 8 16

OVRl OVR2 OVR4

0VR6
OVR16 OVRC PON COM POF AL1 AL2 not.1 If * marked signal is

Ovwide cancel NC power ON NC powor ON/OFF common NC power OFF NC alarm output

Memory operation Manual absolute Extornsl docabration I - X - Y - Z

MEM ABS EDXM* EDYM* EDZM* SA SB

notd Rofor to

next page tabe 1-3 for further details about FSTl-6, OVRl,

Bonro romiy complettd

1001 length measure Tod roforonco point return

TLM HPR

lntgrgonnection

diagram for CND6 of MELDAS 5000C (for relay output)

23

Table 1. F step setting .__

,;P

Table 2. Override -IFs?~~~i? FST 1 2:314 G o-0 0 FST 5 0

Feed o/o 2/0.2 4/0.4 6/0.6 6/0.6 IO/l.0 12/1.2 14/1.4 16/1.6 2Of2.0 40/4.0

0 1 2 3 4 5 6 7 6 9 10

Cl
0

(3
c' 0

0
0 0

IO '0 i

11
12 13 14 15 16

60/6.0
60/8.0 100/10.0 120/12.0 140/14.0 160/16.0 0

0 0 c, 0 .---_. -_
0 0 0

0 0 0 0 0 )

0 T-7

Step/Handle multiple selection

x1000/x100
note 1) note 3)

I 1 I

0 mark means that the connection

go6a to grounding (ON). When both Ml and MP2 are grounded, in -0 of step, x 1000 in casa of handle x 100

not0

21

table 1 F step: upper mm/min. lower inch/min.

24

CNAl-4
MELDAS 6OOOC C N A 1 --4 --. Resolver excitation 1

I
I white

A B C
D

0 Rd i bRd2 OOdl boa2

If Resolver I

2 output 1 2

r---- I ----. 4 __+___ I 1

A B \
C

brown

red

12v

P R S

+12vA A N G i --12vk

??a _I;I

Analog signal grounding -12v

white Tachogenerator 1 r - - - - - - l

2 Tachogenerator

Shield grounded

The detector gear box for motor side

(note) (1) CNAl is for analog cable of X axis. CNA2 CNA3 CNA4 (2) 11 $1 11 Y axis. Z axis. 4th axis.

In interconnection diagram, above Q is indicated in case of CNA 1, X is marked. I, I, I, CNA 2, Y CNA 3, Z 11 11

CNA 4, the 4th 11

tnterconnection diagram for CNAl - 4 of MELDAS 5000C (for resolver detector)

25

3.3.2

MELDAS5100C list of input and output signals CNDl

cycle start automatic halt (feed-hold) tapa editing select memory oparation selact manual data input select tape command salect manual (handle feed)/ (step faad) selection manual fed selection
manual handle feed axis selection (X) ,, (2)

P*-

(the contact is opand for the fwd-hold state)

manual rapid traverse return to the zero select manual jog feed

I, emergency stop single block block delete

vrlnritv intrwunt (drv run)
_._W.., . ..__.._ r.--,

(the contact is opened for the emergency stop state)

input grounding

+24V feed hold indication cycle start indication the zero point indication (X axis) the zero point indication I2 axis)

Interconnection diagrams for CNDI of the MELDAS 51OOC (for relay output) . . . . . extra axes are excluded

26

CND2
MELDAS 5 1 OOC VRlh

feed override 1

I, ,, ,, ,,

2 4 8 16

display lock machine lock error detect chamfering multiple by 10 select absolute ON jog feed step 1 (IO mmlmin) ,, 2 (100 mm/min) ,, 3 (1000 mm/mini

ABS -Oh

FS2 _O FS3 -

input grounding

ON

constant

GRl -{ GR2 ___I GR3 -1 C R 4 .-I

(The points indicated by 0 shall be grounded to (ON) 1

input grounding

OJ -

external power supply ON

input grounding external power supply OFF

-4
P
small

IJ

PON * COM POF ___o

Interconnection

diagram for

CNDP of the MELDAS 51OOC

(extra axes are excluded)

27

CND3

MELDAS 5 10 OC M
function output T function output

Tll

M l 4

14

N fl

T14 T18 T21

f~

M 2 4

(v--j

I/ 11

T24 T28

U? command start

T command start TF T function ou\put common

traverse commend

M.S.T. completed

NC ready completed ,, c o m m oc n -

S command start

S function output common

Interconnection diagram for CND3 of the MELDAS 5100C

(for relay output) . . . . . extra axes are excluded

28

MELDAS
auxiliary function o;t&t NC alarm output

5100C MOO ALA

auxiliary function o;tl;t auxiliary function out ut MB3 the zero point detectgn ,# z

MO2 M30 DCX*

DCZ* ON RST 1 each of these contacts (normally closed contacts) shall be opened when the corresponding limit switch is pressed

input grounding NC reset output

7 overtravel +x ,, #, #, - x +z - z +Lx* -Lx* +Lz* --Lz* OL -v 31 each of these contacts (normally closed contacts) shall be opened when the corresponding limit switch is pressed

input grounding

servo ready

SA

external reset interrupt

E R S

--it---,

STLK --_I+

Interconnection diagram for CND4 of the MELDAS 51OOC (for relay output) . . . . . extra axes are excluded

29

CNAl MELDAS
rotary encoder A phase pulse rotary encoder B phase pulse rotary encoder one pub per revolution output
,, lamp grounding terminal rotary encoder +5W power SUPPlY

PA PB SC PLG +5H

---1 ?- _-_-_--I I _-------

A C B
M

_-_-----

I
I

_-_-_---

I
power supply -12V power supply grounding terminal power supply +12V

shield grounded

;
handle feed encoder B phase pulse handle feed encoder A phase pulse

i.L_______

HB

I spindle rotation analog output signal

I ~

----fdSPSC

;_-___-____q

Interconnection diagram for CNAI of the MELDAS 51OOC

30

CNA3

MELDAS resolver resolver

excitation 1 excitation 2 output 1 output 2

5lOOC A B C D

Rx1
Rx2 0x1

r__--_--(

&___--1
I +__-----

resolver resolver

0x2

I )__-_--1 I I I
P R S

+12v analog signal grounding terminal -12v

P
R

t12VI et
AN0 -12v

I I

tachogenerator output tachogmerator output

PXl PX2

!-_-__-_t K f - - - _ _ - _ I L

shield grounded

OG

(note) (note)

CNA3 is a cable for X axis analog signal. Refer to MELDAS 5000C CNAl - 4 interconnection diagram concerning to the diagram of detector gear box.

Jnterconnection diagram for CNA3 of the MELDAS 5100C (X axis resolver detector)

31

CNA4 MELDAS 5100 C

resolver excitation lrasolver

RZl

r---___,~

A B C

excitation 2-

RZ2
OZl

;_--____
;_--____

resolver output lresolver output

I z-

022

+12v -

I I

:__--___ I I I I

+12v.y

analog signal grounding terminal I -12v -

ANO.-12v ] I I
pz] !__--_--

tachogenerator output 1 -

I
tachogenerator output 2 -

---pz 2v

shield grounded

l
OG

(note) (note)

CNA4 is a cable for i! axis analog signal. Refer to MELDAS 5000C CNAl - 4 interconnection diagram concerning to the diagram of detector gear box.

Interconnection diagram for CNA4 of the MELDAS 51OOC (2 axis resolver detector)

32

CND8 MELDAS 5100C

A ) fjfj,O 1 return X axis data return X axis
strobe return E

axis command readout indicator (extrrhall

metric/inch select

X axis reset

Z axis data return 2 axis strobe return 2 axis reset

Z axis

l-

._-____---

I
No.3 axis data return No.3 axis strobe return No.3 axis reset

V W

I I
No.3 axis

I I I
I I

I
I

L___-----J
r -------- 1
I No.4 axis data return No.4 axis strobe return No.4 axis reset

e f

I I I
I

I
I

No.4 axis

I I I I

I
I

L-_-_--_-J

I I I I

common i

e&-w___________ RGbus RG

6s;

interconnection diagram for CND8 of the MELDAS 51OOC (for external axis command read-out indicator)

33

CHAPTER 4. BLOCK DIAGRAM

4.1 Block diagram (1)

73
CPU
I I
Paper tape reader

MEMORY

RAM

Machine Control Unit Line Receiver Relay Output

MCL!
Setting and indication board

Read-out counter

cl
Paper tape puncher Multidata display

cl
Buffer register Rput Bus Line

1 Ll--o%,-op-- I

r ____-

L-A--, J

T
DPM
Machine sequence

Drive motor

Output Bus Lina

M ; L

L ~ ,, R

Machine sequence control panel

R L k -1

34

4.2

Block diagram (2)

TfvE
c
P u, (LC3) FY-Jq

r
I

(LC2)

Standard spec. memory ROM

#l-+&I NC standard input signals

(LC4)

++jJf+
I

NC input signals relation to axis

(LC21) L A T

(x22 j

R L

NC standard output signals

-KU

(LC23)

c
note) Numerals of

LJ-g
M L ; L R TA R -)L -

--a

-.

-0

Machine sequence control input 81 output

(Z Machine sequence control panel)

():
+ S analogue output

Printed circuit board name

( -+

Spindle drive

SCR amplifierl

35

4.3
IT

MCU block diagram

___-7

.
I lI i II
I r .------~ I -

CNA

36

CHAPTER 5. THE FUNCTION AND THE HANDLING OF LOGIC CARD (from BNP-A2006)
5.1 The function of logic card

CARD NAME

FUNCTIONS CPU (central Processor Unitl input & output control Clock generator relation to CPU Auto restart function of CPU Control switch (to let CPU RUN/STOP by using toggle switches mounted on the logic card) Sequence instructions control Various kinds of ROM (Read Only Memory) 4 bits ALU (Arithmetic Logic Unit) Standard specification memory (ROM) The memory (C MOS) for parameter, zero shift setting, and various kinds of offset Calculation memory (RAM-Read access memory) Memory parity error generator Battery charging/discharging circuit Operation ready sequence System clock generator Timing generator Paper tape reader control Manual handle control

REMARK

LCl

LC2

LC3

Encoder Pulse buffer Circuit 1 NC standard input signal I/F Control words decoder for input & output I/F Setting and indication board I/F Spindle revolution detection (*I
Pulse distribution circuit, Smoothing circuit, Digital Phase Modulation circuit, Resolver exciter, Resolver output filter, Settings of servo system, Input interface relation to axis Flexible memory (RAM) Memory to memorize a processing tape ( BkW RAM 1 Program for option (Memory cycle, Tape editing, Punch out, Special fixed cycle, Nose R compensation) Battery backed up circuit Battery charging circuit Memory parity error generator

1) (*I MBlOOC o n l y 2) When Multidata display unit is connetted, a setting and indication
board can not be available.

Two axes are mounted on one logic card.

LC4

(LC20)

Optional card

LC120

LC21

Relay interface Read-out display (Four axes) S analogue output D/A converter Tape puncher control Multidata, d i s p l a y c o n t r o l OEMTlWJ BD JPJEKWE (fi LA- (CLy9 Memory for machine sequence control (ROM) Machine sequence interface

Optional card

LC22

Optional card

LC23

Optional card

37

5.2

Replacing and handling the logic cards

Switch off the NC power, and replace the card after opening the front door or pulling it out.

Card and card retainer Loosen the two screws and remove the card retainer before drawing the cards out.

Compact cabinet

Large-sized cabinet

a\

I I

Location where card basket is drawn out

This cable is easily damaged A Take care that the cable does not get entangled with the fixtures, etc., When drawing out the basket or replacing it.

38

Card connector (Touching this by hand may result is a defective contact)

__.__ \ (LC 3 card) 7 \

Mini bus

IC plug

AMP MODU connector

f!- AMP BLADE connector

(1)

Mini bus (power supply bus) The base of the mini bus is very easily bent and so take care not to touch it. It will break easily if force is applied to it when the cards are draw out.

(2)

AMP MODU connector When connecting or disconnecting this, rotate the screws at both end uniformly to loosen or to tighten them. AMP BLADE connector Take hold of this with both hands and pull to disconnect it. The reverse procedure is adopted for connection. Card connector Signals are exchanged when the card connector touches the receiving side connector and so when it becomes dirty, this will result in a faulty contact. Therefore, do not touch it directly. C MOS memory (LC2). RAM memory iLC1201, plasma display (LC22) When one of these is added, each of the C MOSS is employed and so after removing the card, it is necessary to cover it with aluminum foil and take sufficient care of static.

(3)

(4)

(5)

(6)
(7) (8)

The ROM memory, RAM memory and IC plug, etc, may work loose due to the vibration sustained during transportation. To forestall defective contact, an effective method is to push these parts in by hand. When removing the cards, take hold of the card in the corner position, and take out. After a card has been inserted, it is necessary to check whether the card has been inserted properly by observing the connector section of the card.

39

(LC 2 card)

RAM memory

C MOS memory

Handle this C MOS with care

A single card has 160 contacts which are connected by connectors at the receiving side with contact pressure. This means that it may require a great deal of force to remove and insert the cards manually.

Note)

Handling the AMP MODU connectors When connecting or disconnecting these connectors for exchanging the cards, etc., loosen the

left and right screws in the photo alternately or tighten them alternately, and never force them.

Loosen these screws alternately a little at a time and then detach them.

40

5.3

Regular inspection of logic cards

Apart from the relay mounted on the LC 21, the logic cards do not use consumables and so there is no need to conduct daily inspections. Nevertheless, after a year has elapsed, it is important for long-term use to clean the logic card connectors with alcohol, remove the dirt and dust adhering to the face of the cards, and check that there are no loose connect/ens in the ROM, RAM and the IC plugs (the setting plugs).

Cleaning the card connectors

Pushing in a ROM on the LC 120 card by hand

41

5.4

Logic card check points

Check point TPl TP2

Card no. LC4

Function X-axis error output Z-axis error output Phase difference (droop) between command DPM and resolver feedback signal 11F XaxisD= 150 x

Waveform

I+) n F-J-I-) command

J--LA
Pulse width = droop (calculated according to left) (704 /..&ec with a Z axis rapid traverse of 9600mm/min) L e v e l +lOV

ZaxisD=

m ,50

D = droop (/&.ec) F = feed rate (mm/min) So X axis x 2 = 0.5j.llP TP3 TP4 X axis resolver feedback signal 2 axis resolver feedback signal These signals are turned into square waves at the Schmitt circuit for TP5, TP6 TP5 TP6 X axis feedback signal 2 axis feedback signal Level = 12V 2: VP-P Amplitude fluctuation = less than 1.5% Frequency = 4.5kHz

....

Only with radius command (lathe)

I
Frequency = 4.5kHz Duty = 1

Level = logic level

TP7 TP8

X axis command DPM Z axis command DPM Command pulse is received and phase changes.

t With (+I c o m m a n d

I
Frequency = 4.5kHz Duty = 1 : 1 Level = logic level

TP9

DPM reference Used for resolver exciter

I
Frequency = 4.5kHz Duty = 1

Level = logic level

42

The check points given on the previous page are used for regular inspections.

It is also possible, however, to

use the connector pins at the rear of the logic boards and check the signals. This method of checking requires a very high level of expertise and a thorough knowledge of the whole machine system, and so it should be performed only by specialist maintenance personnel.

- Upper A 01 address (known as UAOl) - Upper A 40 address (lJA40)

b /------- Upper B 01 address WBOl)

I I I

1
I
I

=III

y;ftnngith ICs mounted (Side Al

Side with patterns (back) (Side B)

---.I
-Y
L

Upper B 40 address WB40)

- Lower 01 address (LB011

Front of logic card

Eadc

of logic card

L Lower B 40 addrass (LB401

Lower A 01 eddress (LAO11 Lower A 40 address (LA401

Card no.

Pin #
UAOl

Signal name

Description

Same for all cards UA40 LG LAO1 LA40 iI-UBOl UB40 7 5v LB01 LB40 !IDC 5V power supply DC +5V return

t,:, >

12V

DC +12V power supply

DC -12V power supply (Cant

43

Card no.

Pin #

Signal name

Description

LA1 3 L B 1 3 LA1 4 L B 1 4 EEt z , > 2 4 V DC24V power supply AG

DC? 12V return

L A 3 8 L B 3 8 LC 1 LAO 4 LAO5 LAO 7

L A 0 6

RG DA3F DAlF DABB DAlB STRBP RDA RDB RDC WRA WRB WRC SNSO SNSl SNS2 SNS3 CNTO CNTl CNT2 CNT3 CLKO CPCL MPER CALM L I T R MPER

DC24V return

output

CPU designation MCU designation

N u I N u 0 IJ I I 1 J I u I fl N
Input output _. Input output Input output

LC2 designation
PTR designation

LB04 L A 2 8
L A 2 9

Having a function to read in data of 16 bits from an input 81 output device (correspond to the address) designated by Device Address.

L A 3 0
L B 2 8

L B 2 9
L B 3 0

The contents of register designated (16 bits) is transfered to an input 81 output device specified by Device Address

LB3 1 L B 3 2 L B 3 3 L B 3 4 L A 3 2 L A 3 3 LA3 LA3 4 5

States that an input & output device designated by Device Address has are desired to search

The function that a control signal is transfered from CPU to an input & output device designated by Device Address

LA3 1 LJA23 L A 0 8 UAO 5 UA18 LC 2 LAO2

U A 2 4

9 MHz crystal oscillator CPU clock Memory parity error CPU stop

T
Memory parity error Parity bit ON

P B I T 0 H output

44

(Cont.)

UB07 UBO8 UB02 UB03 UA22 LC120 UA24 LAO2

DPMl DPPl DPM2 DPP2 DVAL P B I T O H MPER

N N u 1

Digital pulse minus (1 st axis)

,* ,I ,*

I, I, N

plus (1st axis) minus (2nd axis) plus

(2nd axis)

Drive alarm Parity bit ON Memory parity error

45

When adjusting this output signal, volume 1 (lower side) is for zero adjustment and volume 2 (upper side) for output voltages on this printed circuit board.

46

5.5

Inside setting on the printed circuit board

The location of IC chips (Address of IC chips on PCB LCl/LC3/LC4) IC chips are mounted on the printed circuit board as following. Vertical lines are indicated numeral and horizontal alphabetical.

The location of IC chips

IC location on memory board (LC2)

J 1 M I L.l 0 2 K 2 M 2 L 0 I I 3 M 3 J 13 13K1 0 0
1

UAOl

5 M K J I 15 I 0
5 5

(7-q pr-q
16 GI 16 FI

6 M 0 7 M I

16 17 (7
18 LI 18 KI

7 J I 8 J I

I-E-I

9 0

111 Gl 111 FI

48

Pin number of IC chips

UAO 1

14 13 12 11 10 9 8

In case of 14 pins

LA40

1 2 3 4 5 6 7 8

16 15 14 13 12 11 10 9

In case of 16 pins

UA40

-I
49

SETTING OF SERVO CONSTANT AND OTHERS

These settings are only for machine manufacturers because the settings are set to the optimum values before shipment from the factory. The settings can be done by changing the connections of the IC sockets on the printed cards mounted on the logic board in the controller.

(a)

Setting of time constant A servo time constant can be set by selecting required one system among the three systems of A on card LC3 (A 81 B) and setting its detail value on card LC4 (A & B). The rapid feed system for each of the axes can be selected on card LC4 as shown in Table 3. Identical values for axes 1 to 4 (X, Z axes for M5100C) should be set for the cutting feed. The rapid feed can be set for each of the axes within the same system. The setting procedure is shown in Table 1.

(b)

Setting of encoder type (only M5100C). switching of tape store and power controller These are for the switching encoders 1024P/rev. and 204B/rev., controller necessity. The procedures are shown in Table 1. and switching of tape store and power

50

Switch bf tape store necessity

Necessary IC location seal) Setting

3-14

zard Vame

Nil

No connection

2G

16 IM5100C only)

LC3

3-2G XlCl

!! B

Encorder

rrrangemenl 4003A a 3M 1 16

1024 I 2048

4-13

I
X-axis IX-axis) (Z-axis) -_

No connection

LC4 (A,B)

4-3M XIC3

>I

Time constant setting

Ttme constant system setting

krangemen 4004A

F a 9

2M

16 Z-axis

1 1

13 12

2 2

13 12

30ms 15ms

40ms 20ms

50ms 25ms

LC4 (A,Bl

4-2M XIC3

!Y-axis) L 14.axIsI - - -

Arrangemen 4004A

( ) indicates for M5000C

l Table 1

T
Servo time constant setting list

- Not with M5000C (parameter setting)

l The time constants of the cutting feed should be set to the same values for the X-and Z-axes

(c)

Setting of stop method at stroke end This is for setting a stop method at the stroke end, either the linear decelerationstop or the step stop. The setting procedure is shown in Table 2.

(d) Setting of command polarity switch This is for setting the rotary direction of the motor when a command is given for CW or CCW. The setting procedure is shown in Table 2. The polarity switch in the servo loop can be selected by the procedure in Table 3. This setting is required when the polarity of a command is opposite to that of the feedback signal in cases where the detector is mounted separately and the motor is connected directly.

52

I
Direction of motor rotation (with (+I command when viewed from load side)

c
Stop method at stroke end

Card name

C locatior seal 1

Setting

L axis X axis 1

xis jT -.

axis) axis)

--i -t- --l---I

Second LC4

axis 2 -axis Y-axis

Gis) LC 4 (A,B)

.
Setting Servo loop polarity Positive direction Negative direction Z-axis X-axis

t I I t I I I

Card lame

C location seal 1

1-16~2-15~3-14~4-13 5-12~6-11~7-10~8-9
OXXOOXXO XOOXXOOX

5J 4C5J 4-9M

16

(4 axis) - - - J

LC 4c

0 denotes connection X denotes cut !

Table 2

Setting list of stroke end and command polarity

m
0

c-4 -

i2
-

g d

i 8 -

F:

r-

m I
N

P %

2
I
N

hl

n Q

I
c-4

I
c-4

I
N

-_

c-7

c-4

54

5.6

Logic card maintenance parts

The only consumable part on the logic cards is the relay on the LC21. However, providing logic cards themselves as maintenance parts is an effective way of improving the machine tool operation rate.

Maintenance parts

Part name LC1

Standard

Q ty used

Remarks

Logic card

(A,B,C)

___._-_ N
____ __ _ N _ II

LC

(A, B)

L C 3

(A,B.CJ
1 for M5100C 2 for M5000C

L C 4

(A,B,C)

,,

LC120 (A, B ,

C >

LC

21

( A , B)

I, ___N

LC

22

( A , B)

Option

LC

23

(A,

1 -

Optlon -

Miniature relay

5 1

Used for LC21 relay I/F

The A, B and C after the card name are symbols which denote that the physical arrangement of the board has been changed. Their performance is identical.

55

CHAPTER 6. FUNCTIONS AND HANDLING OF STANDARD BOARD (from BNP-A2007)

6.1 Standard board and its functions
Board for MELDAS-5100C (Board SC511

,* J

Setting and indication board

POWER ON

Board for MELDAS5000C (Board SC57)

Functions 1. Control unit power ON/OFF 2. Control unit reset 3. Command indication (universal readout) 4. Manual data input setting/indication 5. Tool position offset, tool radius offset setting/indication 6. Parameter setting 7. Sequence number search 8. Present position indication 9. Alarm content indication 10. Input/output interface check 11. Tape load and tape punchout 12. Editing . . . . . . . . . . . . . 13. Erase . . . . . . . . . . . . . . . . . additional additional specification specification

For details on how to use the functions, refer to the Instruction Manual.

56

6.2 Replacing and handling the standard board

The SC 51 and SC 57 boards are connected to the interior of the NC unit with the 12-pole MR connector

and the 38-pole AMP MODU connector. They are mounted on the main control unit by eight setscrews.

6.3 Regular inspection of standard board

The power ON/OFF switch, reset button, a rotary switch for functions and the numeral and alphabet buttons contain parts that wear. If regular inspections are therefore conducted, it is possible to check whether these

buttons and switches are defective by using the function switch to display the various modes.

6.4 Checking and setting the standard boards

The SC1 (or SCl-1) logic card is mounted on the SC 51 (or SC 57) board, and the rotary switch and buttons are in turn mounted on this card. Furthermore, the two ROMs are plugged into the card by means of sockets, and if there are any defective contacts in these ROMs, trouble will be caused in the character display section at the left end of the board. Each of the character display and numeral display elements is plugged into sockets, and so these elements may work loose or their contacts may become defective. There are no special settings on the logic card inside the board.

6.5 Parts list of standard board

Name of part Rotary switch Push switch Diode Diode Diode Diode LED LED LED LED

Rating GRS 2, 40. 1, 12, 6, 7 FPS 6720526 TIL TLR TLR D-502 01-121 0 1 - 9 0 1 (R) LW-3128 (white) bezel AT-206 black attached 305 306 307 or KBH-A DL-57 Function

Remarks

Numerals, alphabet, etc. Character Numeral Code Lamp indication Reset button Reset button cap Power ON/OFF

Push switch Push switch cap Seesaw switch

57

CHAPTER 7. SETTING AND INDICATION BOARD FUNCTIONS AND HANDLING

7.1 PZ57 board (multidata display) functions and handling (from BNP-A2008)
7.1.1 PZ57 board and its functions

fN I23 G I7 G

02

- Power

switch

Key switches

I_
Multidata display unit

_ Mode selector
rotary swit?h

/- . .

[Functions] 1. MDI data setting/indication 2. Offset data setting/indication 3. Sequence number search 4. Tape editing and punch-out 5. Parameter setting/indication 6. Constant indication 7. Command position indication 6. Command indication 9. Buffer indication 10. Alarm indication 11. Input/output interface check For details on how to use the display unit, refer to the multidata Instruction Manual (BNP-A20321

7.1.2 Replacing and handling the PZ57 board The PZ57 board is connected to the inside of the NC unit by means of three 38-pole AMP MODU connectors and a 12-pole MR connector, and an unit. The MR connector is connected to the connector to the DC power supply, and the three AMP MODU connectors are connected to the receiving side of the LC 22 logic card.
AC

1OOV power line is connected from the inside of the NC

58

Note)

Handling the BECOJU connectors ( BECON : made by TELEDYNE KINETICS (TKC) 1 When connecting and disconnecting the BECON connectors when replacing the cards, etc., use a small Phillips head screwdriver to loosen the three section alternately, or to tighten them up. Do not force them. When attaching the BECON connectors to the card again, first wipe the card connection tabs which come into contact with the BECON connectors with a clean cloth (gauze, etc.) dipped in a little alcohol.

This board contains a high-voltage circuit with a maximum voltage of DC 300V. Therefore, when inspecting or replacing the board, be absolutely sure to switch off the NC units power first.

7.1.3 Regular inspection of PZ57 board

The power ON/OFF switch, the reset, key operation, puncher start, reader start and data send buttons, the mode selector rotary switch and the keys (alphabet, numerals, etc.) as well as the indication lamps and plasma display unit all contain parts that wear, and for this reason it is necessary to check whether there are any defects in the keys, lamps and rotary switch. It is also possible to clean the glass surface of the plasma display unit with a piece of gauze dipped in some alcohol.

7.1.4 Checking the PZ57 board

The LZ 07 logic card is mounted on the PZ57 board, and the plasma display unit is incorporated onto the top of the card by means of sockets. Inside the board is a glass-sealed fuse for the high-voltage DC circuit and so when this fuse blows nothing is displayed on the screen. Most of the board signals are connected to the LC 22 logic card and so it is possible to check for defective contacts in the three AMP MODU connectors and in the IC (character generator/keyboard encoder element) inserted into the IC socket on the top of the LC 22 logic card. There are no special settings for this board.

59

7.1.5 Parts list of Pi!57 board

Name of part

Location

Rating

Remarks .

Fuse Seesaw switch Push switch Switch cap Rotary switch Lamp Lamp

Glass-sealed fuse 0.3 A s 1 s 2 S6 s 2 S6 RSWl PL2 PL6 PL7 PC10

LW-3128 (white) bezel AT-206 black 0 1 - 1 2 1 0 1 - 9 0 1 MS-40PL40412A3015 O L - 3 2 7 0 L-552850 CODlX I, Green/Orange/White/Red

Saga 30 degree endless Oshino Oshino Green

Lamp holder

PLS2 PLS3 P&4 PLS5 PtS6

F - G A / C L / G

Oshino

Lamp holder .

F - G A / C L / R F - G A / C L / A R D M D 5 7 3 2 4 X Y G

Oshino

Red

Oshino Orange

Plasma type display

Okaya

60

~__-------_-- ----- ---

,Q

1 0,

1: = = :_ = = = = = = =0 J_______ =_=_ = =

Q II _J

61

7.2 DP51 and DP52 board functions and handling (from BNP-A2009)
7.2.1 DP51 and DP52 boards and their functions

Command indication board DP51 [Y- 2 for M5100C (2 axes) 1

The DP52 board illustrated above is for only one axis out of two axes. Command position indicator (internal) This function indicates the tape and manual command movement amount for each axis (X, 2 for M5100C, and X, Y, 2 and 4th axis for M5000C). It indicates the counted command pulses to the drive section. This is a coded decimal 8-digit indicator, and the decimal point is positioned to mark off three digits from the right with a millimeter system and four digits from the right with an inch system. The indicator is mounted on the NC operation panel.
l

Display lock function The above command value display is locked with an external input signal (DLK) ON, and even if a command is fed out, the same display will be held.

7.2.2

Replacing and handling the DP51 and DP52 boards

With two axes (or one axis) the DP51 board (or DP52) is constituted. The board is mounted with four setscrews and connected inside the NC unit by a 12-pole MR connector. With two axes, the SC 02 logic card is used for the board, and with one axes, the SC 02-l card is employed.

7.2.3

Checking and setting the DP51 and DP52 boards

Unlike a reversible digital counter, this command value indicator displays the command value stored inside the memory for each and every time interval. The digital pulse and strobe signal for the indicator are sent from the LC 21 logic card. There is no need for daily inspections but it is important to inspect to see whether the elements of the indicator are broken. In particular, the leftmost display digits are not used very often and it is often the case that broken elements are discovered when these digits are used.

62

The indicators elements are mounted with IC sockets and a display defect is sometimes mistaken for a loose contact.

DECIMAL POINT SELECTION OF COMMAND POSITION INDICATOR Apart from general machine manufacturers it is not necessary to set the decimal point display of the command position indicator to one of the digits. However, it can be set by connecting the center point to the digit pins with a short pin in accordance with whether the system is millimeter or inch.

dB
c--da
7.2.4 Light-emitting diode Light-emitting diode Push switch

z + 3 3 3 !I0 3, 3, 3. 3 -f _---__-------I ! 0. +_ ____ - --------- ----- -A I __-------- ----- -4

I
---------

11
I
I

rr

Point digit Millimeter canter point Inch cantor point

When the point digit and the canter point are shortad, that digit point will light up.

1
I

~_=___--------------_______I
_-m-w-

_-----

-I

r-;--i \q to 0; I 0 I lo 01

Command position indicator card

Lo_ __.J

Commend position indicator card and its setting

Parts list of DP51 and DP52 boards TLR307 (code) TLR306 (numeral) MSPE-106F Toshiba Toshiba

63

7.3 DP box 62A and 64A functions and their handling (from BNP-A2010)
7.3.1 Functions

These indicators are used when an indicator is to be installed on the exterior of the NC unit unlike the DP51 command position indicator (or DP52) which is mounted on the front panel of the NC unit. (It is installed when an indicator cannot be mounted because the standard board and machine operation board are mounted.) This function indicates the tape and manual command movement amount for each axis (X, 2 axes for M5100C; X, Y, 2, 4th axis for M5000C). It indicates the counted command pulses to the drive section. This is a coded decimal 8-digit indicator, and it is possible to select the position of the decimal point by means of an internal setting. The indicator is installed in a different location from that of the main NC unit. * Display lock function The above command value display is locked with an external input signal (DLK) ON, and even if a command is fed out, the same display will be held. -

7.3.2 Replacing and handling

This indicator is composed of the DP61 (or DP62 used together) board, and a DC 5V powersupply(input A C 1OOV). The board is connected to the signal line with an MR connector and the power line (DC 5V) is connected to the DC power supply. This means that even if there is something wrong with the indicator, repair work can be performed quite easily by replacing the DP61 (or DP62) board, or the DC power supply without having to replace the DP box 64A (or 62A). A glass-sealed fuse (5A) is used for the AC 1OOV line inside the DP box, and so when this blows, nothing is displayed on the indication section.

7.3.3 Checking and setting

When none of the indicator lights up, it is necessary to inspect whether the AC 1OOV power switch at the rear of the DP box is set to the OFF position and also whether the glasssealed fuse has blown. Furthermore, it is important to remove the DP box lid and check whether a DC 5V voltage is being made available by using a tester. For other details, refer to the section dealing with the checking and setting of the DP51

and DP52 boards (7.2.3). Decimal point position setting The indicator card LZ 02A-1 (for one axis), the LZ 02A-2 (for two axes) and the LZ 048 (used for both one and two axes) which drives the indicator are connected to the DP61A (or DP62A) board by BECDN connectors. The decimal point is positioned by changing over the setting pins of the card at the indicator side. The position of the decimal point can be changed with the LZ 02A-1 or -2 setting pin at the rear of the board.

Axis 1

Connect Connect Connect

? -4 $- - a ? - /\ b -Z b - /* b -

Decimal

: 1st digit from right Decimal point : 2nd digit from right
point Decimal point : 3rd digit from right point point

Axis 2

Connect Connect Connect

Decimal Decimal

: 1st digit from right : 2nd digit from right

3rd digit from right

c\ Decimal point : .I........

+, a, I\, 1

: the square form of the Japanese syllabary

7.3.4 Parts list Glass-sealed fuse DC power supply Toggle switch Push switch Light-emitting diode Light-emitting diode 5A MC3D-05 ST205N52 MSPE-106F TLR307 (code) Fujisoku Toshiba Voltek 5A

TLR306 (numeral) Toshiba

7.4 DP box 628 and 64B functions and their handling (from BNP-A2011)
7.4.1 Functions
These indicators are used when an indicator is to be installed on the exterior of the NC unit unlike the DP51 (or DP52) command position indicator which is mounted on the front panel of the NC unit. (It is installed when an indicator cannot be mounted because the standard board and machine operation board are mounted.) This function indicates the tape and manual command movement amount for each axis (X, 2 axes for M5100C; X, Y, 2, 4th axis for M5000C). It indicates the counted command pulses to the drive section. This is a coded decimal 8-digit indicator, and the position of the decimal point marks off three digits from the right with a millimeter system and four digits from the right with an inch system. The indicator is installed in a different location from that of the main NC unit.
l

Display lock function The above command value display is locked with an external input signal (DLK) ON, and even if a command is fed out, the same display will be held.

7.4.2 Replacing and handling

This indicator is composed of the DP51 (or DP52) board and a DC 5V power supply (input AC 1OOV). Both the signal line and power line are connected to the board by an MR connector, and this means that even if there is something wrong with the indicator, repair work can be performed quite easily by replacing the DP51 (or DP52) board, or the DC power supply without having to replace the DP box 626 (or 648). A glass-sealed fuse (3AI is used for the AC 1OOV line inside the DP box, and so when this fuse blows, nothing is displayed on the indication section.

7.4.3 Checking and setting

When none of the indicators lights up, it is necessary to inspect whether the AC IOOV power switch at the rear of the DP box is set to the OFF position and also whether the glasssealed fuse has blown. Furthermore, it is important to remove the DP box lid and check whether a DC 5V voltage is being made available by using a tester. For other details, refer to the section dealing with the checking and setting of the DP51

and DP52 boards (7.2.3).

7.4.4 Parts l i s t

Glass-sealed fuse D.C. power supply Toggle switch Push switch Light-emitting diode Light-emitting diode

3A MC3C-05 ST205N22 MSPE-106F TLR307 (code) Toshiba Voltek 3A

TLR306 (numeral) Toshiba

66

CHAPTER 8. FUNCTIONS AND HANDLING OF PTR-210 TAPE READER

8.1 Tape reader and its functions
This is the device to read in informations from a paper tape into NC unit. As all information can not be read at once, it is formed of magnets for start and stop control, light source in order to read informations from a paper tape and photo-cell to change an electrical signal.

(from BNP-A2012)

ITk-----W Channyl

9 PCS.

L-

-p-p<

DCBV

Light soure

Start magnet

Stop magnet

Drive circuit

< MOTOR AC1 OOV

OE=+

<

Fig. 8.1

Configuration of tape reader PTR-210

67

Lamps .__. ~

,/,,

OptiT

Brake armature

Photo-cell

Drive magnet

Fig.

8.2

Mechanical configuration of the tape reader

Impedance converter

0 p

= --G- T r a n s i s t o r E B-

.
-

a
> ___) 1 1

2 3 4 5 6 7 6 Sprocket output

Fig.

8.3 Signal reading section

68

8.2 Replacing and handling the tape reader

Card

&la clamp Reader connector Tape handler connector

AC lOOV, DC 5V, 24V ground terminal boards .~ IT1 terminal)

Fixed screws

Fig. 8.4

Rear of tape reader

Note)

When the tape handler does not conform to the specifications, it will not be connected anyone to the tape handler connectors.

Removing the PTR-210 tape reader

i)
ii) iii) iv)

Detach the cable clamp. Detach the externally connected wire connected to the Tl terminal. Detach the P5 connector (See Note 1). Remove the four tape reader fixed screws. After following steps (i) to (iv), it is now possible to remove the PTR-210.

69

Note I)

Removal of connector P5
Depress i/ Lock button

With the lock button depressed, pull the connector firmly in the direction of the arrow,

Fig.

8.5

Removal of tape reader connector P5

Note 2)

There are no settings for the PTR-210 tape reader, and so it can be replaced as

it is.

8.3 Regular maintenance and inspection of tape reader (1) Lubrication

Since a shield type ball bearing and oilless material are used for the bearing section of the capstan motor, no lubrication is required except for overhauling. If the tape lid becomes stiff, apply a little motor oil and grease to the toggle spring.

Motor oil

Grease

spring

(2) Cleaning Dust and dirt adhering to the reading face are liable to be a cause of misreading. Clean the tape path occasionally with the supplied blower brush. A swab dipped in isopropyl alcohol is useful for wiping off debris attached to the capstan, pinch roller, and photo sensor with the oil of the tape when not blown away with the blower brush. Furthermore, if the surface of the optical plate becomes dirty, the attenuation with respect to the light will increase and this is the cause of erroneous read-out. Therefore, wipe the surface of the plate, and especially the ends and curved sections with a swab dipped in a _small amount of isopropyl alcohol.

70

Optical plate Curved section

Clean the parts with this swab dipped in a small amount of isopropyl alcohol.

\ Photo sensor
roller

(3) Reading lamp section Remove the lamp cover and slide the optical plate to the right and left, and back and forth with the screw so that the light beam focused by the lens comes to the center of the photo cell and its width is 2 to 3 mm on the cell.
Focused beam

Photo sensor

Photo cell

(4) Lamp replacement When the inside glass face of the lamp becomes black, replace the lamp even if it is not burnt out. The average life of the lamp is 2,000 to 3,000 hours.

_--- --- Pair of tweezen or

similar instrument

Pull out

71

(5)

Belt replacement Two belts of the same type are looped over the capstan and motor pulleys for securing the drive when one of the belts stretches, wears or breaks. In cases like this, the defective belt should be replaced with a new

one. Two belts are necessary for ensuring the reliable operation of the drive. The average life of the belts is 4,000 to 5,000 hours.

Belt

Capstan pulley --- Motor pulley

(6)

Tape reader tape and sprocket channel adjustments 1) First slip the all marked tape in the tape reader over the ring (endless). Next, detach the reader connector and attach the tape reader channel checker. Set the tape reader operation switch to MANU. The tape should now start to run continuously. In this state, connect the sprocket signal to channel 1 of a synchroscope and attain synchronization with the same signal. Then observe the data output on channel 2 of the synchroscope, all the while comparing it with the sprocket signal. If the waveform of the signal resembles that in the figure below, the signal is satisfactory. If there is no resemblence, rotate the variable resistor at the rear of the tape reader and adjust.

Make sure the reading lamp section is checked beforehand.

all marked tape

72

- 1 period (100%: about 5 ms)-

H Sprocket L

- 2 5 -45%(center value

HData 1 to 8 L More than 5% _____

35%)

- 50 - 8 0 % (center value: 85%)

Data channel 8 Sprocket channel \ Data channel 7

Data chennel 4 Data channel 3

..

Data channel 2 Data channel 1

Data channel 5 Data channel 8

Tape reader channel checker

73

2)

Adjust the tape reader data output by rotating the adjustment variable resistor, all the while observing the waveforms on the synchroscope as in the above adjustment. The pulse width increases when the

variable resistor is rotated to the right, and the width decreases when the control is rotated to the left. Adjust the variable resistors for each channel to produce the required waveforms. VRl is for channel 1, VR2 for channel 2 . . . . . . . . . . VR8 is for channel 8. VRQ is for sprocket adjustments.

\
Sproc channrl

. Da

Note)

The variable resistors are set before the NC unit is shipped from the factory and not be adjusted unless absolutely necessary. R31 R32 R33 R34 R35 R36 R37 R38 R39 Data channel 1 Data channel 2 Data channel 3 Data channel 4 Data channel 5 Data channel 6 Dara channel 7 Data channel 8 Sprocket channel

SO

they should

74

8.4 Tape reader check procedure

Tape reader trouble-shooting chart

Symptom
1 Drive magnet is not excited even when RUN signal is supplied

Cause 1: Failure in drive circuit 2. Disconnection in drive magnet Repalr.

Remedy

Replace magnet. Adjust tape guide lever or replace micro switch.

3. Defective tape guide lever switch

4. Defective connector contacts in any of above three circuits

Repair or replace.

No tape feed even when drive magnet is excited 1. Gap between pinch roller and capstan roller is too wide. Adjust the position of the drive magnet.

2. Tape seam has caught on brake magnet or another part.

Correct seam.

Defective tape feed I, Gap between pinch roller and capstan roller is too wide. Adjust the position of the drive magnet. 2. Worn capstan roller Replace capstan roller.

3. Failure in capstan motor 4 Brake magnet is not excited even when stop signal is supplied 1. Disconnection in brake magnet 2. Disconnection in brake magnet 3. Defective tape guide lever switch

Replace motor. Replace magnet Replace magnet Adjust tape guide lever or replace micro switch.

4. Defective connector contacts in any of above three circuits Repair or replace.

Output width of all channels is below regulated values with a holed tape

1. Failure in photo cell 2. Failure in photo cell bias circuit 3. Disconnection in lamp

Replace photo cell.

Check circuit and repair.

Replace lamp.

4. Defective connector contacts

in

any of above two circuits

Repair or replace

..yIII~LIII

bOJC

r;,,,r;)r

Output width of all channels is above regulated values with a hole-less tape

/ Replace photo cell 1. Failure in photo cell ~___ __----c_-_ /

2. Failure in readout circuit Check circuit and repair. .._---

One or more of the channels signals are supplied only intermittently

, 1. Failure in photo cell _ _ - . k--

2. Defective punched i

3. Dirty focusing lens

---- t---._..__-_-..

i Replace photo cell. _--+_.____-----__ i Replace with tape having tape holes / punched ho,es /
Clean lens.

corr ectly _

8. Defective data seam 8 End of optical plate at lamp side heats up and melts Defect in constant-voltage circuit for lamp power supply (normal voltage of lamp 1s DC 18V) , Replace the transistors for the constantvoltage circuit or replace the Y\I Ihole unit.

8.5 Parts list of tape reader

Lamp unit Gum belt Optical plate Capstan roller

76

_-

CHAPTER 9. POWER SUPPLY FUNCTIONS AND HANDLING

The MELDAS5000C/51OOC contains a main power supply (PD08 or PDO9) which serves to supply power to each of the units.

9.1 PD08A power supply functions and handling (from BNP-A20131

9.1.1 Functions

Output terminal blodc

Input AClOO/llOV 50/50Hz

Converter

\ /

PM3A card +12V constantvoltage circuit Power switch-on sequence auxiliary circuit

+12v +24V 5v

AClOO/llOV selector

1
1-

Battery alarm output

50l60Hz selector

+24V coarse

+6V 30A switching regulator

Fig. 9.1

Block diagram of circuit

77

9 f-

1
J

DJ 2 I
1

Tl

20
AC 1OOV IN 3 4

4-l-Q
Fl

p
DJ 2

5 AC 1M [ 6

To paper. tape reader

7 AC loo

8
9

Ok
E E 1p 2&_

G
1

I
Fig. 9.2

k
Lw 2

Card PMBA

t 24v 6 7 RG + 12v

Charger circuit

AC -12v LC

Relay drive circuit

9 10

To logic card section

11 12

+ 5v REBLL

PD08A power supply diagram

9.2 Functions and handling of PDOSA power supply (from BNP-A2014)

9.2.1 Functions

ON 0
G O

OFF 0

Ii

lFuse HAC1 WV N I---5V 20A SW power SuPPlY

/--I

+5v

GND

+24V

GND

+ 12v 0.8A SW power SuPPlY

I---+
I I

+12v

0 GND

0 -12v

Fig. 9.5 Block diagram

79

9.2.1 .l Power switch-on sequence When the NC power switch is set to ON/OFF by the relay drive circuit, a sequence is formed under which a 5V ?12V, 24V DC voltage is made available. The output voltage detector circuit serves to generate a power failure signal (when either the 5V +12V or 24V voltage is not made available), and this sets the NC unit to the same state as when the NC power switch is set to OFF.

9.2.2 Replacement and handling

VAOJ

0
$5

Fig. 9.6 PDOSA power supply unit

9.2.2.1 Power supply unit removal

(i) Detach all the lines which are connected to the TB23, T624 and TB25 terminal boards.
(ii) Remove the four power supply setscrews. The DC power supply can now be removed.

9.2.2.2 Power supply unit replacement The terminal board connection lines have the terminal board number and terminal number marked on them. Take note of these numbers to connect the wires properly. This power supply is not provided with frequency (50/60Hz) or lOOV/llOV selection functions.

80

9.2.3 Check procedure Input/output voltage check The input/output voltage check is performed at the TB23, TB24 and TB25 terminal boards. AC input 1OOV AC output IOOV DC +24V DC +5V DC +12V DC -12V TB24, across pins 7, 8 TB23, across pins 8, 9 TB25, across pins 8, 9 TB25, across pins 1 (or 2) and 4 (or 5) TB23, across pins 1 (or 2) and 4 (or 5)/ 10 and 12 TB24, across pins 3, 4 TB24, across pins 4, 5

Refer to the table below for the output performance.

Rated output voltage Total voltage fluctuation Ripple voltage

5v + 2% less than 50mV

12v

-12v

24V +15% -10% less than 2.ov

+ 2% less than 50mV

+ 2% less than 50mV

The values in the above table are to be referred to as a general guideline. In order to feed out the constant DC voltage, variable resistors are provided on the circuits for adjusting the voltages. However, do not use these resistors for adjustment since the operation requires the use of a number of measuring instruments.

9.2.4 Parts list Glass-sealed fuse GMB125V o r MF51NR 10A 10A Asahi Toyo Fuse

81

9.3 PMlOA charger functions and handling (from BNP-A20151

93.1 Functions

Terminals for battery leads BT (+I BT (-1

MR connector
(power supply)

MR connector (logic board)

Charger moun screw ss Iction

Fig. 9.7

Output terminal blodc (MR connectorl

Battery charger circuit Battery alarm output circuit Input AC voltage detector circuit BT (+J BT (-)

Block diagram of circuit

Other circuits are also included for charging, when the NC unit power passes through, the battery which is used to back up the tape editing memory.

82

0 Battery charger circuit This circuit serves to convert the AC 13V input voltage into a DC 5.3V to 6.7V voltage and feed it out. There is a selector switch to select between nickel-cadmium (NiCd) and lead (Pb) batteries in accordance with the battery being used. When the battery voltage decreases, the contents stored in the tape editing memory may be destroyed and so a function is provided which generates battery alarm signals.

9.3.2 Replacement and handling Disconnect the two MR connectors indicated in the photo under 9.3.1, remove the two screws which anchor the charger, and the charger can then be removed. Be careful of static on the printed circuit board and take care not to touch it since it uses CMOS ICs.

9.3.3 Check procedure In order to check as if the battery voltage is over 5.45V (NR6F-4 NiCd, Japan Battery), check first that the above battery is supplying the rated voltage by measuring the voltage at the BT(+) and BT(-) terminals illustrated in the photo in 9.3.1. (Measure both when the NC unit power is on and off.) To check whether the battery is charged, disconnect the same ET(+) (or BT(-) 1 terminal (by loosening the screw), insert an ammeter (0 to 1 OOOmA) and check that a current ranging from 0 to 300mA is flowing.

9.3.4 Parts list NiCd battery Pb battery NR6F-4 PE20-6A Japan Battery 6AHr

Japan Battery 20AHr

A pan head iron screw (3 x 0.5 x 8) is used for the terminal board at the charger side and so it is necessary to mount an EJST 2-53 blue AMP terminal made by AMP which matches the screw after first pressuring (clamping) it to the battery lead end.

9.3.5

List of ratings relating to charger

LC /20 I tern
Model 1 Specifications Manufacturer Japan Battery 3.3v Min. 5.45V at 45C -5e to +45C ,I Over 3 years 5 Precautions for use Set switch to NiCd Japan Battery 5.1v 6.75 to 6.9V max oc to 45C ,, 3 years Set switch to Pb Set switch to center position in order to prevent discharging, load locally and set to Pb side. Maintain charge at 6.2V every 2 months. 0 to 1.2A mex 24 hours 100% 15 to 20 hours power with a 1 hour charge Memory capacity 16kW = 50mA NiCd battery (6AHr) NRGF

Pb battery (20AHr) PE20-6A

Remarks

0%
2 Battery voltage 100% 3 Usable temperature Operating Storage

Storage precautions

None

7
8

Storage precautions

Store flat in a cold, dark location. max Cl20 + 260 to 300mA 24 hours 90 to 95% (5.4A) 5 hours power with a 1 hour charge (at 0%)

Charging current Charging time (from 0% to 100%)

T/ Charge ~~ recovery rate

11 12 13 Charging/discharging ratio ( a t 16kW)

Battery error detection voltage Overdischarge prevention voltage

/ /

Less than 4.OV None Less than 4mA 3.3v fl.lV/CL)

5.4 to 5.6V
I

5.4 to 5.6V Less than 4mA 5.25V (1.75OlCLI

Recovery with 6.1V

14 / Battery leak current (charging side) 15 16 17 Discharge stopping voltage Charging voltage Storage characteristics

Max 300mA with 6.9V

6.8 to 6.9V 40% in 6 months if fully charged battery is left in 459: 500 times

45 days, 0% at 2OC

Period left 50% capacitance of initial period

18

Life cycle

500 times

84

9.4 Battery handling (from BNP-A2016)

The batteries which are used with the MELDAS can be broadly divided into two types. One is the small-sized battery (4/450RS) which stores the system parameters, and the other is the large-sized battery PE20-6A) which backs up the tape editing memory. When replacing the small-sized battery, it is necessary to remove the LC2 logic card first, and when replacing the large sized battery, it is necessary to remove the LC120 logic card. The photos show the mounting positions of the batteries. (NR6F-4,

9.4.1 Replacement

Battery (4/450RSl

Fig. 9.8

Position of battery with large cabinet

Fig. 9.9 Battery 4/4501X

85

Battery (NR6F-4)

Fig. 9.10

Position of battery with large cabinet (rear of cabinet)

A
Fig. 9.11 Battery NR6F-4

4/450RS NR6F4

Battery

Fig. 9.12

Position of battery with compact cabinet

9.4.2 Parts list

NiCd battery NiCd battery Pb battery

NR6F-4
4/45QRS

P E20-6A

87

CHAPTER IO. DRIVE AMPLIFIER FUNCTIONS AND HANDLING

10.1 Drive amplifier (3S10/20/406) functions and handling (from BNP-A20171

10.1 .l Functions
Axis SCR AMP
T \I

3.phase transformer r-----

Axis reactor :NF~ - - - - - ~

--

- --1

Relay unit
II r---7 1

Spindle motor + detector gear box r - - - - - - - -1

Grounding plate

0
47

i!

L______~-G

i___; [y

Logic board
I-_____-__

r - - - -

- --_

5 Il-?

System diagram of drive amplifier (3810/20/408)

The drive amplifier serves to amplify the error voltage (command voltage) which is a comparison of the operation result output and the position detector output, and to drive the DC motor mounted on the machine tool. The drive amplifier unit is composed of the control card (THABS-A/B) and SCR stack as well as the no-fuse breaker (NFB), and thermal relay (for overload alarm applications).

10.1.2 Replacement and handling The amplifier is connected externally with the APl and AP2 MR connectors and the cables protruding from the thermal relay and no-fuse breaker. The actual unit is mounted on the NC cabinet with four setscrews. AP2
h

API
out when it is activated) - Thermal relay (This is actuated when an abnormally high load is applied to the motor.)

M R connector control card to 4

Control Card THA3S-A/B

LJ6

V6

W6

.
No-fuse breaker

Exterior view of 3S-10/20/40A/B

88

Mounted on the control card of the unit is an IC plug for frequency selection. Therefore, when replacing the unit, set the frequency to that of the plants power supply and set as shown in the figure below.

50Hz

60Hz (a) For 50Hz (b) For 60Hz

Frequency setting

10.1.3 Regular inspection

There is no particular need for inspection except when the positioning accuracy is poor and it cannot be compensated for even with backlash offset, and when there are other similar problems.

10.1.4 Checking and setting

The control card of the unit is provided with variable resistors and check terminals. The variable resistors are adjusted before the unit is shipped from the plant or when it is installed. This means that adjustments should be lefe to the NC serviceman or a properly trained maintenance engineer. The positions of the variable resistors and check terminals, together with their functions, on the control card are shown in the figure for reference. When replacing the unit, it is important to check that the direction of the IC plug for frequency setting, the setting of the brake across fi and 7 the unit was replaced.

, and across _(-

-f-j\ and 4-z are the same as before

89

10.2

Drive amplifier (SA20/40A/B) functions and handling (from BNP-A2018)

10.2.1 Functions

Transformer

-ran+n,

I- l !I
I
E
n

I I-i-v
Bhl

, ve
,._
TG

L--------:

1
System diagram of SASOAIB, SMO/A/B

.!!

LMR connector which connects th e

control card to the thyristor stadc SCR amplifier SA?A 8. SAlA B _. -I

drive amplifier

The drive amplifier serves to amplify the error voltage (command voltage) which is a comparison of the operation result output and the position detector output, and to drive the DC motor mounted on the machine tool. The drive amplifier unit is composed of the control card (TH30A) and SCR stack, as well as the no-fuse breaker, thermal relay (for overload alarm applications) and brake resistor.

91

10.2.2 Replacement and handling

The drive amplifier is externally connected with the ZPl and ZP3 MR connectors and the TB121 terminal board. The actual unit is mounted on the NC cabinet with four setscrews.

Control card

t THJOA
MR connector which \
connects the control card to the thyristor stack \\ \

Thyristor stack Brake resistor Reset lever This lever flies out when it is reset. \

1 No-fuse breaker (~~1311 dial scale

Thermal relay This is actuated when an abnormally high load is applied to the motor.

Relay

Terminal blocks

(TM21

Exterior view of SA20/40/A/B

Mounted on the control card of the unit are two switches for frequency selection. Therefore, when replacing the unit, set the frequency to that of the plants power supply.

10.2.3 Regular inspection There is no particular need for inspection except when the positioning accuracy is poor and it cannot be compensated for even with backlash offset, and when there are other similar problems.

92

10.2.4 Checking and setting

The control card of the unit is provided with variable resistors and check terminals. The variable resistors are adjusted before the unit is shipped from the plant or when it is installed. This means that adjustments should be left to the NC serviceman or a properly trained maintenance engineer. The positions of the variable resistors and check terminals, together with their functions, on the control card are shown in the figure for reference. When replacing the unit, it is important to check that the direction of the frequency setting switches (21, the setting of the speed feedback resistance selectors ( replaced.

b , ;f, I, Jb and 4 ), the setting of 9, Y. b, 3, z , and t , as well as the setting of 4, a, ~1, *, 3, a, 7 and h are the same as before the unit was

Speed faadback resistance selector

F

Manual spmd input Position loop gain Currant P o s i t i o n loop/ Tzdback faadback gain adjust \ s?sZ%:p \ \ \, \ \ /

C u r r a n t l i m i t servo Offset lC21 output Sped command / I/ IC21 zero adjust / /

CPl,

Ll+, ; 1 1

CPlZiU

Firing angle uancy Servo offset ut comparison adjust IC41 input comparison adjust Exterior IC51 zero adjust

CP 13 j v+ CPlliV cp15,w+ CP16IW

view of TH30A control card

Setting The frequency must be set to the power line of the plant, as mentioned under (21, on the control card.

93

10.2.5 Parts list Circuit breaker (No Fuse breaker) Thermal relay Thyristor stack Relay MC1 RL3 RL4

94

CHAPTER 11. SPINDLE CONTROL DRIVE AMPLIFIER FUNCTIONS AND HANDLING

11.1 Spindle control drive amplifier (S3S50/60A/B) functions and handling (from BNP-A2019) 11.1.1 Functions
Main no-tuoo brukor
TB2 NFBl

Rrctor

To NFB 101

3-phau } To TB13, ground

Domactic 2OOV,,22OV 50& 6CHz

terminal blodc

2OOV. 22OV: 24OV, 38OV, 4OOV42OV 4 4 0 V . 46OV 48OV, SlOV, sSOV, 55uV

System diagram of spindle control drive amplifier

The spindle control drive amplifier serves to amplify the output which has been converted into analog voltage from the S command by the D-A converter and to drive the spindle DC motor mounted on the machine tool. The spindle control drive amplifier unit is composed of the two control cards, SCR stack (sometimes including that for field systems), the no-fuse breaker and the thermal relay.

11 .1.2

Replacement and handling

The drive amplifier itself weighs more than 20 kg and it may take more than one person to replace it. As mentioned above, the unit is composed of two control cards and two thyristor stacks and so it may be possible to deal with defects by replacing the control cards or the stacks.

95

No fur breakor
NFRlOl

1
F2 8

Main motor SDN-BA

T Bl 01

-I
Ii

Intrrpolo

A 0 t

Grol

30 200v

Thrmostat *6----l CP 1

Spindle control drive amplifier S3S6OA/B

96

Spindle motor
1 DC12 0 IB

$cklp UC11 A 0 D

TB13

Ground
AJ 2 AP 2

zoov

If
7,s
0
11 ,l2

Main current detection rwistor

990 b

Card
THA3S-BSO THAS3S B O

Mounted on both the (1) and (2) control cards of the unit are the IC plugs for frequency selection.

Therefore, when replacing the unit (or control card), set the frequency to that of the plants power supply.

11 .1.3 Regular inspection There is no particular need for inspection except when the frequency shifts or there is rotational drift.

11.1.4 Checking and setting The control cards (1) and (2) of the unit are provided with variable resistors and check terminals. The variable resistors are adjusted before the unit is shipped from the plant, or when it is installed. This means that adjustments should be left to the NC serviceman or a properly trained maintenance engineer.

97

11 I
Control card (2) Control card (11 THA3S-ES0

U6

V6

W6

0
OFF

--Il
0
AF104 AJ104

NFBlOl

MRP3 LJ

Exterior view of spindle control drive amplifier S3S50A

99

This switch should be always P side

Current feedback IC 1 output (TG feedback) The measurement of TG feedback : Use CPll on the control card (2)

Synchronous signal

Speed command Current limit 1 IC 1 zero adjust IC 11 zero adjust

Current limit 2

IC 11 output Servo compensation

mt )(u-)(V,)(V-)(W-)(W-)
uvv_ -

az&S&

RV RV RV RV RV RV

Firing angle adjust

$@pj@@
Frequency selector IC plug Cp22 C P 2 3 C P 2 4 C P 2 5 Cp26 @ Q Q Q Q-Firing angle Ground terminal

Spindle control drive amplifier card (1) ~~~$:$~0

exterior view

-. Frequency selection IC plug

CPl CP2 CP3 CP4 CP5 CP6 CPll CP21 CP22 CP23 CP24 CP25

S analog auto input S analog clatch change output ICl output IC2 output IC3 output IC6 output TG feedback IC21 output IC22 output IC23 output Rated field cur! ent IC24 output

CP26 CP27 CP31 CP32 CP33 CP41 CP42 CP43 RVl RV2 RV3 RV4

Field current feedback Weak field start point (only THAS3S6) Synchronous signal U Synchronous signal V Synchronous signal W Firing angle U Firing angle V Firing angle W Spindle override {option) Inching speed L clutch speed M clutch speed

RV5 RV6 RV7 RV8 RV9 RVlO RVll RV21 RV22 RV23 RV31 RV32

H clutch speed Manual input setting ICl zero adjust IC2 zero adjust Zero adjustment of CP6 Acceleration/ deceleration timing setting Not used Meter correction Zero speed Zero spees setting Armature feedback IC21 zero adjustment

RV33 RV34 RV35 RV36 RV37 RV38 RV39 RV40 RV51 RV52 RV53

IC21 zero adjustment Weak field start point Field control compensation IC23 zero adjustment Minimum field current Rated field current Field current loop compensation IC24 zero adjustment Firing angle U Firing angle V Firing angle W

Spindle control drive amplifier card (2) ~~~~~~:~~~

exterior view

101

The positions of the variable resistors and check terminals, together with their functions, on the control cards (1) and (2) are shown in the figure for reference. As mentioned in 11 .1.2, it is necessary to set the frequency in accordance with the power line of the plant on control cards (1) and (2). 11.1.5 Parts list No-fuse breaker Thermal relay Thyristor stack (main circuit) Thyristor stack (field circuit) Relays MCI MC2 RLYl RLY2 RLY16

102

11.2

Spindle control drive amplifier (SSGOA/B/C-MA/NO) functions and handling (from BNP-A20201

11.2.1 Functions
Main no fuse breaker YKHI I

3.phase main transformer

Reactor

Primary tap selector terminal block i

to
THI I t o

TRI:i
Earth

to
TRI I

,,;I
II

L!+J

.--~~

Main current detector resistor _. .~_ ~rator

from

Card THA3S-BS

Card

! THAS3S-BB I

Fig. 11.1

Block diagram of spindle control drive amplifier (I)

103

No fuse breaker Main thyristor sta

)I

Spindle motor

Earth J
/ Thvrictnr stack far field

from TBI 36 05.

.&A

Tachogeneratol

06--..
07. from TB2
08 09 I

\ R3 f%ld current MC2

&
,I M? !

w I s?c

/ detector resistoi u Thermal relay for fan motor CrJ^ v A OCR2 ) I n h

1 I

I
Card THA3S-BSO Card THASBS -BBM

I_

Fig. 11.2

Block diagrati of spindle control drive amplifier (2)

104

The spindle control drive amplifier serves to amplify the output which has been converted into analog voltage from the S command by the D-A converter and to drive the spindle DC motor mounted on the machine tool. The spindle control drive amplifier unit is composed of the two control cards, SCR stack (sometimes including that for field systems), the no-fuse breaker and the thermal relay.

11.2.2 Replacement and handling

TH 1 :i

Control card (2) THAS3S-00MlBB

Control card (I) THA3S-BSIBSO

TBlOl

SHT 1

OCR1 I lll1llllll

arrangement I

TBII

//

TBll terminal arrangement I Reset lever (This lever flies out when it is reset.)

Thermal relay (This is actuated when an abnormally high load is applied to the motor)

SSGOA/B/C-MA/NO

spindle control drive amplifier

The drive amplifier itself weighs more than 20 kg and it may take more than one person to replace it. As mentioned above, the unit is composed of two control cards and two thyristor stacks and so it may be possible to deal with defects by replacing the control cards or the stacks.

105

11.2.3 Regular inspection

There is no particular need for inspection except when the rotation is not settled or rotations commanded can not be got.

11.2.4 Checking and setting

The control cards (1) and (2) of the unit are provided with variable resistors and check terminals. The variable resistors are adjusted before the unit is shipped from the plant, or when it is installed. This means that adjustments should be left to the NC serviceman or a properly trained maintenance engineer.

Keep this switch at [PI __-S p e e d s e t t i n g - - - -

Armature current feedback ICl output

lr/

(TG feedback) Measure the TG feedback at CPll of the control card (2) -- Speed command ~ Current limit 1 3

Synchronous

signal

)--- ICl
Current limit 2

zero adjust

- ICll zero adjust

_-___ Servo offset

~ ICll output

~ Firing angle adjust

Frequency selection IC plug

~ Firing angle

(Lb)
E 8

(1' ) (V 1, ,'(V-1

(W-J

Ground terminal

Exterior view ofTHASS-BS THA3S_BS0 sp indle control drive amplifier control card

106

F. SF:I,F:(:T

Frequency selection IC plug

CPI CP2 CP3 CP4 CP5 CP6 CPll CP21 CP22 CP23 CP24 CP25

S analog auto input S analog clatch change output ICl output IC2 output IC3 output IC6 output TG feedback lC21 output IC22 output IC23 output Rated field current IC24 output

CP26 CP27 CP31 CP32 CP33 CP41 CP42 CP43 RVI RV2 RV3 RV4

Freld current feedback Weak field start point (only THAS3.S6) Synchronous signal lJ Synchronous signal V Synchronous signal W Frring angle U Firing angle V Firing angle W sp;yz;)override
o

RV5 RV6 RV7 RV8 RV9

RVI 0

H clutch speed Manual input setting ICl zero adjust IC2 zero adjust Zero adjustment of CP6 Acceleration/ d,eceleration trmrng settrng Not used Meter correction Zero speed

RV33 RV34 RV35 RV36 RV37 RV38 RV39 RV40 RV51 RV52 RV53

IC21 zero adjustment Weak field start point Field control compensation IC23 zero adjustment Minimum field current Rated field current Field current loop compensation IC24 zero adjustment Firing angle U Firing angle V Firing angle W

RVll RV21 RV22 RV23 RV31 RV32

Inching speed L clutch speed M clutch speed

Zero spees setting Armature feedback IC21 zero adjustment

THAS3S-BB Fig. 11.5 Exterior view of THAS3S_BB&,

spindle control drive amplifier control card (2)

107

The positions of the variable resistors and check terminals, together with their functions, on the control cards (1) and (2) are shown in the figure for reference.

Setting As mentioned in 11.2.2, it is necessary to set the frequency in accordance with the power line of the plant on control cards (1) and (2).

11.2.5 Parts list Circuit breaker (No-fuse breaker) Thermal relay Thyristor stack (main circuit) Thyristor stack (field circuit) Relays MC1 MC2 RLYl RLY2

RLY16

108

12.2 HD m o t o r
12.2.1 Regular inspection of HD motor

(1)

Inspection of brush Inspect the brush about every 500 hours for wear and abnormality of the commutator. Blow off brush powder with compressed air of about 5 kg/cm2.

(2)

Replacement of brush The length of the brush is about 18 mm and it can be used until it wears down to about 3 mm in length (more than 3000 hours). Remove the brush retainer with a slot screwdriver and replace the brush with a new one.

Fig. 12.2

Brush replacement of HD motor

(3)

Treatment after brush replacement Idle the motor for five or six hours after the brush replacement for fitting the brush and the commutators.

12.2.2

List of commutator brushes for HD motor

Table 12.2 Brush dimensions

Size 0.75kW 1.5kW 2.2kW 4.7 X 16 X 16 EG319 Fuji Carbon Co., Ltd.

(mm)

Material

Maker

110

12.3 Low inertia motor

12.3.1 Regular inspection of low inertia motor

(1)

Inspection of brush Inspect the brush about every 500 hours for wear and abnormality of the commutator. Blow off brush powder with compressed air of about 5 kg/cm2.

(2)

Replacement of brush When the length of the brush becomes 13 mm, replace with a new one. To replace, open the inspection window of the motor, pull up the brush retainer spring and then replace with a new brush. There is no need for adjustment since the contact pressure of the brush does not fluctuate much. Treatment after brush replacement After having replaced the brush, check the fit between the sliding surface of the brush and the commutator surface. Refer to 8.2.1.1 item (3) and improve the fit.

(3)

12.3.2

List of commutator brushes for low inertia motor

Table 12.3 Brush dimensions (mm)

Type

Size

Material

UGMMEM-5OAAl UGMMEM-1AAAl

6 X 20 X 25 MG9RB-0 10X20X25

111

CHAPTER 13. DETECTOR GEARBOX FUNCTIONS AND HANDLING (from BNP-A2022)

13.1 Functions
The detector

gearbox is mounted at the opposite side to that of the motor load (it is sometimes directly

mounted on the ball screw in accordance with the machine tool), and so in order to detect the rotation angle of the motor (or ball screw), it is connected to the shaft of the resolver (detector) via a constant gear ratio. This mechanical rotation angle is converted into an electrical angle by the resolver and it then enters the NC unit. In order to enhance the positioning precision, a tacho-generator is mounted via a 1:l gear. The signals from the tacho-generator are sent to the drive amplifier inside the NC unit.

Gear ratio 1:l The gear ratio differs according to the detector gearbox.

Fig. 13.1

Configuration of detector gearbox

Stator output winding Stator exciting coil

I I
Matching transformer

Machine axis -.

Rotor transformu

Fig. 13.2

Resolver phase composite circuit

Motor

Cover removal
SCTOWS

L Gearbox

Fig. 13.3 Detector gearbox

Resolver

I
C.

Cover support arm

Fig. 13.4

Inside of detector gearbox

113

13.2 Replacement and handling

Replace the detector gearbox as follows: (1) (2) Loosen the screws that anchor the detector gearbox. Loosen the setscrews of the bellows coupling, and remove. The mounting screws and setscrews are coated with a special paint, and so they cannot be removed unless this paint is dissolved in thinner, etc. Note 1) Note 2) When the detector gearbox has been replaced, it is necessary to perform zero point adjustment. Handling precautions (1) (2) (3) (4) Do not subject the gearbox to sudden shock. Do not allow cutting oil or other oils to come into the gearbox. Use in an ambient temperature range of OC to 45C. The gearbox is capable of withstanding vibrations up to 3G.

13.3 Regular inspection It is possible to inspect the gear wear visually by removing the detector gearbox cover and the gear cover
(Fig. 13.4). There is no need to inspect the resolver since it is brushless. The tacho-generator is a DC type and so it contains parts which wear. (Refer to cleaning the tacho-generator.) The detector gearbox is protected when it is temporarily covered with oil. However, if it is covered with oil for prolonged periods of time or if it is surrounded by oil, this oil will seep inside and damage the resolver and tacho-generator. Therefore, open the detector gearbox cover regularly and check that oil has not seeped inside. Cleaning the tacho-generator (TG) If the ripple voltage of the TG exceeds the prescribed value, this will cause feed fluctuations and other problems while the NC unit is operating. In cases like this, the rule is to replace the TG and as far as possible not to disassemble and clean the TG. However, if there are no parts at hand and action must be taken quickly, the TG may be disassembled and cleaned as a makeshift measure. (1) Cleaning the TG

1) When the screw of the TG top terminal is removed with a Phillips head screwdriver and radio
plier, the brush with spring will jump out.

2) Loosen the setscrew on the TG top cover and remove the cover.
(When replacing the cover after its removal, the output voltage will fluctuate if it is not returned to its original position. Therefore, when disassembling, make marks between the cover and main unit.) 3) 4) 5) Wipe the commutator lightly with gauze dipped in alcohol. Wipe the sliding surface of the brush with gauze dipped in alcohol. Attach the cover, insert the brush from the terminal opening and anchor with the screw. (Re-assembly)

114

, Bearing

Tachogenerator main unit

Fig. 13.6 Tacho-generator

* The ripple voltage is prescribed as follows: Less than 5% for 10 to 200 rpm Less than 3% for 200 to 3000 rpm (actual values)

13.4 Parts list

Tacho-generator

115

CHAPTER 14. MANUAL HANDLE (HD51) FUNCTIONS AND HANDLING (from BNP-A2023)
14.1 Functions
(1) General This manual handle is rotated by hand, and two types of pulse signals proportionate to the rotation angle are generated. (2) Electrical specifications 1) Input/output terminals

.
Terminal block no. 1 2 3 4 5 Signal Phase A signal output Phase B signal output +12v -12v Ground

2) Power supplies The required voltages are as follows + l2V -12v 3) Signal output Phase A and phase B output signals are fed out, and the following outputs are available with respect to the rotation angle of the handle. Output waveform and phase relationship (when handle is rotated in the (+) direction)

Phase A output -J

Phase B output jl

VH a

: :

5v + 10% P/2 +_ 30% Pl4f.40%

b:

116

4) Maximum output frequency Over 100Hz

THE ENCODER FOR MANUAL HANDLE Exterior view

Front view
h

Rear view

14.2 Replacement and handling

When a DC 12V or -12V voltage is applied to GND, signals are automatically made available from phase A and phase B. This means that if the signals are not made available, the manual handle needs replacing. After replacement, it is necessary to connect the DC 12V and -12V voltage wires properly. If the wires are not properly connected, damage may occur.

118

6) Adjacent pitch error of signal 7) Phase between each channel 8) Usable temperature range 9) Output terminals Receptacle Plug Cable clamp Refer to waveform figure 0C to 50C CANNON connector MS31 02A20-29P MS31 06A20-29s MS3157-12A Less than l/3 of signal period

Pin arrangement
Pin no. A 0 C D E F G H J +5V (for amp) -12V (for amp) Case ground Signal Ch 1 A Ch 2 A Ch 1 B

/ I (

Pin no.

Signal OV (for amp)

K
L M N P R S

i
+12V (for amp) OV (for amp)

I / I
/ !

(Note) OV is common

Mechanical

performance See 15.2 (2) 2.3 x 10e3 kg/cm sec2 Less than 1000 gem

1) Dimensions 2) Input axis inertia 3) Input axis torque 4) Allowable angle acceleration

1 O5 5) Allowable speed 6) Bearings 7) Allowable input axis load Thrust load Radial load 8) Weight

rad/sec2

3000 rpm Oil-less for over 100,000 hours

Less than 4009 Less than 1 kg Approx. 3.1 kg

120

15.2 Replacement and handling

To replace, first switch off the power to the NC unit and detach the CANNON connectors.

(1) Coupling
Make sure the coupling between the rotary encoder input axis and the external force (rotation axis of lathe, for instance) matches the following specifications: Outer diameter of input axis Input axis key groove width Seat for mounting positioning 15 g6 5 +oo.O* 80 g6 (refer to figure of dimensions)

Take special care not to apply shock or an excessive load to the input axis.

121

ROTARY ENCODER

122

(2) Exterior dimensions

-0.0 10 R6-0.029

Kay war dimensions

N i-

i
0 0

1
CANNON plug
M S 3 1 02A20-29P

/
I

136l

123

15.3 (1)

Regular inspection
Trigger level adjustment The photoelectron output signals are connected to the printed circuit which is contained in the encoder,

and they are converted into square wave signals.

The square wave signals are adjusted to a I:1 duty with a lamp voltage of 12V and so there is no need for re-adjustment. Proceed as follows if the 1: 1 duty has undergone any change.

Ch 2 Phase A

Ch 1 Phase B

1)

Remove the rear cover _. variable resistor and adjust.

2) After checking that the lamp voltage is 12V, monitor the signals on a synchroscope, rotate the signals

(2) Lamp replacement The service life of the light source lamp is quite long. Nevertheless, if there is a disconnection inside the lamp due to an abnormal voltage or vibration,
it with a new lamp according to the following procedure.
replace

124

1) 2)

Remove the rear cover first, and then detach the lamp from the light source mounting fixture. Remove the lamp from the small connector, join the new lamp and the small connector together and mount on the light source mounting fixture. Note) A spare lamp is contained inside the main unit. Remove the screw for use.

3) Check that the lamp lights up with a 12V voltage rating and check the output signal. If it is necessary to adjust the duty, proceed as outlined under the trigger level adjustment in item 5.

15.4 Parts list

Lamp For R F2048M-22-1 rotary encoder

125

CHAPTER 16. TAPE HANDLER (TH-400) FUNCTIONS AND HANDLING (from BNP-A2025)
16.1 Functions
This tape handler is equipped with a standard panel and it is designed for the extension, wind-up and rewind of the paper tape of the tape reader. Configuration The tape handler is broadly composed of the following: (1) Drive section (2) Circuit section (3) Tension arm (4) Panel (5) Reels Refer to Fig. 16.1

126

SPOOLERS

witch
\

4 -

6.5

Table center

Frame

I 1 SPOOLERS

.
x I

----_--Iy)

-__- __

183

2213

I\

Rewind reel

1 \ REWIND

switch

SUPPlY red

,; ____.__~~ _ --.-+
_ /

L- __._~___

I I

Fig. 16.1

Tape handler T H - 4 0 0

16.2 Replacement and handling

The TH-400 tape handler is connected to the PTR-210 with a 12.pin connector. It can therefore be removed by removing this connector and also the setscrews which support the tape handler.

Signals of 12-pin connector Connector

pin no. 1 2

Destination A C 1OV ._. ov .

Connector pin n o .

Destination

/ I
DC 27V ~_~.~_ ..--.-.

3 _--__-_----_t-------_-~~_--_._+~

12-pin connector

Glass-sealed fuse

Fig. 16.2 Rear of tape handler

128

16.3 Regular inspection

About once every six months apply a little #BO spindle oil td the six frame guide rollers and four tension arm guide rollers. The application of lubricants and grease is performed during overhaul.

16.4 Checkpoints
Diagnosis of TH-400 trouble spots Trouble
1 Motor does not rotate even when SPOOLERS switch is set to ON. 3. Defective SPOOLERS switch 4. Defective contact in junction connector 5. Defective RS, LS micro-switch Replace micro switches. Replace switch. Reconnect connector or replace.

Cause
1. Tape is not set. 2. Blown fuse

Remedy Set the tape. Replace fuse.

cll....~~~~~~~ches.

-~

Re-adjust based on adjustment value. 3. Defective thyristor 3 No tape rewind 1. Defective MANU REWIND switch 2. Defective thyristor 3. Defective C relay 4 Reel is late in stopping (hunting) 2. Defective tension arm spring 5 Too short time taken from REWIND, STOP operations to START operation 1. Defective A relay 2. Defective capacitor C5 1. Defective motor brake Replace thyristor. Replace relay. Re-adjust based on adjustment value. Replace spring. Replace relay. Replace capacitor. Replace thyristor. Replace switch.

16.5 Parts list

129

CHAPTER 17. SERVO ADJUSTMENT METHOD (from BNP-A2026)

17.1 General outline of NC servo

First, a general description of NC servo mechanisms is given from the NC beginners text book which is used at the MELDAS training school.

17.1.1 NC servo

A servo mechanism for an NC unit can be defined in terms of automatic control whereby the moving position of the machine tools moving table, the rotary angle of the rotating table and other mechanical positions are made the objects of control. Automatic control is defined by the Japan Machine Society as the automatic revision operation which must be performed to detect quantity C of an object, process or machine and to control in accordance with the comparison value (r - x) with the target value r so as to match quantity C with the target value r applied from an external source. block diagram (Fig. 17.1) below. Furthermore, the object that performs the automatic control of the The automatic control system is given in the The target value is the command from the NC,tape, the adjustment mechanical position or angle is the servo mechanism.

section is composed of the DC amplifier and drive amplifier, the operation section is the drive motor, the control object is the moving section of the machine tool, and the detection section is the position detector. Together, they may be called the servo mechanism of the NC unit. (Refer to Fig. 17.2)

_ Operation _ Control object section

output

Detection section

Fig. 17.1

Block diagram of automatic control system

In Fig. 17.2, the command value Ei of the table position from the command tape (e.g. X axis 10 mm movement) and the feedback Ef from the resolver which detects the actual table movement are compared, the error 6 (Ei - Ef) is amplified by the DC amplifier and drive amplifier and it is then applied to the drive motor (DC motor). The motor then lets the ball screw via the gearbox rotate, and when the table is moved, the resolver at the end of the ball screw turns at the same time. As the table advances 6 mm with a single rotation of the ball screw, the phase of the resolver output voltage varies 360. This means that when the phase variation is taken out as a reverse polarity, or negative feedback, as feedback Ef compared with the polarity of the command value, the DC motor rotates. When Ef is varied and & becomes zero, the voltage which is applied to the drive motor becomes zero and the DC motor stops.

130

Command signal

DC amplifier

X axis 10lmm

Error signal

motor Resolver detect

Fig.

17.2 Model of servo mechanism

17.1.2

Types of NC servo systems

(1) Closed loop and open loop systems The usual kind of servo mechanism is based on closed loop principles. The output signals are detected by the detector, they are compared with the input command as a feedback command, and the resulting operation is performed. function. There are three types of closed loop servos, one fully closed type and two semi-closed types. a. Closed loop servo Fig, 17.3 shows a fully closed loop system. The final position of the moving table is detected by the direct-driven detector (e.g. linear inductosyn, magnescale or optical scale), and feedback control is performed to match this quantity with the target value, Under this system, the motor is actuated, the machine is moved while there is an error between the command value and the movement but when these two values coincide, the machine is automatically stopped. This means that the system is characterized by highly accurate control. However, contained in the control loop are non-linear constants peculiar to the machine such as backlash, friction resistance, machine rigidity and machine resonance. If these constants are not within the prescribed values, adjustment of the servo system is performed only with difficulty, with the result that the precision does not meet the prescribed value and hunting occurs. When adopting this system, therefore, it is necessary to identify the machine constants that perform the control and to give sufficient consideration to matching these with the drive system. The system illustrated in Fig. 17.3 is often known simply as the closed loop system.
Dirrctdrivrn detector (inductown)

By balancing these two factors, this system is provided with a self-regulating

yziq~otoJ lhcing
I
I

tabe
Bell screw

Fig. 17.3

Cloyed loop system (fully closed loop system)

131

b. Semi-closed loop servo . . . . . . . . . . 1

Fig. 17.4 shows a type of semi-closed loop system which uses a rotary detector such as a synchro resolver rotary encoder. This is installed in a position opposite to the side where the feed motor is located. The rotary deviation in the feed screw is detected and feedback control performed.

Under this system, the feed screw pitch error, backlash and other mechanical errors are produced outside the loop system and so these directly affect the control precision. At the same time, the machine rigidity based on the inertia of the moving section, the ball screw rigidity and other factors are produced outside the loop system, and so stability can be maintained more easily than with the closed loop system illustrated in Fig. 17.3.

Moving table

Fig. 17.4 Semi-closed loop system

C. Semi-closed loop servo . . . . . . . . . . 2

Fig. 17.5 gives another type of semi-closed loop system. Under this control system, the rotary detector is installed at the mounting position of the motor (at the opposite side to that of the motor load), the feed screw rotary deviation is detected and feedback control performed. Compared with the system in Fig. 17.4, the backlash in the gear mechanism and the ball screw torsion are produced outside the loop system, and so while the control precision deteriorates, it is easy to maintain the stability of the servo system. This system is sometimes known as the quasi-closed loop system although it is usually referred to as the semi-closed loop system.

Moving table

Rotating detector (resolver)

Fig. 17.5 Semi-closed loop system

132

d. Open loop servo An electrical pulse motor or an electrical hydraulic pulse motor is used for the open loop servo with NC units and so this system is known as the pulse motor servo, too. Fig. 17.6~shows its configuration. This system is characterized by the fact that it is unnecessary to provide for stability since the pulse motor tracks in step form with command pulses. This means that as long as there are no irregularities in the operation, no unstable phenomena like hunting will be caused. However, since the mechanical error and non-linear mechanical rigidity are outside the control, it is difficult to maintain control precision.

Moving

table

clNC

Wr ew

Fig. 17.6 Open loop system

As mentioned above, there are three types of closed loop systems. It is common for small-sized and medium-sized machine tools to adopt the semi-closed loop system in Fig. 17.5, and for machines, that require precision machining, to adopt the fully closed loop system in Fig. 17.3. Furthermore, largesized machine tools which require a high level of precision adopt a type of hybrid servo system, the dual feedback system, which combines the merits of the semi-closed loop systems stability and the control precision of the closed loop system.

(2) Analog and digital servos

C

a. Analog servos (amplitude servd and phase servo) The commands from the NC unit are given in digital amounts of electrical pulses. When the input commands to the servo mechanism are given in analog quantities, the servo system is known as an analog servo of which one type is the amplitude servo. Figs. 17.7 and 17.8 give examples of the principle of amplitude servos. The input command pulse from the NC unit passes through the D-A converter and is applied to the coarse, medium and fine stator windings of the synchro resolver as analog voltage at a level with corresponds to the input numerical value. The output voltage of the rotary windings of the resolver becomes zero only at a certain rotary angle. In Fig. 17.7, the electronic switches operate with an input command so that the coarse resolver is configured as a closed circuit. is configured as a closed circuit. so that the fine resolver closes, An amplitude (such as synchro voltage) is used as the input command, and this is compared with the amplitude value (feedback synchro voltage) corresponding to the movement from the detector, the Next, the control error is reduced, and when the signal enters the When the control error is reduced even further, switching occurs

detection range of the medium resolver, the electronic switches operate so that the medium resolver

133

amplitude difference is amplified as the error signal and the servo mechanism drives the drive motor until this error is reduced to zero. Generally, this system is not very resistant to drift and it is This is why it has not been used recently as the servo in

difficult to obtain a high level of precision. NC units.

Command

Multi-speed synchro resolver Coarse synchro feedback signal Medium synchro feedback signal Fine synchro feedback signal

,
Fig. 17.7

.~,.._

Explanatory figure of multi-speed synchro resolver system

Coarse

resolver
E&ronic E l e c t r o n i c Drive -- switch *switch -z amplifier (2)

Each command unit with respect to rotating angle 1

Fig. 17.8

Principle of multi-speed synchro resolver detection system

On the other hand, the phase servo accepts command pulses as the input, it generates phase modulation signal by digital methods, compares this signal with the phase modulation signal that corresponds to the movement from the detector in the phase discriminator, amplifies the phase error as the error signal, drives the motor until this error is reduced to zero, and causes the machine to stop at the spot where the command and the feedback phases tally perfectly. This phase servo mechanism is

used in the MELDAS series, and an example of this system is given in Fig. 17.9. In Fig. 17.9, the digital phase modulation (DPM) serves to feed out the reduced frequency of the reference clock pulse like the reference pulse generator. terminal for pulses from the gate circuit. It is provided with another pulse input

When positive or negative pulses enter this terminal,

the DPM output phase either advances with respect to the output of the reference pulse generator, or is delayed. This phase shift is proportionate to the number of input pulses from the gate circuit, and the shifting speed is proportionate to the density of the input pulses.

134

For instance, if the mechanism serves to shift the phase exactly 360 with a table movement of 4 mm and 400 pulses for a single rotation of the resolver, the phase will be the same if 400 pulses are applied in one direction only when there are no input pulses. The phase discriminator compares the output phase of the resolver with the phase from the DPM, and it discriminates the phase difference. A positive error signal is generated when the resolver output phase lags behind that of the DPM output phase, and a negative error signal is generated when it advances. The error signal is rectified, DC amplified and the motor is driven. When the difference is reduced to zero, the machine is stopped. Fig. 17.10 illustrates the phase difference signal. When a + command pulse is applied once to the DPM input terminal, the DPM output phase advances 360/4000 only compared with the output phase of the resolver. Therefore, a + error is generated in the phase discriminator, and the motor is driven in the direction in which the output phase of the resolver advances. The machine then stops at a position where the resolver is rotated 0.09 times. Compared with the previous position, this is the position where the resolver has rotated 0.09 times and the table has moved 0.001 mm. In this way, the number of positive and negative input pulses to the DPM correspond to the movement of the machine table and their repeat frequency also corresponds to the movement speed of the moving table. Compared with the position servo which is composed of a phase discriminator, drive amplifier, drive motor and resolver, the phase servo system controls the speed by giving position commands from time to time in the form of the phase signals from the DPM. This means that unlike speed control by speed feedback, it is possible to increase the allowable speed range to infinity. Under this system, the arithmetic processes are dealt with digitally and so there are no adverse effects of noise and drift, and the signal transmission is extremely accurate.

Reference clock pulse 4.5 kHz r . Reference phase 1 AMHZ

I._.

4.5 kHz
IM,d d.I,1&9 i
h

Fig.

17.9 Example of phase servo system Command pulp, 1

Reference clock pulse 1.. 8 hIH z

r
Rotary angle I+ -Q

Fig.

17.10

Explanatory figure of phase difference signal of phase servo

135

b. Digital servo A digital servo features digital signals based on pulses generated from the data of the major parts. An example of this system is given in Fig. 17.11.

In Fig. 17.1 1, pulses are generated from the pulse generator for every unit angle in the output axis, the command pulses and the number of feedback pulses are compared by the reversible counter, the difference (in digits) is converted into analog voltage by the D-A converter, it is amplified and the motor is driven. The feedback pulse generator must be provided with a function that discriminates the rotation direction and it is necessary to install asynchronous circuits so that the command pulses and the feedback pulses do not enter the reversible counter at the same time. Under the digital servo system, there are no problems in the size of the signals and it is possible to transmit the signals in the simple form of identifying whether there are or are not pulses. This means that there are no adverse affects of noise and that the signals can be transmitted very accurately. The pulse motor system mentioned in the explanation of the open loop servo in section h

17.1.2( 1) d. may be described as a type of digital servo in the way that the signals are transmitted.

Photoelectric pulse . + Axis cpmmand pulse - ronized~ d S, $f 2 z Moving generator table H b& D-A Drive converter. motor amplifier

+ direction feedback Feedback pulse circuit ? Synchronous pulse

- direction feedback pulse

Fig. 17.11

Example of digital servo system

17.1.3 MELDAS servo system

Semi-closed loop system This system features a resolver mounted on the motor shaft at the opposite side to that of the load for detection. It is exactly the same as the so-called open loop system. Under this system, the machine characteristics are produced outside the closed loop system and so a high level of stability is featured. However, on the other hand, its main demerits consist in the fact that the

feed screw pitch error, backlash and other mechanical errors are not corrected. In Fig. 17.12, the input command pulses from the tape are phase modulated, and the signals are converted into signals whose phase is shifted by angle 0 which is proportionate to the number of input pulses, with respect to the reference phase. As the output of the resolver phase shifter, signals are produced whose

phase is shifted by angle 8, which is proportionate to the rotary angle of the resolver axis, with respect to the reference phase after the waveforms of those output signals are shaped. Therefore, both phases are discriminated, the error Be = Bi - B. is amplified and the motor is driven. The closed loop system is configured until the error Be is reduced to zero.

136

11111

J-u-L--lLJL
8, Drive Phase r Phase m o d u - ----+ discrim- --+ amplilater inator fier A 00 A

N/C
-

I
a

Machine side Moving table

r l

I Waveform shaper

Drive motor

Detector gearbox

(x,

R e s o 1l v e r

p h a s e

s h i f t e r

Fig. 17.12

Block diagram of semi-closed loop system

Note 1.

The limitations on the machine constants are given below (1) Load GD*,_ (converted to motor axis) (2) Maximum static friction torque (3) Maximum dynamic friction torque (4) Maximum cutting torque (dynamic friction torque cutting) (5) Backlash (6) Machine stiffness

Depends on drive motor specifications Less than rated motor torque ,,

,I 127 pulses maximum offset No particular limitation

137

17.2

NC servo system diagram

Command DPM

Error output Analoguo error voltago

PP
Command

PM

DPM circuit

DIA converter

(to 9CR amplifier) )

DPM circuit

ER 1

@ Resolver feedback

0 Resolver feedback

Reference DPM

r4
f

Feedback signal (sine wave)

Feedback signa! It&are wave)

No feedback signal detection 11 c i r c u i t

1st axis: 9M 2nd axis : 9M

Drive alarm signal

3rd axis (2nd logic card) : 9M 4th axis (2nd logic card)

: 8M

Reference DPM

;za;ez;,

k ] t o R e Amplifier s o l v -FiFi

r-L-1
e r

Fig.

17.13

Printed circuit board LC4 system diagram

138

TG feedback

. . . . ..circuit Analog error voltage

SCR gate

El3

E ?! ;

---I

L FZng angle

command Manual speed input Position/Speed loop selection

Synchronous signal

Fig.

17.14

Drive amplifier (3810/20/4083

TG feedback

Servo compensation i IC21 o u t p u t TG output IC51 output

to SCI? gate
Analog error voltage +12V Position loop P 1 Manual speed input gain command E;ionon;pe;d 0

Svnchronous

signai

8
-12v Current feedback

IC41 output

d7
Current feedback gain adjustment

IC31 input comparison IC31 input comparison adjust

IC41 input comparison

Fig.

17.15

Drive amplifier (SA20/40A/B)

139

17.3

Servo adjustments and regular inspection

There are no adjustable locations at the logic card (LC 4) side, but (1) If synchronization is attained with the DPM reference, and if the command DPM or feedbacR DPM (square wave) signals are observed, it is possible to check whether the commands are being made available and whether the machine is moving. (2) If the command DPM and feedback signals (square waves) are viewed on the synchroscope ADD, it is possible to measure the droop (phase shift error), and so if the droop at a certain speed is measured in advance, this can be used as a reference for regular inspections and trouble-shooting. (3) The amplitude variations in the feedback signal (sine waves) have a great effect on the detection accuracy, and so if the machine is moved at a low speed and the amplitude variation rate is measured, it is possible to use this value as a reference to check whether the accuracy of the detector (resolver + phase synthesizer) is succumbing to aging. The control cards of the drive amplifier (3S10/20/408, SA20/40A/B) have check terminals and variable resistors h

(1) If the TG feedback voltage at a constant machine speed (motor speed of about 1000rpm) and the
waveforms are observed and the ripple is measured, it is possible to use these data when the TG output waveforms are the cause of increased roughness in the cutting surface. (Measure the waveforms with both (+) rotation and (-) rotation directions.) (2) When adjusting the linear IC zero adjusts and firing circuit, switch off the power supplies of the NC unit, detach the MR connectors which connect the thyristor stack and the control cards (refer to the exterior views of the drive amplifiers), and set so that the machine does not move. Now switch the power on again. (2)-l Linear IC zero adjust Ground each of the check terminals at the IC input side, observe the signals at the check terminals on the output side using a synchroscope, and set to zero. (2)-2 Firing circuit adjustment First ground the check terminals of the firing circuit input (analogue input) and then observe (U+, U-) (V+, V-) (W+, W-) with. respect to synchronous signals U, V, W (use a 1O:l synchroscope probe). If the firing angle is not set to 9

, use the variable resistor for adjusting the firing angle

to set it to this value. (The numbers of the variable resistors correspond to the check terminals.) The following figures show the synchronous signal and switching waveforms.

140

Synchronous signal

U phase V phase W phase

)
Level 560 VP_p 50/60Hr t

Switching

waveforms U pham (-)

phase (+I

V phase (+I
V phase (-1 W phase (-1

W phase (+I

9 firing angle

(3) When it is desired to use a discrete drive amplifier to move the machine, set the position loop/speed loop selector switch to speed loop, and the machine can be moved with the manual speed input by variable resistor. At this time, the feedback signal will move with the command DPM at a standstill. This means that the excessive error detector is actuated when preparing to operate, a drive section alarm is issued and the NC operation preparations are shut down. Therefore, move the machine after removing

the IC plug, corresponding to the axis which is to be moved, on the logic card.

Note:

If the logic card IC plug k removed and the position loop/speed loop selector switch is set to speed loop, the machine will move in the same direction with a very small voltage caused by a very low manual speed input (the variable resistor is not necessarily set to the center position) or by a shift in the IC zero drift. This means that it is necessary to monitor the movement at the machine side and that somebody who can depress the emergency shutdown button stand on the machine side.

(4) Included in the servo system are the logic cards, drive amplifier as well as the motor and detector gearbox. The latter two contain parts which are subject to mechanical wear (motor brush, tacho-

generator) and so refer to the sections for each of the units and check and clean the parts regularly.

141

CHAPTER 18. PARAMETER SETTINGS

The most representative parameters which determine the specifications of the NC unit with MELDAS are given

below (they differ according to the type of machine tool). Parameters : (1) Low speed feed speed with zero point return

(2) Absence or presence of optional and special optional specifications (3) Absence or presence of machine control sequence (4) Timer constants relating to machine control (5) Backlash offset (6) Zero point setting (7) Pitch error offset (8) Rapid feed acceleration/deceleration time constant setting

18.1

System parameter tape loading

Reading the system parameter tape into the memory determined inside the NC unit is known as loading. The system parameter tape attaches with the NC unit. Load it, therefore, when necessary, when inserting or

taking out the logic cards and when the battery alarm has been issued. Loading a) b) Switch off the power to the NC unit. Open the front door of the NC unit and release the door interlock.

c) Switch on the power to the NC unit. d) Logic card LCl is mounted in the logic section of the NC unit and two switches are arranged on the card. Operate these switches in the following sequence :
(I) Set the top switch SW1 down to ON.

The control unit stops and the CPU alarm lamp comes on. (2) Load the system parameter tape which comes with the NC unit into the tape reader. (3) Set the bottom switch SW2 up to ON. The reader starts operating and the tape is read through. (4) When the top SW1 is set up to ON, the NC unit returns to normal.

Note 1)

Operations (I) and (2) may be performed in any order. The power may be cut off after operation (4). However, the battery will overcharge, and so it is recommended that the power be cut off after power has been flowing to the NC unit for one hour and after the battery recovers.

2)

142

Logic section

DC power supply section

@ Set SW1 down to ON SW1

EI SW2

($ SetSW2uptoON

@ Sat SW1 up to ON

Inside of main unit

Fig. 18.1

Tape loading switches and their operation

Once the system parameter tape has been loaded, it is now necessay to set the other parameters. For the settings of these parameters, refer to the section 7 on Internal Settings of the Instruction Manuals of the MELDAS-5000C and the MELDAS-5100C.

143

CHAPTER 19. SELF-DIAGNOSIS

The setting and indication board has the following selfdiagnosis functions, it gives the following alarms and displays.

19.1

Alarms and states indication

This comes on when the operation preparations for the NC unit are completed. This comes on when there is something wrong with the computer inside the NC unit. Restart is performed with the start button (mounted on the LCl logic card) inside the NC unit. (Switching the power to the NC on and off is performed in the same way.)

(1) READY (2) ERROR

(3) BATTERY (4) ALARM

This comes on when the memory battery has overcharged and the NC is set to the READY OFF mode. This comes on when the NC unit detects any of the alarm states below.
h

(a) OT (overtravel) (b) SERVO (servo error) (c) (d) TH TV (parity (parity H) V)

(e) P/S (program setting error) The contents of the ALARM are displayed on the numeral display when the function switch is set to ALARM. (5) BUFFER (6) EDIT machine side. This comes on when the next block data of the tape is stored in the buffer. This comes on during tape editing.

When the CPU, BATTERY and ALARM lamps have come on, all the (AL) alarm signals are sent to the

19.2 ALARM contents check

When the ALARM lamp on the setting and indication board has come on, it is possible to find out its contents by using the setting and indication board. When the ALARM lamp has come on, set the function switch to ALARM, and the contents of the alarm (section (1) 4) are displayed. With a program setting error, the error number that indicates the cause is displayed and so refer to alarm contents indication under the section on Setting and Indication Board Handling in the Instruction Manual of the MELDAS5oooc/51 ooc.

19.3 Interface check

Interface refers to the input and output signals that bridge the gap between the main NC unit and the machine tool (or power controller, machine operation board). The main NC unit operates in accordance with the

interface conditions. Set the function switch to I/F CHECK and check on the setting and indication board. The name of the signal corresponding to number H differs with the MELDAS5000C/51OOC and so refer to the section on Interface Checks in both the Instruction Manuals.

CHAPTER 20. TROUBLE-SHOOTING (from BNP-A2027)

1)

I
NO

No NC

power

YES

Side or rear panel is open. Or doors are not closed properly and so door interlock limit switch is not completely ON.

Check .+,rether main no fuse breaker in main NC unit has failed and wheth-

NO

er this is cause of no power.

Blown AC 1OOV or 24V fuse in DC When NC power switch is set to ON, observe tape reader lamp and setting and indication display. Do they come on if only for an instant ? NO power supply section (~~08 or PD09) ?

1
YES

YES

r
supply in NC power supply section is IrtesI~pP,:.g51 ZtFi ~ZeIower 1

to main no-fuse breaker ?

NO

J
If normal up until now, unit is defective and should be replaced. If defect after repair or inspection inside NC, DC output may have shorted.

NO ..-

I
Find out why. If no voltage applied here, voltage is not being supplied to transformer.

NO

Check whether voltage is being applred to AC 1OOV input of DC power supply section (PDOB or

j I----= PD09,.

,
YES

Inspect for defective contact in MR connector which connects NC power supply switch and DC power supply as reason that NC power is off. Check MR connector connections.

145

Power is on but no READY (preparation for operation) state.

SERVO alarm lamp is on. No ALARM lamps on.

Is BATT alarm lamp on 7

YES

4
(1) Axis drive amplifier no-fuse breaker has been tripped. (2) Axis drive amplifier thermal relay has been tripped. (3) Position detector cable is not connected. (4) Spindle drive amplifier no-fuse breaker has been tripped. (5) Spindle drive amplifier thermal relay has been tripped.

I -

Emergency stop state

I
Battery power has fallen below prescribed level.

Leave in this state for several hours and then depress reset button after having recharged battery. Now it is necessary to re-load system parameter tape. Special care is required since tape editing memory may be damaged. (However, when system parameter tape is loaded, the tape editing memory area is cleared.)

146

3) The ALARM lamp comes on

Set the function switch on the setting and indication board to ALARM, display the contents of the alarm, and determine and remove the cause.

Alarm contents

Adjustment

method

Remedy, countermeasure Move the axis which has overtraveled in

OT

Find the axis which has overtraveled.

the opposite direction with handle feed manual feed.

OI

(1) No-fuse breaker of axis (or spindle) drive amplifier has been actuated. SERVO (2) Thermal relay of axis for spindle) drive amplifier has been tripped. (3) Position detector cable is not connected or has come loose. I After remedying cause, depress reset button of thermal relay. Or set no-fuse breaker to ON. Connect cable (CNA14 or CNA3-6) or tighten
COnneCtiOn

(1)

Tape itself is set or parity V state.

to

parity H

(1) Re-inspect tape. If there is a mistake ir the tape, correct.

TH, TV

(2) Tape sprocket hole (feed) has shifted. (3) There are many fibers around sprocket hole

(2) (3) Re-inspect puncher which is beinf used. If there is something wrong witl the puncher, repair or replace.

(4) Tape reader photo cell or optical (4) Inspect tape reader. plate is dirty. Clean tape reader.

Refer to the alarm contents indication PIS Check the number of the error. under the section on Setting and Indication Board Handling in the Instruction Manual.

147

4)
ALARM lamp comes on during operation and SERVO section goes to 1.

Lamp remains on Depress reset button

Lamp goes off

(1) Overload has tripped thermal relay_ of axis (or spindle) drive amplifier. (2) (3) tion detector cable. (4) Oil has seeped into position detect01 (normally on the opposite side to that of the motor load), and there is something wrong with the resolver and phase synthesizer. No-fuse breaker of axis (or spindle) drive amplifier has been tripped.

c_
Excessive error Perform disengaged operation-under non occurs.

same

conditions and check whether same phenome

148

5)

No tape reader start

Tape advances only one character or one block.

V
(1) Parity error (2) Program error (3) Incorrect advance direction of paper tape

Tape reader switch is set ,

r
I

J
Check ALARM.

not set to RUN ?

switch to MANU.

Defective contact of tape

(1) Inspect tape reader. (2) Inspect tape. 1

it

NO

(1) Defective tape reader

-i

(2) Defective LC3 logic card

Note)

It is possible to perform an interface check to check whether automatic start signals are being fed out.

149

Tape reader does not stop

9 Does not stop even with error stop (parity H, V, program error).

Does not stop even when end of block is read.

----) * Check tape reader. 6 Use a synchroscope to check that output waveforms of tape reader with all mark endless tape as well as sprocket

Something wrong

V
I (1) Output waveforms and sprocket waveforms not adjusted with variable resistors. (2) (3) Check whether lamp voltage is DC 18V. Check whether optical plate is ,

waveforms agree with those on the data sheets.

Replace tape reader

Try replacing LC3 logic card. I

150

7)

YES

(+I f-) polarities are, reversed or axis is wrong.

Defective switch or related part at machine side stroke end.

8)

MELDAS-BlOOC?

Moves

(1)

Override is set to 0.

V
(1) No feed speed command F (21 No rotation of rotary encoder for spindle does not rotate)

(2) Feed hold is set. (3) Stroke end is set.

Present position display counter only moves but machine does not move ?

Movement with GO command 7

YES

J
,

B
Problems with setting of LC3, LC4 IC plugs ?

NO

Machine lock ?

Something wrong with LC4 or axis drive amplifier

Servo actuated ?

NO

151

9)

(1) Battery has overcharged. (2) Logic card (especially LC2, LC120) has been inserted or taken Out.

Use

the switch on logic card LCl and reload

the system parameter tape.

Note 1. After loading the system parameter tape, it is necessary to set the backlash offset, zero point, pitch error offset, rapid feed time constant, power sequence timer constant and other values peculiar to the machine tool again. 2. If it is thought that the battery has discharged extremely, it is desirable to run power through it for continuous 4 hours or more.

10)

NO

Try reloading system parameter tape

Not
released

Defective LCl logic card preventing CPU from starting from fixed address

Check method of use of control unit when ERROR lamp Logic card: Check connections of ROM, RAM, micro CPU plug type chips mounted on LCl, LC2, LC120, LC23 for looseness by pushing them in. comes on, and check whether there is reproducibility.

Q
Try re-loading system parameter tape c 1 Try replacing in turn of LCl, 2, 120 and 23 logic cards.

Note)

ROM (read only memory) A memory where fixed commands are stored. RAM (random access memory) This is a tape store memory that can be freely written into or read out.

153

11)

I
NO

No manual feed

NO
handle feed and zero point

No movement in only one mode

No movement with cutting feed only

Is axis

selected 7
h

Use interface check to check which mode does not come

Override is set to 0%.

J
OK Inspect with interface check to see if JOG or handle/step mode has come.

Use interface check to see whether axis has been selected

Has not come

Use interface check to see whether override signals are available.

OK

(1) Check connections between power controller and NC unit. (2) Try replacing LC3 logic card.

If fault is related to axis, try replacing LC4 logic card. If signals come as far as NC unit but can not confirm at interface check, try replacing LC3 logic card.

154

12)

Emergency stop

Auto 1

No stopping even when manual cutting, rapid feed buttons are depressed and released,or when OFF button isdepressed.

READY lamp does not go off even when emergency stop i button is depressed.

No stopping even when feed hold button is depressed.

1
Use interface check mode and check .ON/OFF operation with JOG (+) (-) as button input. Check that line U P to CNDl-T, which is entrance to NC unit, opens and closes with button ON/OFF operation. ! No ON/OFF

Use interface check mode to check that feed hold signals are set ON/OFF.

V
OK Inspect JOG (+) f-) signal line from button input up to operation board, power controller Check signal line of feed hold from button input in order of operation board and power controller.

I \u
I

OK

V
Buttons must be set to OPEN.

Try replacing LC4 logic card (1 card with 2 axes; with more than 2 axes, view from front and left side LC4 corresponds to 1st and 2nd axes, and second LC4 card corresponds to 3rd and 4th axes. I

OK

1 1 Try replacing LC3 logic card.

155

13-3)
Movement speed differs from that

0 +
NO
M-51 OOC 7 Something wrong with override ? Something wrong with LC3 logic

Check machine operation board and power controller related

14)

I
h

Manual data input does not function.

Check machine (CNDl-G) signal come ? and power controller related parts.

z;zL;g

wrong with LC3

157

15) Something is wrong with zero point return

15-l)

No movement with rapid feed speed even when zero point return mode is selected and manual JOG button is depressed.

Zero point return mode 7

Is JOG signal available ?

NO

\1

NO

Something wrong with LC3 logic card

15-2)
No low speed even when zero point detection dog is kicked

Is zero point detection signal available ?

15-3)

(ill
Low speed after zero point is detected 7

NO

158

15-4)

NO

Try varying zero

Inspect and determine whether dog length is

16) No precision
16-l)
Defective detector precision

Check that amplitude variations of detector output signal are within rating (less than 1.5%)

Note)

The test points on the LC4 logic card for checking the amplitude fluctuations are: TP3 . . . . . . . . . . 1st axis (or 3rd axis) TP4 . . . . . . . . . . 2nd axis (or 4th axis) First measure the peak-to-peak voltage (VP-p) of the sine waveforms, and then enlarge the voltage range as far as possible. fluctuating) Check that fluctuation is: 2 AV VP-P x loo(%) ri 1.5(%) Move the machine slowly and measure the voltage (A V) which is

159

16-2)
Defective coupling with detector I

V
Inspect bellow coupling which connects detector gearbox to drive motor.

Note I) 21 3)

When the detector gearbox is behind the drive motor, the bellow coupling can be seen from the outside if the cover is removed. If the bellow coupling works loose, it will not be possible to maintain the repeat accuracy. Because of its construction, the bellow coupling may be considered a consumable and so it is recommended to have a spare available for maintenance purposes. Contact a MELDAS serviceman to find out what type is used.

160

16-3)

1
High machine friction torque

\1/

(1) High starting current (2) ALARM lamp (SERVO) comes on

Note)

When the machine is assembled (or under normal conditions), measuring the torque at the motor load, when the machine starts up and when the machine is moving, produces results which are used as appraisal references (trouble in the electrical system, failure in the mechanical system) to deal with trouble. It is therefore a good idea to proceed with these measurements.

16-4)

Method by which ball screw is being used is extreme, and the error increases to (+).

161

16-5)

Measure backlash at total stroke 2 or 3 locations.

Re-set backlash offset

16-6)

High residual current when drive amplifier is stopped.

16-7)
Lack of precision due to ball screw pitch error

V
Measure precision for single rotation of ball screw. ,

(1) Use pitch error offset if available. (2) Repair at machlne side if no pitch error offset is available.

162

17) Hunting

17-l)
Defective TG feedback

V
inspect TG feedback voltage. ,

(1) (2)

Inspect wiring inside detector gearbox. Inspect wiring route from detector gearbox to NC unit.

Note)

Measure the TG feedback voltage at the CPl of the drive amplifier corresponding to the axis. D C 7V/lOOO rpm

17-2)

53
Defective TG characteristics

J/

Besides ripple in TG feedback waveforms, disturbance in other waveforms is high. (2) Defective rotational speed voltage specifications.

(1)

1
Clean TG or replace TG

163

17-3)

Defective TG coupling I

V
inspect coupling inside detector

I
Note)

Repair trouble spots or replace detector gearbox.

If the polarities of the TG (tacho-generator) are reversed and signals enter the NC unit, the machine will move in the one direction as soon as the NC enters the ready state (this is due to positive feedback), and the machine will stop with the SERVO alarm (due to excessive error).

164

CHAPTER 21. TROUBLE-SHOOTING WITH SOFTWARE (from BNP-A2028)

Software in connection with the MELDAS 5OOOC/51OOC refers to the memory program arrangement in which

the standard specifications, optional specifications including tape editing, special optional specifications, power controller sequence and the functions of these three sections are housed. With the MELDAS 5OOOC/51OOC, the contents of the software are stored in a fixed type of memory known as a ROM (read only memory), and so with trouble in the software, the fault lies with the ROM IC. Following is a description of the action to be taken when there is something wrong with the logic cards, on which the ROM ICs are mounted, or with the ROM ICs themselves.

21.1

LC2, LC120, LC23 logic cards

There are three logic cards, LC2, LC120, LC23, on which the ROM ICs are mounted. These cards are configured so as to accommodate a maximum of 88, 48 and 16 ROM ICs, respectively. The positions of the ROM ICs mounted on each of the logic cards are shown in the following figures.

165

r
I

LC 2 .----------(LEEIIX~ I
22liner x4rows 88 pieces

UAO 1

I
I

I
I

I I I
I I I

I I I I I I
I

I I I

I
I I
h

I
I

I
I I

I I

I
I I
I

I
I

I I I I

I
I I I I
I

I I
I

I I I

I I
I

I
I I I I
I

I I I
I I

I
I
I
I

I I
I
I-

_- -----M L K

--__.J

LA40

ROM
(Read Only

Printed circuit board LC2

LC120

1 7 l i n e s x2rows -_--- -----l

- - 34 pieces (RAM) 12 lines x 4 rows 48 pieces (ROW ~~~~~~~__~~- -__

I I

I
I
I I

I I
I
I I

In
I

I
I I

I
I I I

I I

I I I

I I I
I

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I I F

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I I I I

I I
I I

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I I I

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IG
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I I I
I

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I I I I

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I

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I I

I
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I

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I
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I
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I
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IK
I L I IM

I
I

I I I I
I ;

I
I

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I I I
I

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LAO I

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I I I

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I

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~el~li_l
I

L_-_--_-__-_

I
I

I I

I
I
I

T-- - -

ROM (Read Only Memory chips) RAM (Reed Access Memory chips) Printed circuit board LC120

167

LC23A

UAO 1

4 lines x 4 roWs - - 16 pieces

(ROM)

r---------1

Connector ROM (Read Only Memory chips)

LC23A

Printed circuit board LC23 e

168

Note)

The RAM memory on the LC120 logic card refers to the random access memory which allows free writing and reading and which is used for tape editing.

21.2

Action when there is something wrong with LC2, LC120 or LC23 logic card

When something wrong occurs with these cards, in most cases the parity check function is applied during operation, memory parity is set, the CPU stops and a CPU error is recorded. When the memory parity is not set, CPU rotates the routine in the software, and external interruptions can no longer be accommodated.
Possible causes of this are: (1) ROM IC has worked free of socket (2) Defective characteristics of ROM IC (3) Defective characteristics of other IC, resistor or capacitor (4) Defective soldering (5) Defective pattern (6) Defective soldering at both ends of jumper wires (7) Defect in mini bus supplying DC 5V, ground to each row When an identical spare is available, try replacing the logic card and observe the variation from the trouble. Mounted on the LC2, LC120 and LC23 logic cards are the following memories: Standard specification memory on LC2 logic card Optional specification and special optional specification memory, and tape editing RAM on LC120 logic card Power controller sequence memory on LC23 logic card The types of these memories may change for each and every machine. Therefore, when a spare logic card is at hand, it is possible to judge the trouble by replacing the ROM ICs and finding out which ROM IC is defective and the trouble on the circuit board of the logic card.

169

21.3 Trouble-shooting

ERROR lamp comes on I

Defect in CMOS IC area which stores contents of system parameters (LC2) or defect in operation RAM area (LC21

Switch off power and switch on again.

Re-load system parameter tape.

NO

Try pushing in ROM ICs (or RAM ICs) mounted on the LC2, LC120 and LC23 logic cards by hand.

Y
Replace logic cards in sequence (including

LCl 1.

If something is wrong with LC2, LC120 or LC23 logic cards, find trouble spot by replacing ROM ICs and find out if trouble is ROM IC or the printed circuit board.

170

CHAPTER 22. MAINTENANCE PARTS LIST (from BNP-A2029)

22.1 Spare parts

Name of parts

Standard Tape reader lamp unit

Quantity

Place used

Tape reader spare parts Cleaning brush Fuse Fuse Air filter Glass-sealed type 10A

1 set

Paper tape reader

2 1 1

Power supply Power supply Rear door

Glass-sealed type 3A

Above parts are standard spare parts of MELDAS 5OOOC/51OOC.

22.2

Printed circuit board (Logic card)

Name of parts iroup of boards Functions Board name Remarks

LCl

LCIB LCIC

CPU input & output control, Clock generator, relation to CPU, Auto restart function of CPU, Control signal generation, Sequence instructions control

LC2

LCZA LC2B

Standard specification memory, The memory for parameter, Calculation memory, Memory parity error generator, Battery charging/discharging circuit

_
LC3 LCSB LC3C
Operation ready sequence, System clock generator, Timing generator, Paper tape reader control, Manual handle control, Spindle revolution detection, NC standard input signal I/F, Control words decoder for 110 I/F, Setting and indication board I/F

_
LC4 LC4B LC4C

-_Pulse distribution circurt, Smoothing circuit, Drgital Phase Modulation circuit, Resolver exciter, Resolver output filter, Settings of servo system, Input I/F relation to axis Two axes are mounted on one logic card.

_
LC120 LC 120A LC12OB LC12OC

__~. Memory for processing tape, Program for optional function, Batten/ backed up circuit, Battery charging circuit, Memory parity error generator Optional card

(Cont.)

171

(Cont.) Name of parts Functions Board name LC2lA LC2lB Relay I/F, Read-out display, S analog output, D/A converter Remarks

;roup of boards LC21

LC22,

LC22A L C 2 2 8

Multi data display control, Tape puncher control

Optional card

L C 2 3

LC23A LC 23A- 1

Memory for machine sequence control Machine sequence I/F

h

22.3 Board

Name of parts Board Board S C 5 1 SC57

Functions

MELDAS- 10 OC Standard board

MELDA S- 5 0 0 0 C standard board Board with multi data display unit (suitable for the standard board o f MELDAS 5OOOC) Position read-out display for 2 axes for 1 axis for 2 axes for 4 axes for 2 axes for 4 axes

Board P Z 5 7

Board I/ D P box n D P box I,

DP 5 1

D P 5 2
-

N
Position read-out display

6 2 A 6 4 A
6 2 B 648

N
Position read-out display I/

.. 22.4 Power supply

Name of parts PD08A

Functions DC5V, +lZV, -12V. 24V, Power ON-OFF sequence, Battery charger circuit _.._

PDOSA Charger PM

DC5V, +12V, -12V. 24V, Power ON-OFF sequence

OA/PM 1 OB

Battery charger circuit

172

22.9 Drive amplifier

Suitable motors Name of part4 Low inertia motor Cup motor 4ocw, 7 5 a v 4oav, 75&v, 1.5kw, 2.2kW Direct drive motor -

3SlOA/B 3S20A/B 3S40A/B/

18(Iw, 39OW, 75&V 18UV,39(Mr, 75M, 1.5kW 3kW

75OW, 1.5kW, 2.2kw 75av, 1.5@hJ, 2.2w I I

h

3.7kW, 5.5kW 1 4OaV,75Wv,l.5kW,2.2kW) 3.7&v, 5.5kw I I

S A 2 0 A / B 1 18OW,39(Iw,75(Iw,l.5M;v SA40A/B S3S50A,Bl S3S6OA/B

s s 6OA/B/C

3kW

22.10 Motor

Name of parts Low inertia motor

Functions

UGMMEM-06AAl UGMMEM-13AAl UGivlMEM- 2 5AA 1 UGMMEM- 5 OAA 1

1 8 0 W 3 9 ow 7 5 ow 1.5 KW 3 KW

UGMMEM-1 AAA 1
Cup motor

UGCMEM-0 4 UGCMEM-0 8 UGCMEM-- 15 UGCMEM-2 2 UGCMEM-3 7 UGCMEM-5 5

Direct drive motor

4 0 ow 8 0 OW 1.5 KW 2.2 KW 3.7 KW 5.5 KW

HD7 SOW HD 1.5KW HD 2.2KW ClOOO-2.0 c2000-20 c3000-15

7 5 ow 1.5 KW 2.2 KW 7 5 ow 1.5KW 2. 2. KW

174

22.11 Motor brush

1)
Low ineritia motor

Size of brush (mm)

Type of brush

Materials

PCS of brush

UGMMEM-06AAl UGMMEM-13AAl UGMMEM-25AAl UGMMEM-50AAl UGMMEM-1AAAl

4x12.5x22 4x12.5x22 5x20~25 6x20~25 10x20~25

DP6404699-1 DP6404699-1 DP64047 14-1 DP64047 144 DP6404714-3

MH-372 II II MGQRB-0 b

2 2 2 2 2

2) Cup

motor

Type
UGCMEM-04 UGCMEM-06 UGCMEM-15 UGCMEM-22 UGCMEM-37

Size of brush (mm)

Type of brush

Materials

PCS of brush

4x10~12 I I 6x12.5x22 I,

MG-9RBO I I, I! n -

4 4 4 4 6

3) HD

motor

Type

Size of brush (mm)

Type of brush _ _ _

Materials

PCS of brush

HQ750 W HDl.5KW HD2.2KW

4.7~16~10 I *

EG319 I, I

8 8 8

175

22.12 Thermal relay

Table 20-l. Motor

- Thermal relay . Drive amplifier

Motor Thermal relay Drive amplifier Prescribed current 6.5A

Tvpe

I t e m .

Rated output

Item

Dial

.
8 i; E .; c :; s

UGMMEM-06AAl

180 W

TH-20FS

6.2A

UGMMEM-13AAl

390 w

I,

I,

7.4A SA2OA,8

&

UGMMEM-25AAl

750 w

I,

11 A

12A

UGMMEM-50AAl

1.5KW

I,

12.1A

UGMMEM-1AAAl

3.OKW

TH-6OFS

28 A

24A

SA40A,8

UGCMEM-04

400 w

TH-20

8.5A

6.5A

UGCMEM-08 b g E 9 u

750 w

8A SAPOA,B

UGCMEM-15

1.5KW

TH-20FS

11 A

12A

UGCMEM-22

2.2KW

TH-60

21 A

18A

UGCMEM-37

3.7KW

I,
I

28A

28A SA40A/ B

UGCMEM-55

5.5KW

31 A

HD07510 b i; E ? HD220-10

750 w

TH-60

21 A

22 A

HD150-10

1.5KW

28A

24A

SA40A/ B

;.LKW

,,

28 A

24A

176