Electronics Manual CNC

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V-1

ELEKTRONIK.CNC.BA.V2.USA

Electronics Manual CNC97/98

All machines for construction glass and automobile glass



Maschinen AG

_{}

INC.

Industriestrasse 5 30, Commerce Drive CH - 4922 Bützberg Hauppauge, NY, 11788 Telephone +4162 958 77 77 Phone +1516 231 1212 Telefax +4162 958 77 00 Fax +1516 231 1040

E-Mail [email protected] email [email protected] http:/www.bystronic.ch

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Electronics Manual CNC 97/98

The work, including all its parts, is protected by copyright. Any use outside the narrow limits of the copyright law is not permitted without Bystronic’s consent.

Information on operating instructions

Author: P. Ingold Date: 2.2.1999 Initials: PI Version: 2.0

Order-No.: ELEKTRONIK.CNC.BA.V2.USA

Checked & Approved

Technology: Th. Plüss Date: 29.1.1999 Initials: TP Documentation: R. Fankhauser Date: 5.2.1999 Initials: rf

When reordering, always state the above order number and version of this Manual. Information concerning errors and proposals for changes should be sent to:

Bystronic Maschinen AG Abt. Dokumentation Industriestrasse 5 CH-4922 Bützberg Telefax +4162-958 77 00 E-Mail [email protected]

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V-3

ELEKTRONIK.CNC.BA.V2.USA Page organization Page organization

The pages of the operating instructions have the following structure.

Using this Manual

Information on structure of the operating instructions

1 The header contains the name of Title 1 2 Title 1

3 Brief summary of the present chapter 4 Contents of the chapter contains three stages

1st stage Main title, this appears only in the contents at the beginning of the Manual and in the contents of the chapter.

2nd stage Title 1, these chapters deal with a topic on a certain machine or assembly.

3rd stage Title 2, this subsection always deals with a topic which is discussed in the corresponding Title 1.

5 Order number of the operating instructions. This number reveals the machine type, the type of instructions, the version of the operating instructions and the language.

6 Page numbering of the current chapter. 7 Table caption and brief explanation. 8 Figure caption and brief explanation.

9 Information with preceding pictogram must be complied with. 10 Refers to pages with more detailed information.

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Important information

Before you begin working on the machine, it is essential to read the

general safety requirements in the maintenance instructions.

This Electronics Manual is designed for service personnel with a

thorough knowledge of industrial electronics. It is t

thorough knowledge of industrial electronics. It is therefore not

herefore not

necessarily suitable for t

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V-5

Table of Contents

1

1 Block diagra

Block diagram

m 1-1

1-1

2

2 EElle

eccttrro

on

niiccs

s rra

acck

k

2 2--11

3

3 SStte

ep

pp

piin

ng

g m

mo

otto

or

r rra

acck

k

3 3--11

4

4 P

Pe

erriip

ph

he

erra

al l cca

arrd

dss

4 4--11

5

5 P

Pa

an

ne

el l P

PC

C

5--11

5

6

6 D

Drriiv

ve

e ssy

ysstte

em

m

6 6--11

7

7 Drive supply module

Drive supply module

7-1

8

8 D

Drriiv

ve

e m

mo

od

du

ulle

e 8

8--11

9

9 P

Prre

essssu

urre

e cco

on

nttrro

olllle

err 9

9--11

10 10 Positioning module UNIPOS

Positioning module UNIPOS

10-1

11

11 Adjustment instructions

Adjustment instructions

11-1

12

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1-1

Block diagram

1.1 1.1 Block

Block diagram

diagram ...

...

... 1-2

1-2

1.1.1 XYZ97/98 1.1.1 XYZ97/98 1.1.2 XYZF97/98 1.1.2 XYZF97/98 1.1.3 XYZF97/98R 1.1.3 XYZF97/98R 1.1.4 XYZF97/98DS 1.1.4 XYZF97/98DS 1.1.5 PSM-XYZF98 1.1.5 PSM-XYZF98 1.1.6 KSM97/98 1.1.6 KSM97/98 1.1.7 KSBM97/98 1.1.7 KSBM97/98 1.1.8 PSM97/98 (Stand alone) 1.1.8 PSM97/98 (Stand alone) 1.1.9 PSM97/98 Compact 1.1.9 PSM97/98 Compact 1.1.10 PBM98 1.1.10 PBM98 Contents of Chapter 1

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1-3

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1-5

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1-7

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1-9

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1-11

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1-13

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2-1 ELEKTRONIK.CNC.BA.V2.USA Contents of Chapter

Electronics rack

2.1 The CNC

2.1 The CNC Rack

Rack...

...

.... 2-2

2-2

2.1.1

2.1.1 RACK SUPRACK SUPPLPLY 2Y 2

2.2 2.2 CPU

CPU ...

...

...2-8

2-8

2.2.1 CPU 386SX 2.2.1 CPU 386SX

2.2.2 Light emitting diodes on CPU 2.2.2 Light emitting diodes on CPU 2.2.3 CPU switches 2.2.3 CPU switches 2.2.4 CPU Jumpers 2.2.4 CPU Jumpers

2.3 2.3 ROM/RAM2

ROM/RAM2 ...

...

... 2-12

2-12

2.3.1 ROM/RAM2 Jumper 2.3.1 ROM/RAM2 Jumper

2.4 CUTCON2

2.5 IMPGEN

2.5 IMPGEN ...

_{2.5.1 Impgen switches}_{2.5.1 Impgen switches}

...

.. 2-18

2-18

2.6 2.6 POSCON

POSCON ...

...

... 2-22

2-22

2.7 SERCOM2

2.7 SERCOM2 ...

...

... 2-28

2-28

2.7.1 Adapter cards for SERCOM2 2.7.1 Adapter cards for SERCOM2

2.8 DIOCOM

2.8 DIOCOM ...

...

... 2-36

2-36

2.8.1 Adapter cards for DIOCOM 2.8.1 Adapter cards for DIOCOM

2.9 2.9 POSCAD

POSCAD...

...

... 2-44

2-44

2.9.1 POSCAD switches 2.9.1 POSCAD switches

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2.1 The CNC Rack

The" CNC rack has space for the power supply, a CPU card andcards for peripherals.

The card guides () are equipped with spring contacts which provide optimal protection from ESD. As soon as the peripheral cards have been inserted, the ESD protection components of the peripheral cards are connected to ground and can thus eliminate any static charges before the bus connection is made. Electrostatic discharge

The discharge of static electricity from an external source, e.g. as a result of touching with the hands, often leads to destruction of the circuit

The metallic plug fastening rail () at the back of the rack permits extensive contact with the cable screens via the plug housing of the incoming and outgoing cables. The back panel () makes the connection between power supply, CPU and the other peripheral cards used. A slot number for addressing is available for every slot.

The back panel (NCBUS) is in the form of a multilayer circuit board with 3 signal layers and 5 supply layers. A signal layer is enclosed between every two supply

layers. The screening effect of the supply layers results in optimal attenuation of the cross-talk between the signal lines. It is also possible in this way to adapt the

impedance of the signal lines to the driver ICs on the peripheral cards.

Electrostatic discharge

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2-3

2.1 CNC Rack

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2.1.1 RACK SUPPLY 2 2.1.1 RACK SUPPLY 2

The RACK SUPPLY 2 provides the rack with the stabilized voltages, 5 V/20 A digital part, ± 12 V ⁄ 1.5 A analogue part, and the unstabilized voltage 14 V/6 A of the encoder supply.

To ensure satisfactory operation of the CNC control, all voltages are monitored. If the mains voltage fails, an AC powerfail is generated after two half-waves (one

period, 20 ms). The CNC control detects this and can save the most important data and bring the system to a safe state before the DC voltage fails.

The RACK SUPPLY 2 is equipped with 3 signal inputs. The inputs ALARM A and ALARM B () are managed by the watchdog of the CPU, which is activated by the machine software. The third signal RESET is triggered by the reset switch on the CPU. If one of the 3 signals responds, the relay K3 (in the CNC cabinet, NC Ready) will drop out. The relay K3 is used for communicating the failure of the supply voltage (in the CNC rack) to a superior control (NC Ready). The presence of the four voltages is indicated by means of LEDs (, , , ) on the front panel and can additionally be measured via 5 VDC (), ± 12 VDC (,

) and 14 VDC () test jacks. If one of the controlled DC voltages falls below its minimum reference value, a DC powerfail is generated. The situation currently

leads to a system reset. At the same time, the relay K3 (in the CNC cabinet) will drop out.

The RACK SUPPLY 2 requires 4 different input voltages. These voltages are supplied by a mains transformer which is electrically isolated from the mains input. The four inputs are protected by fuses ().

The housing of the RACK SUPPLY 2 contains four reserve fuses () which, if required, can be used as a replacement for the faulty fuses (). 2.1 CNC rack

C CC C

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2-5

2.1 CNC rack

Fig. 2.1b (RACK SUPPLY 2) Legend:

1R eserve fuses 7 -12 VDC LED

2 Fuses 8 -12 VDC test jack

3 +5 VDC LED 9 14 VDC LED

4 +5 VDC test jack 10 14 VDC test jack 5 +12 VDC LED 11 Alarm A + B LED 6 +12 VDC test jack

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Fig. 2.1c (Block diagram of RACK SUPPLY 2) 2.1 CNC rack

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2.2 CPU

2.2.1 CPU 386SX 2.2.1 CPU 386SX

The CPU card is equipped with an 80386 SX microprocessor from Intel. The processor is operated at 20 MHz clock frequency. The system thus achieves a processing speed of approx. 5 MIPS. The processor loses little power and therefore

needs no cooling system. Owing to the intensive computational use in calculation and for working through the NC program, the CPU card is equipped with an 80387SL coprocessor from Intel. The efficiency of the system is greatly increased especially in floating point calculations. The CPU card is equipped with a univer-sal port module. 2 independent ports are thus available, channel A and channel B.

Channel A is connected as an RS232C port and is used for connection of a CMR terminal (Console Monitor). This port serves for program development and testing and is used exclusively by the Bystronic Development Department. Channel B can be operated as an RS 232C or as a fibreoptic port (TOS link). When configured as an RS232C port, channel B connects the AT terminal to the older (CNC89/92) machines. When configured as a TOS link (Opto port), channel B connects the CNC by means of a fibreoptic cable to the operator terminal (Panel PC) of the CNC 97/98 machine generation. The 2 ports are electrically isolated from the rack and from one another. The transmission rate is 115.2 kbit/s. 2.2 CPU Abbreviation for m mm m

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2-9

2.2 CPU 2.2.2 Light emitting diodes on CPU

2.2.2 Light emitting diodes on CPU LED

LEDH1 yellowH1 yellow BUSY

BUSY indicates by means of its luminous intensity the level of utilization of the processor.

LED

LEDH2 greenH2 green IDLE

IDLE indicates by means of its luminous intensity the time for which the processor has been waiting in a queue for work.

LED LEDH3 redH3 red HALT

HALT indicates that the processor has encountered a HALT instruction when executing the program and cannot continue performing the current task. This error can be eliminated only by a cold system start or by an interrupt.

LED LEDH4 redH4 red SHUTDOWN

SHUTDOWN indicates that a serious error has occurred during execution of the program. Possible causes are the interrupt 8, 13 or a stack overflow. The system can be recovered from the situation only by an NMI (NNon MMaskableIInterrupt)

or a cold start. LED

LEDH5 yellowH5 yellow Bus timeout

Bus timeout. The processor has unsuccessfully waited for a ready signal from an

addressed interface card and has itself terminated the bus cycle after the maximum waiting time. In this situation, further execution of the program is possible without problems, but this is a warning that an interface card is not present in the system or is faulty.

LED LEDH6 redH6 red INT

INT ERRUPT REQUESERRUPT REQUES TT lights up during execution of an interrupt routine. It is activated by the INTA signal of the processor and is cleared again by the software at the end of the interrupt routine.

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2.2.3 CPU switches 2.2.3 CPU switches S1

S1

The CPU performs a cold start and triggers a system reset. S2

S2

Position of the memory on the CPU card. (Standard setting: No. 1 at ON/No. 2 at OFF applies to all machines.)

S3 S3

Serves for switching channel B from RS 232C to the fibreoptic (Opto).

Position 1: Fibreoptic (Tos link) Position 2: RS 232C

2.2.4 CPU Jumpers 2.2.4 CPU Jumpers J5

J5

Configuration of external interrupts:

Pin 1 with 8 external NNon MMaskableIInterrupt (NMI) connected to internal NMI

Pin 2 with 7 external AC powerfail (ACPF) connected to internal NMI Pin 3 with 6 external AC powerfail (ACPF) connected to INT9 Pin 4 with 5 external IN T9 connected to internal IN T9 Factory settings for all machines

Factory settings for all machines Pin 1 connected to 8

Pin 4 connected to 5 2.2 CPU

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2-11

2.2 CPU

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2.3 ROM/RAM2

The ROM/RAM2 is the main memory and program memory card of the CN control. The card is equipped with 1 MB memory chips. It is divided into 4 memory banks (bank 0 to bank 3). The first bank (bank 0) is equipped with RAM. The 4th bank (bank 3) is equipped with flash EPROM and thus serves as a read-only memory for holding the CNC software. The 2nd and 3rd banks (bank 1 and bank 2) are not used at present and thus serve for later memory extension. The RAM section, bank 0 to bank 2, is protected with a lithium battery to prevent

data loss. The battery capacity is sufficient for maintaining the data for about 5 years.

2.3.1 ROM/RAM2 Jumper 2.3.1 ROM/RAM2 Jumper J1

J1

The RAM section of the card is connected to the lithium battery () by jumper

J1 (). When the card is stored, jumper J1 must be removed to protect the battery. 2.3 ROM/RAM2

RRRRRead OOOOOnly MMMMMemory/RRRRRead AAAAAccess M

MM M Memory

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2-13

2.3 ROM/RAM2

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2.4 CUTCON2

2.4 CUTCON2 2.4 CUTCON2

The CUTCON2 generates path-dependent real-time control signals for the various working processes.

The card contains four RS422 outputs and one 16 bit TTL output and one analogue (0-10 VDC) input and output. With the PLD CUT2-A, the switches SW1, SW2 and SW3 are inactive.

Information!

In the glass machines, the 3 switches (SW1, SW2 and SW3) are never In the glass machines, the 3 switches (SW1, SW2 and SW3) are never used.

used. TT he swhe switch itch settings arsettings are therefore therefore unimpe unimportant.ortant.

LED`s LED`s

The four LEDs (1, 2, 3 and 4) are not actuated and thus have no function as error or status indicators.

Cut CutCut Cut

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2-15

2.4 Cutcon2

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2.4 Cutcon2

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2-17

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2.5 IMPGEN

The feed pulse generator card IMPGEN generates all feed frequencies required for the axis system and controls the connected axis cards (CUTCON2/ POSCON).

A green light emitting diode shows when the IM PGEN actuates the cards connected to it. The red LED indicates that the maximum acceleration has been reached. The pulse generator card can control up to max. 7 axes.

2.5.1 IMPGEN switches 2.5.1 IMPGEN switches Interrupt:

Interrupt:

The switch block SW1 defines the interrupt address of the card. The default setting (SW1) of the third switch on all machines is ON (switched on). The remaining switches must be set to OFF (switched off ).

Master frequency: Master frequency:

The switch block (SW2) defines the divider ratio of the master frequency. The default setting of all switches is OFF (switched off ). The more switches set to ON (switched on), the slower the axes of the machine travel since the frequency for actuating the Poscon is lower.

Encoder input: Encoder input:

The switch block (SW3) defines the multiplication factor with which the encoder inputs of the hand wheel on the remote control are multiplied. This option is not used at present in the glass machines.

2.5 IMPGEN

Im ImIm Im

Impuls GenGenGenGenGenerator Master card for controlling the POSCON cards                           

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2.5 IMPGEN Overview of the switches according to machine type:

Overview of the switches according to machine type:

Tab. 2.5b (IMPGEN switch settings) LED

LED1:1:

The IMPGEN actuates one or more POSCONs. LED

LED2:2:

The maximum acceleration was reached.

Fig. 2.5a (IMPGEN)

                                                                                                               

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Fig. 2.5b (Block diagram of IMPGEN) 2.5 Impgen

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2-21

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2.6 POSCON

The position control card POSCON controls a complete servo axis. The required analogue value of ± 10 V is output via a 12 bit D/A converter to the speed controller (drive module). While working through the CNC code (cutting, drilling or grinding plan), the path is interpolated under IMPGEN control.

The approach to the reference and movement by means of the hand keys is

performed independently by the POSCON; these actions are indicated by means of the green light emitting diode (RUN).

When the axis is exactly on the zero mark of the encoder, the red LED lights up. If the maximum required value of ± 10 VDC is present, the red LED also lights up.

Potentiometer P2: Potentiometer P2:

The potentiometer P2 is used for symmetrical adjustment of the ± 10 volt required value.

LED LED1: Red1: Red

• The maximum required value is present (overflow) • The axis is exactly on the zero mark of the encoder LED

LED2: Green2: Green

• The Poscon actuates the axis without Impgen control (approach to reference_{and manual movement)}

Fig. 2.6a (Output voltage POSCON) 2.6 POSCON

Pos PosPos Pos

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2-23

2.6 POSCON

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Switch block SW1: Switch block SW1:

The multiplication factor of the encoder channels is set with switch block SW1.

Tab. 2.6a (POSCON switch positions) 2.6 POSCON                                                                                                                                                                                                                                                                                                                                                        

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2-25

2.6 POSCON Wire wrap configuration

Wire wrap configuration

Tab. 2.6b (Wire wrap configuration)

                                                                                                                 

(47)

Key to wire wrap configuration Key to wire wrap configuration

Fig. 2.6c (Wire wrap connections)

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2.6 POSCON

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2.7 SERCOM2

The SERCOM2 board is a serial interface card. It has four independent ports which are electrically isolated from the rack and from one another.

These four ports can be adapted to the port required in each case by mounting different interface adapters (SER232, SER422, SERCUL, SERCOPT). The parameters of the ports (baud rate, parity ...) are configured on the panel PC in the MMC program (hardware config.).

The transmission rate is determined by the interface adapter. The upper limit of the transmission rate limits the USART 16C552 on the SERCOM2 board. It is 1.5 Mbit/s. There is only one configuration switch on the SERCOM2 card. It fixes the address for the master interrupt controller.

Interrupt: Interrupt:

Switch block SW1 defines the interrupt address of the card. The default setting of the seventh switch is ON (switched on) for all machines. The remaining switches must be at OFF (switched off).

Tab. 2.7a (SERCOM2 switch positions) 2.7 SERCOM2

Ser SerSer Ser

Serial ComComComComCommunication Card

                                                         

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2-29

2.7 SERCOM2

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2.7 SERCOM2

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2-31

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2.7.1 Adapter cards for SERCOM2 2.7.1 Adapter cards for SERCOM2 SEROPT

SEROPT

The SEROPT module is a bidirectional optical port. It is capable of transmitting data at a rate of up to 60 Mbit/s, over a maximum transmission distance of 1 km.

The data transmission takes place optically in a optical fibre. This method of transmission is insensitive to electromagnetic and electrostatic interference. This method of data transmission is very suitable for achieving a fast and safe link in an environment with strong electrical disturbances. Another advantage is the complete electrical isolating of the communicating devices, since no screen connection is required.

However, the fibreoptic cables are not so resistant to any mechanical stress. It is advisable to handle the fibreoptic cables carefully, i.e. not to bend them excessively and especially not to buckle them. There are no configuration facilities (switches) on the SEROPT module.

Fig. 2.7c (SEROPT) 2.7 SERCOM2

Ser SerSer Ser

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2.7 SERCOM2 Ser232

Ser232

The SER232 module is a bidirectional interface with a V24 port referred to 0 V (ground). The module is capable of transmitting data at a rate of max. 115,200

bit/s. The line length is dependent on the cable characteristics. The capacitive load may not be greater than 2500 pF with a maximum load of 3000 ohm. This corresponds approximately to a cable length of 30 metres.

richt ungefähr einer Kabellänge von 30 Metern.

The module supports the port specifications according to DIN 66020. There are no configuration facilities (switches) on the Ser232 module.

Fig. 2.7d (Ser232)

Ser SerSer Ser

Serial 232232232232232 Adapter Card

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2.7 SERCOM2

SER422 SER422

The SER422 module is a bidirectional interface with a symmetrical port which is not referred to ground. The module is capable of transmitting data at a rate of up to 100 kbit/s over a maximum transmission distance of approx. 1 km. With shorter links, the maximum rate increases. At a length of 100 m, it is thus possible to communicate at a transmission rate of up to 1 Mbit/s. However, these values can

be achieved only if the impedance of the transmission line is 120 ohm and the data lines are terminated at both ends with the corresponding end-of-line resistor.

Fig. 2.7e (Ser422)

Ser SerSer Ser

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2.7 SERCOM2 SERCUL

SERCUL

The SERCUL module is a bidirectional interface between the DUART 16C552 and an external device. The module is capable of transmitting data at a rate of max. 19200 bit/s over a maximum transmission distance of 1 km. However, these

values can be achieved only in an optimal environment (no interfering electrical fields).

The interface is in the form of a current loop. Signal state 1 is indicated by a current of 20 mA. If no current flows in the loop, the signal state is 0.

The transmission circuit can be configured as an active or passive signal source using switch S1. The receiving circuit, too, can be selected as active or passive with switch S2. The 2 loops are in the form of a constant current source or constant current drain and are thus short-circuit-proof.

The two green LEDs indicate whether the current is flowing in the transmission circuit and/or in the receiving circuit.

The LED H1 indicates the current in the transmission circuit and LED H2 that in the receiving circuit.

Tab. 2.7a (SERCUL switch position)

Fig. 2.7f (SERCUL)

Ser SerSer Ser

Serial CuCuCuCuCurrent LLLLLoop Adapter Card

    

  

   

 

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2.8 DIOCOM

The DIOCOM board is an interface card for the Bystronic CN control. It serves as a basis for the input/output communication of the CNC.

Various communication modules can be mounted in the 4 slots (DIOPORT 1-4).

The 16-bit DIOCAN module permits communication with a CAN field bus (SELECAN protocol).

With the 16-bit DIOSSI module, external devices, such as the manual control, the cutting pressure control, etc., are actuated.

The DIOPAR module serves for communication with PARCOM-compatible devices.

Interrupt: Interrupt:

Switch block SW1 defines the interrupt address of the card. The default setting of the 4th switch (SW1) is ON (switched on) in all machines. The remaining switches must be at OFF (switched off ).

DIOCOM slot STD DIOCOM slot STD 2.8 DIOCOM D DD D

Digital IIIIInput OOOOutputO Com ComCom Com Communications Card                                                                         

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2-37

2.8 DIOCOM

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Fig. 2.8b (Block diagram of DIOCOM) 2.8 DIOCOM

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2-39

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2.8 DIOCOM

2.8.1 Interface boards for DIOCOM 2.8.1 Interface boards for DIOCOM DIOPAR

DIOPAR

The DIOPAR module is a simulation of a PARCOM port. It makes it possible to actuate PARCOM-compatible terminals of the CNC89 generation via the DIOCOM board.

The DIOCOM is used exclusively for actuating the auxiliary keyboard (manual control keys X+/X-).

Information! Information!

The DIOPAR module contains no switches or LEDs. The DIOPAR module contains no switches or LEDs.

Fig. 2.8c (DIOPAR)

D DD D

Digital IIIIInput OOOOOutput ParParParParParallel Adapter

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2-41

2.8 DIOCOM DIOSSI

DIOSSI

The DIOSSI module transmits two 16 bit ports (port 1&2). The DIOSSI module

is used as a connection to the pressure controller and to the input/output assemblies (MODULE RAIL S3, I/O M ODULE SSI).

The settings of jumper block J1 are determined by the board layout (cannot be changed) and relate to the following parameters:

• Data inverted (e.g. with open collector actuation) • Transmission rate (250 kbit/s or 500 kbit/s) • Master/slave configuration (timing line)

• OE (Output Enable). Determines whether the data are to be written directly to the output after reception. The output module rail should, for example, output the received data immediately; however, the input module rail may not write its input signals directly to the bus. The data are scanned by the CPU.

Fig. 8.2d (DIOSSI)

D DD D

Digital IIIIInput OOOOOutput SSSSSynchronous SSSSSerial IIIIInterface

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DIOCAN DIOCAN

The DIOCAN module transmits and receives data from a SELECAN network and is thus the connection between the CN control and a Selectron PLC control. The communication to the CAN bus is achieved on the DIOCAN module by a microprocessor in conjunction with a CAN controller. The node address of the DIOCAN in the CAN network is set together with other properties of the node

on configuration switch S1. Owing to its size, the DIOCAN module can be used only in the slots DIOPORT 1 and 2 on the DIOCOM. The green LED lights

up briefly to confirm that the initialization procedure after a restart has been successfully completed. The red LED lights up if a communication error has occurred on the CAN bus.

Information!

The DIOCAN module is currently (October 1998) not used in the glass The DIOCAN module is currently (October 1998) not used in the glass machines.

machines.

Fig. 8.2e (DIOCAN) 2.8 DIOCOM

D DD D

Digital IIIIInput OOOOOutput CCCCController A AA A Area NNNNetworkN               

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2-43

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2.9 POSCAD

The position controller card POSCAD serves for movement of CNC auxiliary axes.

Through the various configuration possibilities, the POSCAD card can be used for the following drive concepts:

• 2 stepping motors without actual value recycling • 1 stepping motor with actual value recycling • 1 servo motor

2.9.1 POSCAD 2.9.1 POSCAD switch switch

Frequency: Frequency:

The switch block (SW1) defines the divider ratio of the master frequency. The more switches at ON (switched on), the slower the down circuit auxiliary axes (motor) travel since the frequency for actuating the stepping motor cards is smaller. Encoder input:

Encoder input:

The switch block (SW2) defines the multiplication factor with which the encoder pulses are multiplied.

2.9.1 (POSCAD switches)

Pos PosPos Pos

Position CCCCController AAAAAcceleration D DD D Deceleration                                               

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2-45

2.9 POSCAD

Fig. 2.9a (POSCAD)

Fig. 2.9b (POSCAD switch positions)

*) With switch 9, the encoder channels A and B are rotated (interchanged) electronically. This causes a change in the counting direction of the channel (±). The procedure for correct setting of switch 9 is described in the commissioning instructions.                                                                  

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2.9 POSCAD                                                                                                                                                                                                                                                                                                                                                                                            

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2-47

Fig. 2.9b (Block diagram of POSCAD)

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3-1

Contents of Chapter

Stepping motor rack

3.1 3.1 Stepping

Stepping motor

motor rack

rack ...

...

.. 3-2

3-2

3.2 S

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3.1 Stepping motor rack

The stepping motor rack is a 19" sub-rack provided with a Bystronic back panel. It permits the integration of the Berger-Lahr stepping motor control cards of Series D550 and D900 in the Bystronic CN controls.

The stepping motor rack can hold one voltage supply module () and up to four stepping motor control cards ().

The required supply voltage (3 x 85 VAC) is delivered by an external transformer which is connected to plug X1 (POWER IN) on the stepping motor rack.

Fig. 3.1a (Front view of Berger stepping motor rack)

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3-3

3.1 Stepping motor rack Control signals:

Control signals:

The control signals of the CNC drive cards (POSCAD) are connected to the 25-pin D-SUB jacks.

X8: Stepping motor control card 1 X9: Stepping motor control card 2 X10: Stepping motor control card 3 X11: Stepping motor control card 4 Power output:

Power output:

The stepping motors (power output) are connected to the 4-pin jacks. X12: MOTOR 1 X13: MOTOR 2 X14: MOTOR 3 X15: MOTOR 4 Error messages: Error messages:

The 3-pin plug X2: ERROR is connected to a potential-free changeover contact relay on each control card. In the event of a fault, the relay on the relevant card will pick up or drop out and thus short-circuit or open the ERROR bus. Voltage supply module:

Voltage supply module:

The 3 x 85 VAC (POWER IN) are rectified to 120 VDC and filtered by the voltage supply module () in the stepping motor rack. A fuse () protects the DC voltage circuit from short-circuit. The output voltage (120 VDC) can be measured at the test jack (, ). The light emitting diode () lights up as soon as the AC-side voltage is min. 10 V.

Information!

T

The he LED (LED () provides no information about the level and quality of the) provides no information about the level and quality of the voltage. It serves merely for indicating that a voltage is present. voltage. It serves merely for indicating that a voltage is present.

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3.2 Stepping motor cards D900

The Berger card D900 serves for actuating 3-phase stepping motors. They are used in the following applications:

• Positioning stops (KSM/VSM/KSBM/PSM) • Spindle height adjustment (PSM)

• Drill feed (PBM)Spindelhöhenverstellung (PSM)

The card is actuated with the pulse, direction, door, current zeroing and micro step signals by a superior control (POSCAD). With these control signals and the (120 VDC) supply voltage, the card drives a 3-phase stepping motor with a current

consumption (adjustable) between 1.35 A and 5.5 A.

Light emitting diodes: Light emitting diodes:

LED1 (green) = Ready (the supply voltage is above 80 VDC) LED2 (red) = Short-circuit between 2 phases

LED3 (red) = Excess temperature (> 75°C) at heat sink LED4 (red) = Overvoltage (> 140 V)

LED5 (red) = Undervoltage (< 80 V)

LED2, 3, 4, 5 = Pulse frequency too high or interfering pulses.

Attention!

In the event of a fault (LED 2 to LED 5), the current to the motor is cut In the event of a fault (LED 2 to LED 5), the current to the motor is cut off and the card reports „Not ready“ (LED 1 goes out).

off and the card reports „Not ready“ (LED 1 goes out).

A currentless motor no longer has a holding moment. This can lead to A currentless motor no longer has a holding moment. This can lead to undesired reactions.

undesired reactions. 3.2 Stepping motor cards D900

                                                    

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3-5

Rotary switch for motor phase current Rotary switch for motor phase current

Tab. 3.2b (Rotary switch for motor phase current)

Information!

The value printed in bold in the Table corresponds to the factory setting. The value printed in bold in the Table corresponds to the factory setting. The set phase current must be equal to or less than the rated phase current The set phase current must be equal to or less than the rated phase current shown on the motor rating plate.

shown on the motor rating plate.

Fig. 3.2a (Stepping motor card D900)

3.2 Stepping motor cards D900

                               _    

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Peripheral cards

4.1 4.1 TERMIF

TERMIF...

...

... 4-2

4-2

4.1.1 TERMIF plugs 4.1.1 TERMIF plugs

4.2 4.2 P

PARAN

ARAN ...

...

.... 4-4

4-4

4.2.1 PARAN plugs 4.2.1 PARAN plugs

4.3 Speed

4.3 Speed limit m

limit monitor

onitor SLIM

SLIM ...

...

.. 4-6

4-6

4.4 SSI

4.4 SSI module bus

module bus S3

S3 ...

...

.. 4-10

4-10

4.5 I/O Module SSI

4.5 I/O Module SSI ...

...

... 4-12

4-12

4.5.1 Light emitting diodes SSI 4.5.1 Light emitting diodes SSI 4.5.2 Plugs on module SSI 4.5.2 Plugs on module SSI

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4.1 TERMIF

The TERMIF is an interface between the hand terminal (HANDTERM) and the CN/PLC control. On the TERMIF, the various HANDTERM signals are divided and are transmitted to the corresponding superior controls (IMPGEN, DIOCOM and PLC).

The two channels A/B of the handwheel incremental encoder are transmitted to the IMPGEN card.

The key channels 1 and 2 and the timing of the SSI link are connected to the DIOCOM card.

The contacts of the emergency stop switch are looped in the safety circuit of the line control.

In addition, detection of whether a function key has been pressed is performed on the key channel 2 of the SSI link. This information is additionally fed into the safety circuit via a relay contact.

This permissive function is possible only with HANDTERM2 since HAND-TERM3 transmits the key to channel 1 (however, only channel 2 is monitored). 4.1 TERMIF

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4-3 ELEKTRONIK.CNC.BA.V2.USA 4.1.1 TERMIF plugs 4.1.1 TERMIF plugs X X11 Terminal 1 +24 VDC Terminal 2 0 VDC (ground) Terminal 3 PE (ground) X X22

Plug for connection to hand terminal (HANDTERM). X

X33

Plug for connection to DIOCOM card (DIOSSI module on Dioport 1). X

X44

Plug for connection to IMPGEN card. X

X55

Function keys contact

These lines are only looped on the TERMIF. The contact is on the HANDTERM. X

X66

Permissive contact

These lines are only looped on the TERMIF. The contact is on the HANDTERM. X

X77 Not-Aus Emergency stop

These lines are only looped on the TERMIF. The contact is on the HANDTERM. 2.10 TERMIF

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4.2 PARAN

The PARAN board provides two isolated analogue voltages (0 VDC - 10 VDC) at plug X3. The voltages are generated by a digital input signal which is 2 x 8 bits wide (plug X1).

Fig. 2.11a (PARAN electronics card)

4.2.1 PARAN plugs 4.2.1 PARAN plugs X

X11

Plug X1 connects PARAN to the DIOPAR card on the DIOCOM board. X

X22

Power supply input for the PARAN board: Terminal 1 24 VDC

Terminal 2 0 VDC X

X33

Analogue voltage output:

Reference value 1 Terminal 1 0-10 VDC Terminal 2 Ground Reference value 2 Terminal 3 0-10 VDC

Terminal 4 Ground 4.2 PARAN

Par ParPar Par

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4-5

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4.3 Speed limit monitor SLIM

The speed limit monitor SLIM monitors the grinding disc speed as a function of the grinding disc diameter and detects whether or not the spindle is rotating. LE

LE DDss

H1 = V max, the set speed has not been exceeded H2 = Stop, spindle is stationary

H3 = Coding switch B active H4 = Coding switch A active H5 = V1 low speed H6 = V2 high speed

H7 = The speed limit indicator of the spindle lights up if the switch (S1 speed monitor) in the spindle is operated.

P1: P1:

Frequency oscillator of this potentiometer is set at the factory and may not be changed.

Speed setting Speed setting

Switch S1 (250 mm) and S2 (150 mm) coding switches A + B

Information!

T

T he vhe value printed in bold alue printed in bold in the in the Table corrTable corresponds to the factory sesponds to the factory setting.etting. 4.3 Speed limit monitor SLIM

SSSSSpeed LimLimLimLimLimit

                                              

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4-7

X 1.1 = +24 VDC supply X 1.2 = 0 V

X 2.1 = +24 VDC from coding switch A X 2.2 = +24 VDC from coding switch B X 2.3 = Signal from the spindle X 3.1 = +24 VDC Enable X 3.3 = 0 V

X 4.1 = Output Limit / K1 contact closed if X 4.2 = Output Limit / n <Limit

X 4.3 = Output Stop / K2 contact closed at X 4.4 = Output Stop / Spindle stop

Information!

This terminal assignment serves only as an example. The correct This terminal assignment serves only as an example. The correct assignment is shown in the connection diagram of the machine. assignment is shown in the connection diagram of the machine.

Fig. 4.3a (Speed limit monitor SLIM)

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4.3 Speed limit monitor SLIM

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4-9

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4.4 SSI module bus S3

The IO MODULE BUS is a device for converting the external binary signals of

switches, contacts or processes into a communication signal according to Bystronic SSI specifications (INPUT) or for converting the SSI signals of the CNC into the external signal levels required for the process (valves, relays, ...) (OUTPUT). The device is designed for mounting on a C bus in the CNC cabinet. The jumpers J1 and J2 on the module bus can be used for selecting the available number of inputs or outputs. The module bus is always configured for 16 inputs and 16 outputs at the factory.

Possible settings Possible settings

16 + 16 Inputs and outputs (24 V) 32 Inputs (24 V)

32 Outputs (24 V)

The green LED H1 lights up when the TTL supply voltage is at least 4.75 volt and the reset signal for the SSI-ASIC has been cleared.

The LED pairs H3 - H5 (green) and H2 - H4 (yellow) indicate the configuration of the channels 1 (H3, H2) and 2 (H5, H4):

• Yellow stands for output (LED H2 and H4) • Green stands for input (LED H5 and H3)

If the SSI master is not connected or the communication terminates for any reason, the SSI-ASIC (U36) automatically switches both channels to input. This ensures that the connected output modules and their actuated outputs are immediately

deactivated.

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4-11

Fig. 4.4a (Module bus S3)

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4.5 I/O module SSI

The IO MODULE SSI is a device for converting the external binary signals of

switches, contacts or processes into a communication signal according to Bystronic SSI specifications (INPUT) or for converting the SSI signals of a control system

into the external signal level required for the process (OUTPUT). Thanks to its compact dimensions, it can be used both in a switch cabinet and in

a ventilated terminal box. The internal modular concept permits a simple design as a decentral IO unit with alternatively:

16 + 16 Inputs and outputs (24 V) 32 Inputs (24 V)

32 Outputs (24 V)

4.5.1 Light emitting diodes SSI 4.5.1 Light emitting diodes SSI Power:

The green LED POWER lights up if the I/O module is supplied with 24 VDC, the TTL supply voltage is at least 4.75 volt and the reset signal for the SSI-ASIC has been cleared.

CH1 and CH2:

The LED pairs CH1 and CH2 underneath indicate the configuration of channels 1 and 2: yellow stands for output and green for input. If the SSI master is not connected or the communication is terminated for any reason, the SSI-ASIC automatically switches both channels to input: this ensures that the output modules connected to the IO-SSI board or their actuated outputs are immediately deactivated if the cable breaks or the master fails.

X1 - CH1 output:

To the right of each output terminal is the corresponding yellow signal LED. This lights up if the output circuit is actuated by the TTL logic and is supplied from

outside (terminals 17 and 18), independently of whether a load is connected to the output.

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4-13

4.5 I/O Modul SSI X2 - CH2 Input:

To the right of each input terminal is the corresponding green signal LED. These light up if a voltage is applied between the input terminal and the reference potential

terminal, independently of whether the IO MODULE is switched on or not. Each input on the TTL side is made bounce-proof with a 5 ms time constant.

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4.5.2 Plugs on module SSI

Supply:

The external supply voltage is connected via the 3-pin plug X4. The protective earth must be connected since otherwise the ESD protection is not effective.

Speisung: Input:

The input signals are connected to the first 16 terminals of the 18-pin input plug (X2 - CH2). The protective earth must be connected to terminal 17 since otherwise the ESD protection of the input circuit is not effective. The total 0 V reference potential of the 16 inputs is connected to terminal 18.

Output:

Each of the 16 outputs (X1 - CH1) is provided with short-circuit protection: as

soon as the output current is more than 3.5 A, the actuation of all outputs on the TTL side is blocked and the red LED to the right of terminal 17 lights up. To restore the normal function, the cause of the overload must be eliminated and the supply of the outputs briefly interrupted. The short-circuit protection is sluggish

so that the actuation of capacitive loads is possible without problems. Communication with CNC:

The SSI master is connected via the 9-pin plug X3. 4.5 I/O Modul SSI

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4-15

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Panel PC

5.1 The

5.1 The Panel PC

Panel PC ...

...

... 5-2

5-2

5.1.1 Overview of the interrupts and

5.1.1 Overview of the interrupts and I/O addresses in the PPCI/O addresses in the PPC 5.1.2 Description of Bystronic interface cards in the PPC 5.1.2 Description of Bystronic interface cards in the PPC 5.1.3 Jumpers and switches

5.1.3 Jumpers and switches 5.1.4 Switch S1 I/O address 5.1.4 Switch S1 I/O address

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5.1 Panel PC

The PPC is a universal industrial computer for use in a machine environment. Depending on requirements, all commercial PC components from motherboard to passive bus slot systems can be installed.

Failures of the standard PC components through excessively high temperatures, dust, moisture, vibrations, interference and an aggressive environment are prevented

by the following measures:

•Complete protection from electromagnetic fields •Protection from dust and splashes

•Monitoring of the mains and computer voltages •Controlled booting of the computer

•Improved cooling with excess temperature monitoring •Vibration-damped installation of the drives

The Panel PC used in the Bystronic machines are tested for the following requirements.

•Safety

•Noise voltage and spurious emission •Noise immunity to ESD

•

Noise immunity to electromagnetic fields

•Noise immunity to fast transients

The Panel PC is basically considered as a complete unit. Changing or replacement of individual plug-in cards, TFT display or other hardware components outside the Bystronic parent company or its subsidiaries is not permissible. 5.1 Panel PC

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5-3

Fig. 5.1a (Front view of Panel PC)

1 TFT screen

2 100 MB ID E zip drive 3 1.44 MB drive

4 Indicator lamps and reset button 5 Mouse

6 Hand control keys 7 Pull-out PC keyboard 8 CNC control keys

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5.1.1 Overview of the interrupts and

5.1.1 Overview of the interrupts and I/O addresses in the PPCI/O addresses in the PPC

Tab. 5.1a (IRQ and I/O addresses in the Panel PC) 5.1 Panel PC                                                                                                                                             

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5-5

5.1 Panel PC

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5.1.2 Description of Bystronic interface cards in the PPC 5.1.2 Description of Bystronic interface cards in the PPC PCOLA serial interface card with optical fibres

The PCOLA board is a serial interface card for installation in a 16-bit ISA slot or an IBM-AT or compatible personal computer. The card guarantees 100% address and register compatibility with a standard IBM serial interface card and has two

16550 FIFO UARTs and an extended interrupt selection. The use of a PCOLA board permits the addition of up to two electrically isolated serial connections via a TOSLINK optical fibre.

5.1.3 Jumpers and switches 5.1.3 Jumpers and switches

The jumper J1 defines the address range of the PCOLA board. When jumper J1 is not inserted, the 2 serial interfaces are configured as COM1 and COM2

(addresses 3F8h and 2F8h); when jumper J1 is inserted, they are configured as COM3 and COM4 (addresses 3E8h and 2E8h, factory setting). It is not possible

to switch off one of the two ports.

The interrupt for the first and the second port is selected with the slide switches S1 (IRQ5, factory setting) and S2 (IRQ6, factory setting).

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5-7

PCTIF keyboard interface PCTIF keyboard interface

The PCTIF board is a keyboard controller card for installation in an 8- or 16-bit ISA slot of an IBM-AT or compatible personal computer.

The use of the PCTIF board permits the operation of the Bystronic CNC foil keypad parallel with the standard PC keyboard.

The PCTIF board can operate the Bystronic CNC keyboard with up to 88 keys and 3 switching keys. This results in up to 160 unambiguous pieces of input information. A key switch can be used to enable the keyboard. The PCTIF board

can directly actuate up to 24 LED lamps on the CNC keyboard.

The PCTIF board is connected to the CNC keyboard via a 50-pin flat cable not more than 0.5 metre long.

J

Jumpeumper J1 Inter J1 Interrrurupt conpt configfigururaatiotionn

Tab. 5.1b (Interrupt setting on PCTIF)

5.1 Panel PC                     

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5.1 Panel PC

Fig. 5.1e (PCTIF board) 5.1.4 Switch S1 I/O address 5.1.4 Switch S1 I/O address

Fig. 5.1d (I/O address on PCTIF)

Switches S2 and S3 (scanning of parameter register) Switches S2 and S3 (scanning of parameter register)

These two switches are not used. All switches should be at OFF. .

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5-9

5.1 Panel PC PTCON (Power and Temperature Control)

PTCON (Power and Temperature Control)

The voltage and temperature monitor PTCON guarantees the operational safety

of the Panel PC in exceptional situations, such as sluggish switching on and off, voltage fluctuations, switching on and off at short intervals or insufficient cooling. The Panel PC is started up only when the +5 VDC and +15 VDC electronics supply are within the tolerance limits for about five seconds.

The internal temperature of the Panel PC is monitored by a temperature sensor.

If the internal temperature of the Panel PC exceeds 45°C, the overtemperature indicator lamp at the front of the Panel PC is actuated. This warning lamp indicates that the cooling of the Panel PC is no longer sufficient. A reliable operation of the Panel PC can no longer be guaranteed.

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