Electronics Manual CNC

P.
Ingold
Electronics Manual CNC97/98

All machines for construction glass and automobile glass
BYSTRONIC
Maschinen AG
BYSTRONIC
INC.
Industriestrasse 5
CH - 4922 Btzberg
30, Commerce Drive

Hauppauge, NY, 11788
Telephone +4162 958 77 77

Telefax +4162 958 77 00
Phone +1516 231 1212

Fax +1516 231 1040
E-Mail support.glass@bystronic.ch
http:/www.bystronic.ch
email service@bystronicusa.com
ELEKTRONIK.CNC.BA.V2.USA
V-1
Electronics Manual CNC 97/98

Copyright of the edition 1999 Bystronic Maschinen AG
The work, including all its parts, is protected by copyright. Any use outside the narrow limits of the copyright law is not permitted
without Bystronics consent.
Information on operating instructions

Author: P. Ingold
Date: 2.2.1999
Initials: PI
Date: 29.1.1999
Date: 5.2.1999
Initials: TP
Initials: rf
Version: 2.0
Order-No.: ELEKTRONIK.CNC.BA.V2.USA
Checked & Approved

Technology: Th. Plss
Documentation: R. Fankhauser
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 Btzberg
Telefax +4162-958 77 00
E-Mail RolandFankhauser@bystronic.ch
Trade marks:
Bystronic would like to draw attention to the fact that the company names and trade names mentioned and product
designations may be protected by patent and trade mark law.
V-2
Using this Manual
Page organization
The pages of the operating instructions have the following structure.
Information on structure of the operating instructions
1
2
3
4
5
6
7
8
9
10
11
The header contains the name of Title 1

Title 1
Brief summary of the present chapter
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.
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.
Page numbering of the current chapter.
Table caption and brief explanation.
Figure caption and brief explanation.
Information with preceding pictogram must be complied with.
Refers to pages with more detailed information.
Explanation of a technical word used or of an abbreviation.
V-3
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 therefore not
necessarily suitable for the operator.
V-4
Table of Contents
Block diagram 1-1
Electronics rack
Stepping motor rack
Peripheral cards
5 Panel PC
2-1
3-1
4-1
5-1
Drive system
6-1
Drive supply module
Drive module 8-1
Pressure controller 9-1
7-1
10 Positioning module UNIPOS

11
Adjustment instructions
10-1
11-1
12 Appendix 12-1
V-5
V-6
Contents of Chapter 1
Block diagram
1.1 Block diagram ........................................................................1-2
1.1.1 XYZ97/98
1.1.2 XYZF97/98
1.1.3 XYZF97/98R
1.1.4 XYZF97/98DS
1.1.5 PSM-XYZF98
1.1.6 KSM97/98
1.1.7 KSBM97/98
1.1.8 PSM97/98 (Stand alone)
1.1.9 PSM97/98 Compact
1.1.10 PBM98
1-1
Block diagram XYZ97/98
1-2
Block diagram XYZF97/98
1-3
Block diagram XYZF97/98R
1-4
Block diagram XYZF97/98DS
1-5
Block diagram PSM-XYZF98
1-6
Block diagram KSM97/98
1-7
Block diagram KSBM97/98
1-8
Block diagram VSM97/98
1-9
Block diagram PSM97/98 (Stand alone)
1-10
Block diagram PSM97/98 Compact
1-11
Block diagram PBM98
1-12
For your notes
1-13
For your notes
1-14
Contents of Chapter
Electronics rack
2.1 The CNC Rack..................................................................... 2-2
2.1.1 RACK SUPPLY 2
2.2 CPU.......................................................................................2-8
2.2.1 CPU 386SX
2.2.2 Light emitting diodes on CPU
2.2.3 CPU switches
2.2.4 CPU Jumpers
2.3 ROM/RAM2 ...................................................................... 2-12

2.3.1 ROM/RAM2 Jumper
2.4 CUTCON2
2.5 IMPGEN ............................................................................. 2-18
2.5.1 Impgen switches
2.6 POSCON ........................................................................... 2-22

2.7 SERCOM2 .......................................................................... 2-28
2.7.1 Adapter cards for SERCOM2
2.8 DIOCOM ........................................................................... 2-36

2.8.1 Adapter cards for DIOCOM
2.9 POSCAD............................................................................ 2-44

2.9.1 POSCAD switches
2-1
2.1 CNC rack
2.1 The CNC Rack

The " CNC rack has space for the power supply, a CPU card and cards for
peripherals.
Electrostatic discharge
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.
2-2
2.1 CNC Rack
Fig. 2.1a (Electronics rack)
2-3
2.1 CNC rack
2.1.1 RACK SUPPLY 2

The RACK SUPPLY 2 provides the rack with the stabilized voltages, 5 V/20 A
digital part, 12 V1.5 A analogue part, and the unstabilized voltage 14 V/6 A of
the encoder supply.
C omputer N umerical C ontrol
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 ().
2-4
2.1 CNC rack
Fig. 2.1b (RACK SUPPLY 2)
Legend:
1 Reserve fuses
2 Fuses
3 +5 VDC LED
4 +5 VDC test jack
5 +12 VDC LED
6 +12 VDC test jack
7
8
9
10
11
-12 VDC LED

-12 VDC test jack
14 VDC LED
14 VDC test jack
Alarm A + B LED
2-5
2.1 CNC rack
Fig. 2.1c (Block diagram of RACK SUPPLY 2)
2-6
For your notes
2-7
2.2 CPU
2.2 CPU
2.2.1 CPU 386SX
Abbreviation for
m illions of i nstructions p er s econd
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 universal 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.
Fig. 2.2a (CPU 386SX)
2-8
2.2 CPU
2.2.2 Light emitting diodes on CPU

LED H1 yellow
BUSY indicates by means of its luminous intensity the level of utilization of the
processor.
LED H2 green
IDLE indicates by means of its luminous intensity the time for which the processor
has been waiting in a queue for work.
LED H3 red
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 H4 red
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 (Non Maskable Interrupt)
or a cold start.
LED H5 yellow
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 H6 red
INTERRUPT REQUEST 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.
2-9
2.2 CPU
2.2.3 CPU switches

S1
The CPU performs a cold start and triggers a system reset.
S2
Position of the memory on the CPU card. (Standard setting: No. 1 at ON/No.
2 at OFF applies to all machines.)
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

J5
Configuration of external interrupts:
Pin 1 with 8
Pin 2 with 7
Pin 3 with 6
Pin 4 with 5
external Non Maskable Interrupt (NMI) connected to internal

NMI
external AC powerfail (ACPF) connected to internal NMI
external AC powerfail (ACPF) connected to INT9
external INT9 connected to internal INT9
Factory settings for all machines

Pin 1 connected to 8
Pin 4 connected to 5
Fig. 2.2b (CPU 386SX)
2-10
2.2 CPU
Fig. 2.2c (Block diagram of CPU 386SX)
2-11
2.3 ROM/RAM2
2.3 ROM/RAM2
R ead O nly M emory/RR ead A ccess
M emory
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 readonly 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
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.
Fig. 2.3a (ROM/RAM2)
2-12
2.3 ROM/RAM2
Fig. 2.3b (Block diagram of ROM/RAM2)
2-13
2.4 CUTCON2
2.4 CUTCON2
Cut
Cutting Con
Controller
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
used. The switch settings are therefore unimportant.
LED`s
The four LEDs (1, 2, 3 and 4) are not actuated and thus have no function as error
or status indicators.
2-14
2.4 Cutcon2
Fig. 2.4a (Cutcon2)
2-15
2.4 Cutcon2
Fig. 2.4b (Block diagram of CUTCON2)
2-16
For your notes
2-17
2.5 IMPGEN
2.5 IMPGEN
Im
Impuls Gen
Generator
Master card for controlling the
POSCON cards
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 IMPGEN 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

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:
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:
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.
Switch
position
1
2
3
4
5
6
7
8
9
Encoder
channel
A
A
A
A
B
B
B
B
A&B
Multiplication
factor
1
2
4
direct (for test only)
1
2
3
Electronic
interchange
of A & B channel
Tab. 2.5a (IMPGEN)
2-18
2.5 IMPGEN
Overview of the switches according to machine type:

Machine
XYZF97/98(R)
XYZF97/98 DS
XYZF97/98L FF
XYZF97/98 FF
KSM97/98
KBM97/98
KSBM97/98
VSM97/98
PSM97/98
PBM97/98
PSM - XYZF98
Interrupt SW1
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
3 ON Rest OFF
Master frequency SW2

all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
Handwheel SW3
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
all OFF
Tab. 2.5b (IMPGEN switch settings)

LED 1:
The IMPGEN actuates one or more POSCONs.

LED 2:
The maximum acceleration was reached.
Fig. 2.5a (IMPGEN)

2-19
2.5 Impgen
Fig. 2.5b (Block diagram of IMPGEN)
2-20
For your notes
2-21
2.6 POSCON
2.6 POSCON
Pos
Position Con
Controller
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:
The potentiometer P2 is used for symmetrical adjustment of the 10 volt required
value.
LED 1: Red
The maximum required value is present (overflow)

The axis is exactly on the zero mark of the encoder
LED 2: Green
The Poscon actuates the axis without Impgen control (approach to reference
and manual movement)
Fig. 2.6a (Output voltage POSCON)
2-22
2.6 POSCON
Fig. 2.6b (POSCON)
2-23
2.6 POSCON
Switch block SW1:

The multiplication factor of the encoder channels is set with switch block SW1.
Machine
POSCON SW1
XYZF97/98(R) Bridge
Tool carriage
Cutting tool
Grinding tool
XYZF97/98DS Bridge
Tool carriage
Cutting tool
XYZF97/98L FF Bridge
Tool carriage
Cutting tool
XYZF97/98 FF Bridge
Tool carriage
Cutting tool
PSM-XYZF98
Bridge
Tool carriage
Cutting tool
KSM97/98
Bridge
Tool carriage
Cutting tool
KBM97/98
Bridge
Tool carriage
Breaking roller
KSBM97/98 Bridge
Tool carriage
Cutting tool
Breaking tool
VSM97/98
Bridge
Tool carriage
Cutting tool
Rotary suction cup
PSM97/98
PBM97/98
Linear
Polar
Drilling station 1&2
Longitudinal Tool carriage
Rotary suction cup
Factor
4
2
2
1
4
2
2
4
2
2
4
2
2
4
2
2
4
2
2
4
2
2
4
2
2
2
4
2
2
Gear 1:15 = 2
Gear 1:30 = 1
Gear 1:5 = 1
2
3
3
3
4
Switch positions Switch 9

3 & 7 ON
2 & 6 ON
2 & 6 ON
1 & 5 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
2 & 6 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
2 & 6 ON
3 & 7 ON
2 & 6 ON
2 & 6 ON
2 & 6 ON
1 & 5 ON
1 & 5 ON
2 & 6 ON
1&2&5&6 ON
1&2&5&6 ON
1&2&5&6 ON
3&7 ON
See note
See note
9 OFF
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
See note
See note
9 OFF
9 OFF
See note
See note
9 OFF
9 ON
9 ON
9 ON
9 ON
9 ON
9 ON
9 ON
9 OFF
Tab. 2.6a (POSCON switch positions)
Information!
The encoder channels A + B are rotated (interchanged) electronically with
switch 9. This changes the counting direction of the channel (). The
procedure for correct setting of switch 9 is described in the instructions for
commissioning.
2-24
2.6 POSCON
Wire wrap configuration

Machine
XYZF97/98(R)
XYZF97/98DS
XYZF97/98L FF
XYZF97/98 FF
PSM-XYZF98
KSM97/98
KBM97/98
KSBM97/98
VSM97/98
PSM97/98
PBM97/98
POSCON
Bridge
Tool carriage
Cutting tool
Grinding tool
Bridge
Tool carriage
Cutting tool
Bridge
Tool carriage
Cutting tool
Bridge
Tool carriage
Cutting tool
Bridge
Tool carriage
Cutting tool
Bridge
Tool carriage
Cutting tool
Bridge
Tool carriage
Breaking roller
Bridge
Tool carriage
Cutting tool
Breaking tool
Bridge
Tool carriage
Cutting tool
Rotary suction cup
Linear
Polar
Drilling station 1&2
Longitudinal Tool carriage
Rotary suction cup
Wrapping
D
D
B
B
D
D
B
C
D
B
C
D
B
C
D
B
D
D
B
D
D
B
D
D
B
B
D
D
B
A
C
C
D
D
F
Tab. 2.6b (Wire wrap configuration)
2-25
2.6 POSCON
Key to wire wrap configuration
Fig. 2.6c (Wire wrap connections)
2-26
2.6 POSCON
Fig. 2.6d (Block diagram of POSCON )
2-27
2.7 SERCOM2
2.7 SERCOM2
Ser
Serial Com
Communication Card
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:
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).
Machine
XYZF97/98(R)
XYZF97/98DS
XYZF97/98LFF
XYZF97/98FF
PSM-XYZF98
KSM97/98
KBM97/98
KSBM97/98
VSM97/98
PSM97/98
PBM97/98
Interrupt SW1
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
7 ON Rest OFF
Tab. 2.7a (SERCOM2 switch positions)
2-28
2.7 SERCOM2
Fig. 2.7a (SERCOM2)
2-29
2.7 SERCOM2
Fig. 2.7b (Block diagram of SERCOM2 )
2-30
For your notes
2-31
2.7 SERCOM2
2.7.1 Adapter cards for SERCOM2
Ser
Serial Opt
Optical Adapter Card
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)
2-32
2.7 SERCOM2
Ser
Serial 232 Adapter Card
Abbreviation for picofarad
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 ungefhr einer Kabellnge 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)
2-33
2.7 SERCOM2
Ser
422 Adapter Card
Serial RS422
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)
2-34
2.7 SERCOM2
Ser
Serial Cu
Current L oop Adapter Card
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.
Application
Byshow
PSM
Suction display
Breaking station (PLC)
S1 (Transmitter) S2 (Receiver)
active
active
active
not used
active
active
Tab. 2.7a (SERCUL switch position)
Fig. 2.7f (SERCUL)
2-35
2.8 DIOCOM
2.8 DIOCOM
D igital I nput O utput
Com
Communications Card
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 14).
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:
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 STE
Machine
Interrupt SW1
XYZF97/98(R) 4 ON Rest OFF
XYZF97/98DS 4 ON Rest OFF
XYZF97/98L FF 4 ON Rest OFF
XYZF97/98 FF 4 ON Rest OFF
PSM-XYZF98 4 ON Rest OFF
KSM97/98
4 ON Rest OFF
KBM97/98
4 ON Rest OFF
KSBM97/98 4 ON Rest OFF
VSM97/98
4 ON Rest OFF
PSM97/98
4 ON Rest OFF
PBM97/98
4 ON Rest OFF
Machine
Interrupt SW1
XYZF97/98(R) 5 ON Rest OFF
XYZF97/98DS 5 ON Rest OFF
XYZF97/98L FF 5 ON Rest OFF
XYZF97/98 FF 5 ON Rest OFF
PSM-XYZF98 5 ON Rest OFF
KSM97/98
5 ON Rest OFF
KBM97/98
5 ON Rest OFF
KSBM97/98 5 ON Rest OFF
VSM97/98
5 ON Rest OFF
PSM97/98
5 ON Rest OFF
PBM97/98
5 ON Rest OFF
Tab. 2.8a (DIOCOM switch positions)
2-36
2.8 DIOCOM
Fig. 2.8a (DIOCOM)
2-37
2.8 DIOCOM
Fig. 2.8b (Block diagram of DIOCOM)
2-38
For your notes
2-39
2.8 DIOCOM
2.8.1 Interface boards for DIOCOM
D igital I nput O utput Par

Parallel
Adapter
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!
The DIOPAR module contains no switches or LEDs.
Fig. 2.8c (DIOPAR)
2-40
2.8 DIOCOM
D igital I nput O utput S ynchronous

S erial I nterface
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 MODULE 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)
2-41
2.8 DIOCOM
D igital I nput O utput C ontroller

A rea N etwork
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
machines.
Fig. 8.2e (DIOCAN)

Switch
1
2
3
4
5
6
7
Node address
1
2
4
8
16
Transmission rate
OFF
20 kbit/s ON 100 kbit/s OFF 500 kbit/s ON 1Mbit/s
OFF
OFF
ON
ON
CMR Monitor
On
OFF
Enable
Disable
Fig. 2.8b (Switch 1)
2-42
For youe notes
2-43
2.9 POSCAD
2.9 POSCAD
Pos
Position C ontroller A cceleration
D eceleration
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 switch

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:
The switch block (SW2) defines the multiplication factor with which the encoder
pulses are multiplied.
Switch Encoder channel Multiplication factor
position
1
A
1
2
A
2
3
A
4
4
A
5
B
1
6
B
2
7
B
3
8
B
9
A&B
Electronic
interchange
of A & B channel
2.9.1 (POSCAD switches)
2-44
2.9 POSCAD
Machine
KSM97/98
KSBM97/98
PSM97/98
PBM94/97
PBM98
Axis
X-stop
Y-stop
X,Y-stop
Grinding spindle
SW1 (frequency) SW2 (encoder multiplication factor

8 ON
not provided
8 ON
not provided
8 ON
not provided
Drill spindle
Drill spindle
all ON
2 & 3 & 5 ON
2 & 3 & 5 ON
not provided
1 & 3 & 4 & 6 & * ON
1 & 5 & * ON
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.
Fig. 2.9a (POSCAD)
2-45
2-46
Version
VAR01 SM
VAR01 SM
VAR01 SM
VAR02 PBM
VAR PBM98
Axis
Stops
Spindle
Stops
Drill spindle
Janbac
Drill spindle
Fischer
Machine
KSM97/98
PSM97/98
PBM94/97
CNC89
PBM98
CNC97
SYNPBM
SYN-PBM
not provided
not provided
not provided
PLD
IC U25
COM-A
COM-A
not provided
not provided
not provided
(PAL,
IC U26
PBM96
POSCAD
POSCAD
POSCAD
Eprom
RGC-C P0123.1A
RGC-C
RGC--B
RGC--B
RGC--B
GAL)
IC U27
A (1-2)
A (1-2)
A (1-2)
A (1-2)
A (1-2)
Jumper
J1
no wrap
no wrap
not provided
not provided
not provided
Wrap field
J2
A
A
2.9 POSCAD
Fig. 2.9c (POSCAD configuration)
2.9 POSCAD
Fig. 2.9b (Block diagram of POSCAD)
2-47
For your notes
2-48
Contents of Chapter
Stepping motor rack

3.1 Stepping motor rack .......................................................... 3-2
3.2 Stepping motor cards D900 ............................................ 3-4
3-1
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)
Fig. 3.1b (Back of Berger stepping motor rack)
3-2
Control signals:
The control signals of the CNC drive cards (POSCAD) are connected to the 25pin D-SUB jacks.
X8: Stepping motor control card 1
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:
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:
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!
The LED ( ) provides no information about the level and quality of the
voltage. It serves merely for indicating that a voltage is present.
3-3
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)Spindelhhenverstellung (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:
LED 1 (green)
=
Ready (the supply voltage is above 80 VDC)
LED 2 (red)
=
Short-circuit between 2 phases
LED 3 (red)
=
Excess temperature (> 75C) at heat sink
LED 4 (red)
=
Overvoltage (> 140 V)
LED 5 (red)
=
Undervoltage (< 80 V)
LED 2, 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
off and the card reports Not ready (LED 1 goes out).
A currentless motor no longer has a holding moment. This can lead to
undesired reactions.
Switch
Number of steps without micro step (Pins OFF)

1
ON 200 ON 400
OFF 500
2
OFF
ON
ON
OFF
OFF
1000
Number of steps with micro step (Pins ON)

1
ON 2000 ON 4000 OFF 5000 OFF 10000
2
OFF
ON
ON
OFF
Current lowering
3
OFF On
ON Off
4
No function
Fig. 3.2a (Dip switch settings on Berger card D900)
Factory setting:
Steps:
Current lowering:
3-4
1 OFF 2 ON (500 steps)

3 OFF current lowering on
Rotary switch for motor phase current

Position Phase current (A)
0
1.35
1
1.65
2
1.9
3
2.2
4
2.45
5
2.75
6
3
7
3.3
8
3.6
9
3.9
A
4.15
B
4.4
C
4.7
D
5
E
5.2
F
5.5
Tab. 3.2b (Rotary switch for motor phase current)
Information!
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
shown on the motor rating plate.
Fig. 3.2a (Stepping motor card D900)

3-5
For your notes
3-6
Contents of Chapter
Peripheral cards
4.1 TERMIF................................................................................. 4-2
4.1.1 TERMIF plugs
4.2 PARAN ............................................................................... 4-4

4.2.1 PARAN plugs
4.3 Speed limit monitor SLIM ................................................. 4-6

4.4 SSI module bus S3 ........................................................... 4-10
4.5 I/O Module SSI ................................................................ 4-12
4.5.1 Light emitting diodes SSI
4.5.2 Plugs on module SSI
4-1
4.1 TERMIF
4.1 TERMIF
Ter
m inal I nterff ace Adapter
erm
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 HANDTERM3 transmits the key to channel 1 (however, only channel 2 is monitored).
Fig. 2.10a (TERMIF)
4-2
2.10 TERMIF
4.1.1 TERMIF plugs

X1
Terminal 1
Terminal 2
Terminal 3
+24 VDC
0 VDC (ground)
PE (ground)
X2
Plug for connection to hand terminal (HANDTERM).
X3
Plug for connection to DIOCOM card (DIOSSI module on Dioport 1).
X4
Plug for connection to IMPGEN card.
X5
Function keys contact
These lines are only looped on the TERMIF. The contact is on the HANDTERM.
X6
Permissive contact
X7
Not-Aus
Emergency stop
4-3
4.2 PARAN
4.2 PARAN
Par
Parallel An
Analogue Converter
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

X1
Plug X1 connects PARAN to the DIOPAR card on the DIOCOM board.
X2
Power supply input for the PARAN board:
Terminal 1 24 VDC
Terminal 2 0 VDC
X3
Analogue voltage output:
Reference value 1 Terminal 1 0-10 VDC
Terminal 2 Ground
Reference value 2
4-4
Terminal 3 0-10 VDC

Terminal 4 Ground
For your notes
4-5
4.3 Speed limit monitor SLIM

S peed Lim
Limit
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.
LEDs
H1
H2
H3
H4
H5
H6
H7
=
=
=
=
=
=
=
V max, the set speed has not been exceeded

Stop, spindle is stationary
Coding switch B active
Coding switch A active
V1 low speed
V2 high speed
The speed limit indicator of the spindle lights up if the switch (S1 speed
monitor) in the spindle is operated.
P1:
Frequency oscillator of this potentiometer is set at the factory and may not be
changed.
Speed setting
Switch S1 (250 mm) and S2 (150 mm) coding switches A + B
Information!
The value printed in bold in the Table corresponds to the factory setting.
Position
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
250-type disc
S1
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
150-type disc
S2
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
Tab. 4.3a (Speed setting)
4-6
X 1.1
X 1.2
X 2.1
X 2.2
X 2.3
X 3.1
X 3.3
X 4.1
X 4.2
X 4.3
X 4.4
= +24 VDC supply

= 0V
= +24 VDC from coding switch A
= +24 VDC from coding switch B
= Signal from the spindle
= +24 VDC Enable
= 0V
= Output Limit / K1 contact closed if
= Output Limit / n <Limit
= Output Stop / K2 contact closed at
= Output Stop / Spindle stop
Information!
This terminal assignment serves only as an example. The correct
assignment is shown in the connection diagram of the machine.
Fig. 4.3a (Speed limit monitor SLIM)
4-7
Fig. 4.3b (Block diagram of speed limit monitor SLIM)
4-8
For your notes
4-9
4.4 SSI module bus S3
S ynchronous S erial I nterface
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
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.
4-10
Fig. 4.4a (Module bus S3)

4-11
4.5 I/O module SSI
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
32
32
Inputs and outputs (24 V)

Inputs (24 V)
Outputs (24 V)
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.
Each of the 16 outputs is provided with short-circuit protection: as soon as the
output current is more than 3.5 A, the actuation of all outputs is blocked on the
TTL side 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 must be briefly interrupted. The short-circuit protection is sluggish
so that the actuation of capacitive loads is possible without problems.
4-12
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.
Fig. 4.5a (I/O module SSI)
4-13
4.5 I/O Modul SSI
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.
Fig. 4.5b (I/O module SSI)
4-14
For your notes
4-15
For your notes
4-16
Contents of Chapter
Panel PC
5.1 The Panel PC ....................................................................... 5-2
5.1.1 Overview of the interrupts and I/O addresses in the PPC
5.1.2 Description of Bystronic interface cards in the PPC
5.1.3 Jumpers and switches
5.1.4 Switch S1 I/O address
5-1
5.1 Panel PC
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.
5-2
5.1 Panel PC
Fig. 5.1a (Front view of Panel PC)
1
2
3
4
5
6
7
8
TFT screen
100 MB IDE zip drive
1.44 MB drive
Indicator lamps and reset button
Mouse
Hand control keys
Pull-out PC keyboard
CNC control keys
5-3
5.1 Panel PC
5.1.1 Overview of the interrupts and I/O addresses in the PPC

IRQ
0
1
2
3
I/O address Assigned hardware
Remarks
0040 - 0043 System timer

0060 - 0060 PC keyboard
0020 - 0021 Interrupt controller
02F8 - 02FF COM 2

4
03F8 - 03FF COM 1
5
300
CNC keyboard
6 03F0 - 03F5 1.44 MB floppy drive
7 0378 - 037B Parallel Port 1 (LPT1)
8 0070 - 0071 CMOS/Real-time clock
9 00A0 - 00A1 Second interrupt controller
10 03E8 - 03EF COM 3
11 02E8 - 02EF COM 4
12 0340 - 034F Network card
13 00F0 - 00FF Coprocessor
14 01F0 - 01F7 PCI IDE controller
15 01F0 - 01F7 First IDE controller
Mouse
Not used
Not visible in system control
Hardware protection (Dongle)
Fibreoptic connection to CNC CPU

Fibreoptic connection not used
Connection to Ethernet
Hard disks and zip drive
Hard disks and zip drive
Tab. 5.1a (IRQ and I/O addresses in the Panel PC)
5-4
5.1 Panel PC
Fig. 5.1b (Block diagram of Panel PC)
5-5
5.1 Panel PC
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

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).
Fig. 5.1c (PCOLA board)
5-6
5.1 Panel PC
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.
Jumper J1 Interrupt configuration

Bridge (Jumper J1)
1 with 2
3 with 4
5 with 6
7 with 8
IRQ3
IRQ4
IRQ5 Factory setting
IRQ7
Tab. 5.1b (Interrupt setting on PCTIF)
5-7
5.1 Panel PC
5.1.4 Switch S1 I/O address
Fig. 5.1d (I/O address on PCTIF)
Switches S2 and S3 (scanning of parameter register)

These two switches are not used. All switches should be at OFF.
.
Fig. 5.1e (PCTIF board)
5-8
5.1 Panel PC
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 45C, 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.
Fig. 5.1f (PTCON board)
5-9
For your notes
5-10
Contents of Chapter
Drive system
6.1 AC drive system .................................................................. 6-2
6.2 AC motors........................................................................... 6-4
6.2.1 AC integrated synchronous motor
6.2.2 AC standard synchronous motor
6.2.3 Motor feedback unit
6.2.4 Incremental encoder
6-1
6.1 AC drive system
6.1 AC drive system

The Bystronic drive system essentially consists of the POSCON axis card with
reference input generation and bearing control, the supply and drive module (VM/
AM) and the transducers, incremental generator and motor feedback unit.
The structure of the BYSTRONIC drive system is in principle identical for all
CNC axes equipped with AC motors.
Fig. 6.1a (Block diagram of drive system)
6-2
For your notes
6-3
6.2 AC motors
6.2 AC motors
The use of AC motors completely dispenses with the need for servicing the motors
in future, since, apart from the rotor bearing (ball bearing), there are no longer
any mechanically stressed parts (carbons) in the motor.
We make a distinction between two different types of motors:
AC integrated synchronous motor
AC standard synchronous motor
6.2.1 AC integrated synchronous motor

The AC Einbau [integrated] synchronous motor (AE...) is a direct drive motor
with high torque per unit weight (Nm/kg) and impressive dynamics. The design
involving direct integration of the motor in the machine permits compact structure
and substantial weight savings. This continuously energized 12-pole synchronous
motor is used as a bridge drive.
Fig. 6.2a (AC integrated synchronous motor)
Legend:
1 Motor feedback unit
2 Incremental generator
3 Clamping device
4 Stator
5 Drive shaft
6 Rotor
6-4
6.2 AC motors
Signal diagram for AC integrated synchronous motor

The signals shown below are obtained when the motor is manually rotated on
the drive shaft.
Fig. 6.2b (Signal diagram for AC integrated synchronous motor)
6-5
6.2 AC motors
6.2.2 AC standard synchronous motor

The optimized standard AC synchronous motor in the long AL or in the short
AK design with increased power data, compact dimensions and low torque
harmonic oscillations meets very high requirements in terms of dynamics, speed
range and centricity. These continuously energized 6-pole synchronous motor are
used on all machine axes with the exception of the beam axes.
Synchronous motor with motor feedback, large (Art. No.
)
Fig. 6.2c (AC standard synchronous motor)
Legend:
1 Motor feedback plug
4 Motor housing (stator)
6-6
6.2 AC motors
Signal diagram for AC standard synchronous motor with motor feedback, large
the drive shaft.
Abb. 6.2d (Signal diagram for AC standard synchronous motor)
6-7
6.2 AC motors
AC standard synchronous motor with motor feedback, small

(Art.No.
)
Fig. 6.2e (AC standard synchronous motor)
Legend:
3 Motor feedback plug
4 Motor housing (stator)
6-8
6.2 AC motors
Signal diagram for AC standard synchronous motor with motor feedback,

small
the drive shaft.
Fig. 6.2f (Signal diagram for AC standard synchronous motor)
6-9
6.2 AC motors
Pin assignment for motor connection plug

(applicable for AK, AL and integrated motors)
Fig. 6.2g (Pin assignment for motor connection plug)
Pin designation
1
2
3
4
A
B
C
D
Connected in motor
Motor phase U
Housing earth
Motor phase W
Motor phase V
Not yet used
Not yet used
Brake + (if present)
Brake - (if present)
Tab. 6.2a (Pin assignment)
6-10
6.2 AC motors
6.2.3 Motor feedback unit

The motor feedback unit performs the function of supplying the drive module
with the following information.
Speed of the drive
Direction of rotation of the drive
Position of the rotor relative to the stator of the motor
The rotor of the motor feedback unit is clamped to the motor shaft by means of
a clamping device (). The stator () of the motor feedback unit is screwed to the
motor housing by means of clamping jaws.
If the motor feedback unit is mounted on a motor, it must then be adjusted by
means of a tester. This adjustment is described in more detail in the service
instructions.
The adjustment by means of the tester can be performed only by a Bystronic
specialist. If a motor feedback unit or a motor is thought to be faulty, the entire
motor must be changed.
The motors are supplied by Bystronic, together with the adjusted motor feedback
unit.
Fig. 6.2h (Motor feedback unit, large Art. No. 218303)
Legend:
1 Plug
2 Cable
3 Stator
4 Rotor clamping device
5 Rotor
6 Cable
7 Plug
6-11
6.2 AC motors
Signal assignment for plug ( )

Absolute magnetic generator signal for determining the position of the rotor relative to the stator in the motor.
Pin number
Signal
1
+ 15Volt DC
2
0V GND
3
U
4
W
5
V
6
X
7
Z
8
Y
Tab. 6.2b (Signal assignment for the motor feedback plug)
Signal assignment for cable ( )

Feedback of speed and direction of rotation
Wire colour
Signal
white
RA (winding 1 Start)
brown
RE (winding 1 End)
green
SA (winding 2 Start)
yellow`
SE (winding 2 End)
grey
TA (winding 2 Start)
pink
TE (winding 3 End)
Tab. 6.2c (Signal assignment for the motor feedback cable)
The signals of () and () are combined at the plug () and fed together, without
signal processing, by means of a shielded cable to the AMFEED card (plug X53)
on the drive module.
Fig. 6.2i (Arrangement of the motor feedback unit in the motor)
6-12
6.2 AC motors
Pin assignment of motor feedback plug (Fig. 6.2i Pos 2)

PIN 1
PIN 2
PIN 3
PIN 4
PIN 5
PIN 6
PIN 7
PIN 8
PIN 9
PIN 10
PIN 11
+15 V
0 V GND
U
V
W
X
Y
Z
RA
RE
SA
PIN 12
PIN 13
PIN 14
PIN 15
PIN 16
PIN 17
SE
TA
TE
free
free
inner shield
Abb. 6.2j (Signal assignment for the motor feedback plug)
Information!
The list of the connections in the motor feedback circuit is shown in the
corresponding CNC diagram.
6-13
6.2 AC motors
Motor feedback unit, small (Art. No. 218154)
Abb. 1.2k (Motor feedback unit, small)
Legend:
1 Plug
2 Stator
3 Rotor clamping device
4 Cable
Pin assignment for plug ( )
Absolute magnetic generator signal for determining the position of the rotor relative to the stator in the motor.
Pin number
Signal
1
+ 15 Volt DC
2
0 Volt GND
3
U
4
W
5
V
6
not used
7
not used
8
not used
Tab. 6.2d (Pin assignment for plug)
6-14
6.2 AC motors
Signal assignment for cable

Feedback of the speed and the direction of rotation
Pin number
Signal
1
+ 15 Volt DC
2
0 Volt GND
3
U
4
W
5
V
6
not used
7
not used
8
not used
Tab. 6.2e (Signal assignment for cable)
The signals from and are combined at the plug and fed together, without signal
processing, by means of a shielded cable to the AMFEED card (plug X53) on the
drive module.
6-15
6.2 AC motors
Arrangement of the motor feedback unit in the motor
Fig. 6.2l (Arrangement of the motor feedback unit in the motor)
6-16
6.2 AC motors
Pin assignment for motor feedback plug ( )

PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
+15 Volt
0 Volt GND
U
V
W
free
free
free
RA
RE
SA
SE
TA
TE
free
free
Inner shield
Fig. 6.2m (Pin assignment for motor feedback plug)
Information!
The list of connections in the motor feedback circuit is shown in the
6-17
6.2 AC motors
Incremental encoder
The encoder (incremental encoder) performs the function of delivering a specific
number of electric pulses per distance covered. This information (pulses) tells a
superior system (POSCON) how far and in which direction the drive is moved.
The encoder is mechanically connected to the motor shaft, without compensating
coupling. The output (electrical connection) is transmitted directly to the superior
control (Poscon) without additional signal processing.
The encoder has an RS422 interface which is led to a plug () (protection type
IP65).
The channels A and B and the zero mark as well as the associated inverse signals
are used. The signal voltage varies between 3 volt.
Fig. 6.2n (Incremental encoder)
Legend:
1 Clamping device for the connection between encoder and motor
2 Plug with RS422 interface
3 Bolt for clamping the encoder to the motor shaft.
6-18
6.2 AC motors
Pin assignment for encoder plug

The pin assignment is the same for all encoders and axes.
PIN 12
PIN 10
PIN 5
PIN 6
PIN 8
PIN 1
PIN 3
PIN 4
PIN 7
Encoder supply
Encoder supply
Channel A
Channel A inverse
Channel B
Channel B inverse
Zero mark
Zero mark inverse
free
+10 V bis +30 V

0 Volt GND
Fig. 1.2o (Encoder plug)
Information!
The list of connections in the encoder circuit is shown in the
6-19
For your notes
6-20
Contents of Chapter
Drive supply module

7.1 The supply module ............................................................... 7-2
7.1.1 Power unit of supply module
7.1.2 Control unit
7-1
7.1 The supply module
7.1 The supply module...

...generates and monitors the intermediate circuit voltage of the drive module
Furthermore, in the event of an excessively high intermediate circuit voltage (negative acceleration of a drive), the supply module destroys this voltage via a pulse
resistance ().
The module is designed for 50 amp continuous current and is protected from
any overload by means of two temperature sensors () and ().
The intermediate circuit voltage has bus capabilities (). Thus, the drive modules
can be arranged on the left as well as on the right side of the supply module.
We make a distinction between two different supply modules. At present,
exclusively version 1 is used.
Standard version
Intermediate circuit voltage Version 1
320 VDC intermediate circuit voltage (supply 3 x 230 VAC 10%)
Special version
Intermediate circuit voltage Version 2
560 VDC intermediate circuit voltage (supply 3 x 400 VAC 10%)
Fig. 7.1a (Supply module standard version)
7-2
7.1.1 Power unit of supply module

The rectifier modules () with 80C temperature sensor (), circuit capacitors (),
) with 100C temperature sensor ()
an IGBT transistor (), a pulse resistance (
and the intermediate circuit monitoring electronics are located on the VMBASE
power unit.
Fig. 7.1b (Power unit of supply module)
Legend:
1 Cooling fan
2 Intermediate circuit capacitors
3 Monitoring and control electronics
4 Voltage supply bus
5 Rectifier modules
6 Rectifier plate temperature sensor
7 Pulse resistance
8 IGBT transistor
9 Pulse resistance temperature sensor
7-3
7.1.2 Control unit

The VMDRIVE control unit contains the electronics supply, the intermediate
circuit monitor, the temperature monitor and the IGBT control.
The status of the power module in shown in a simple manner with the aid of the
light emitting diodes (LED).
Fig. 7.1c (Control unit VMDRIV)
7-4
emitting diodes
H1 Red
Excess temperature pulse resistance

The pulse resistance is overloaded. The fan (1 Fig. 4.1a) may not
be operating or the ventilation slots may be soiled.
H2 Green Supply module is ready for operation (voltage module OK)

H3 Red
Excess temperature rectifier module

The rectifiers are overloaded. The supply module may be soiled.
H4 Green Voltage supply (240 volt AC) for the internal electronic supply
(terminal X2) is in order.
H5 Yellow Pulse resistance is switched on.
H6 Yellow The intermediate circuit voltage was reduced. The terminals X4,
5+6 are activated.
Fuse
The fuse F1 (T1A250V) protects the electronic supply on the supply module.
7-5
Plug X4
Terminals 1 + 2
Intermediate circuit in order (ZWOK), normally open contact;

if the intermediate circuit is not in order, the contact drops off
immediately.
Terminals 3 + 4
Normally closed contact. Same function as the terminals X4,

1+2. However, it closes if the intermediate circuit is not in order.
Terminals 5 + 6
Intermediate circuit reduction (ZWRED)
If terminal 5 is connected to 6, the power in the intermediate circuit is reduced

to about 10%, i.e. the power of the intermediate circuit is dissipated via the pulse
resistance.
The terminals can be activated by the safety control if the supply voltage of the
supply module was reduced or the supply module is completely disconnected from
the main power.
Information!
When the full supply voltage is applied, the intermediate circuit reduction
(ZWRED) may not be switched on. Otherwise, the supply module would
be destroyed.
7-6
Terminals X2
220 volt AC are connected to the terminals X2. The

voltage is used for operating the control logic unit on the
supply module.
Plugs X1 and X3
The two plugs are used for making the connection to the
power unit of the supply module.
Fig. 7.1d (Block diagram Voltagemodul)
7-7
For your notes
7-8
Contents of Chapter
Drive module
8.1 AC drive module ................................................................. 8-2
8.1.1 Power unit
8.1.2 Power control unit
8.2 AMCONT.............................................................................. 8-8

8.2.1 Logic control unit
8.2.2 LEDs, plugs and switches
8.3 AMADAP ........................................................................... 8-12

8.3.1 Test points and potentiometers
8.4 AMFEED ............................................................................. 8-16

8.4.1 Test monitors, switches and plugs
8.5 AMCOMM ..........................................................................8-18

8.5.1 Switches, plugs and LEDs
8.6 Overview of LED`s and switches on the drive module8-20
8-1
8.1AC drive module
AC drive module
The AMAC is a drive module with analogue or digital interface for controlling
continuously energized synchronous motors with 3-phase currents.
The governor permits complete 4-quadrant operation, i.e. driving and braking in
both directions of rotation, there being no interruption at the transition between
the quadrants.
The rotor-oriented regulation transforms the quantities of state measured in the
(stationary) stator system, such as current, speed and rotor position, into a
coordinate system rotating with the rotor. This results in a governor structure
similar to the direct current machine. Current of any phase structure for better
motor utilization for improving the torque ripple is therefore possible without
problems.
The hardware of the drive module is mounted on two main boards. The power
and control unit are thus not only electrically isolated but also spatially separated.
Drive modules with 25, 50, 100 and 200 amp output power are available for the
various axes.
Attention!
Replacement of individual cards or components of a card is not
permissible. The drive module must be regarded as an integral element. If
a drive module is thought to be faulty, it must be replaced as a whole.
Replacement of printed circuit boards between different drive modules is
not advisable.
Fig. 8.1a (Block diagram AC drive module)
8-2
8.1AC drive module
Fig. 8.1b (Cards in the drive module)
Fig. 8.1bb (Cables on the drive module)
8-3
8.1AC drive module
8.1.1 Power unit

The AMBASE power unit consists of a large heat sink (). This removes the waste
heat of the three IGBT power half-bridges (). The temperature of the heat sink
is monitored by means of a temperature sensor ().
Depending on the required motor power, different IGBT modules (25, 50, 100
and 200 amp) are used. They differ in the maximum current which they can
switch.
The terminals for the motor () are also located on the power unit.
Fig. 8.1c (Power unit)
Legend:
1 Heat sink
2 Heat sink temperature sensor
3 IGBT power half-bridges
4 Motor terminals
8-4
8.1AC drive module
8.1.2 Power control unit

The AMDRIVE power control unit is screwed directly to the AMBASE. Together
they form a unit. The power control unit contains the control logic of the IGBT
power half-bridges on the AMBASE.
A fuse () for the power circuit is located on the AMDRIVE. This fuse protects
the IGBT power half-bridges and the voltage supply module (VM) from any
short-circuit.
The plug X12 () provides a connection to the next card (AMCONT) by means
of a flat cable.
Furthermore, two compensation current transformers () are present on the power
control unit. These two transformers measure the motor phase current U and V.
Fig. 8.1d (Power control unit)
Legend:
1 Plug X12
2 Compensation current transformer
3 Fuse
8-5
8.1 AC drive module
Overview of the connections on the power

Power output
Drive module
Connection to motor
PE
W
V
U
PE
Motor housing
W
V
U
Servo housing
Tab. 8.1a (Overview of the connections on the power unit)
Information!
Plug X12
The pin assignment of plug X12 is not described in more detail since only
internal signals of the drive module are applied to the plug.
Fig. 8.1e (Block diagram AMBASE)
8-6
For your notes
8-7
8.2 AMCONT
8.2 AMCONT
8.2.1 Logic control unit
The AMCONT logic control unit is the main board of the drive module. On
this board, all information is processed by means of a microprocessor and the
respective actions are initiated.
After application of the supply voltage, an automatic system reset is performed
and all elements are checked for their operability. If everything is in order, the drive
module is enabled.
A watchdog timer additionally monitors for correct program sequence and blocks
the power unit actuation in the event of any program error.
The AMCONT includes the following functions:
Voltage supply to the logic unit for the total electronics
Field orientation
Phase current regulation
Pulse width modulation
Monitoring of the electronics voltages for overvoltage and undervoltage
Monitoring of the intermediate circuit for overvoltage and undervoltage
Temperature monitoring of the heat sink
Setting and storage of the operating parameters
Hardware reset button
Backing up the electronic supply
Output of safety signals
Input for enabling the drivesSteuerteil
8-8
8.2 AMCONT
Fig. 8.2a (AMCONT)
8-9
8.2 AMCONT
8.2.2 LEDs, plugs and switches

Light emitting diodes
H1 (green) Electronic supply +15 V
The +15 volt supply for the logic unit of the drive module is in order.
H2 (green) Electronics supply -15 V
The -15 volt supply for the logic unit of the drive module is in order.
H3 (green) Electronics supply +5 V
The +5 V supply for the logic unit of the drive module is in order.
H4 (red) Watchdog
The watchdog monitors for correct program sequence. If the program is not
worked through in the required time (CPU is blocked, etc.), the watchdog switches
off the power output stage.
Attention!
The watchdog monitors only the program sequence. A hardware fault, for
example a faulty power half-bridge, a faulty motor, a faulty motor feedback
unit, etc., cannot be detected.
H5 (yellow)
The drive module is ready for operation.
The software (of the drive module) has enabled the drive module.
H6 (red)
Not yet implemented.
Fuse
The fuse F1 protects the electronics supply (logic) of the drive module.
Technical data of the fuse F1:
Rated current:
Response time:
Rated voltage:
Dimensions:
Designation:
8-10
250 mA
slow-blow
250 V
5 mm diameter, 20 mm long
T250 mA/250 volt
8.2 AMCONT
Button S1
In the event of a fault, the drive module can be initialized by means of this button.
The button has the same effect as switching the drive module off and on again.
Electronic supply
At plug X31 230 V, +15%/-10%
Terminal 1 L
(Phase)
Terminal 2 N
(Neutral)
Terminal 3 PE (Ground)
Safety interface X38
Terminal 1
Drive enable 24 VDC +/-20%
Terminal 2
Drive enable 0 VDC
Terminals 3 + 4 Drive not ready (normally closed contact 230 V/6 A)
Terminals 5 + 6 Drive not ready (normally open contact 240 V/6 A)
Fig. 8.2b
Information!
The pin assignment of the plugs X32 to X37 is not described in more detail
since only internal signals of the drive module are applied at these plugs.
HEX switches S2 and S3
These two switches configure the drive module to the required characteristics for
optimally controlling the associated axis.
The settings 00 to FE are available for configuration of the axis. The suitable setting
for each machine is shown in the CNC diagram of the respective machine.
The setting FF is used for manual configuration of the drive module.
8-11
8.3 AMADAP
8.3 AMADAP
The drive module adapter AMADAP is a digital configurable governor assembly
and serves for adapting the axis-specific data, such as the governor parameters, and
current and speed values, to a standard 10 V setpoint interface.
The potentiometers for setting the offset voltage and adjusting the tacho are also
on the AMADAP.
In addition, various analogue monitors (test points) are also present.
Fig. 8.3a (AMADAP)
8.3.1 Test points and potentiometers

Potentiometers
P1 Setting the offset
With forward and backward movement of the axes, the same voltage must be
measured on the plug X43, terminals 3 + 4 (setpoint input).
P2 Tacho adjustment
With forward and backward movement of the axes, the same voltage must be set
on the plug X43, terminals 3 + 4 (setpoint input) on all axes.
8-12
8.3 AMADAP
Jumpers
J1 = 1-3
J1 = 2-4
J1 = 3-5
J1 = 4-6
Plugs
Plug X43
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
1
2
3
4
5
6
7
External setpoint speed 10 V (standard)

External setpoint torque 10 V
Internal setpoint speed
Internal setpoint torque
Actual tacho value

Tacho signal GND
Setpoint value +
Setpoint value Setpoint value GND
Auxiliary voltage +15 V
Auxiliary voltage -15 V
Information!
Only terminals 3 + 4 (setpoint value) may be used for operating our
systems.
Plug X41
The pin assignment of plug X41 is not described in more detail since only internal
signals of the drive module are applied at this plug.
Test points
TP1 = Actual speed
TP2 = Actual current
TP3 = Signal GND
Test reference point for test points TP1 and TP2
8-13
8.3 AMADAP
Fig. 8.3b (Block diagram AMADAP)
8-14
For your notes
8-15
8.4 AMFEED
8.4 AMFEED
The motor feedback interface AMFEED generates the phase current reference values
and the actual speed and is tuned to the Bystronic motor feedback unit.
Depending on the rated motor speed and the number of poles and the method of
commutation, various configured versions are used.
We make a distinction between the following versions:
Variants
Motor speed
Variants
Designation
rpm
Designation
1x
2x
3x
4x
5x
6x
7x
8x
300
750
1500
2000
3000
500
1000
2500
x1
x2
x3
Commutation type
6-pin block-commutated (MFB 218154)
6-pin sine-commutated (MFB 218303)
12-pin sine-commutated (MFB 218154)
Tab. 8.4a (Motor feedback variants)
Information!
The version code suitable for the axis is shown on the CNC diagram of the
corresponding machine.
Fig. 8.4a (AMFEED card)
8-16
8.4 AMFEED
8.4.1 Test monitors, switches and plugs

Test monitors
TP1
Actual speed 10 V corresponds to the rated speed
TP2
Signal GND test reference point for test point TP1.
Switches
The direction of rotation of the motor (viewed from the shaft end with positive
setpoint value) can be changed with switch S1:
CW
Clockwise
CCW
Counterclockwise
Information!
The switch changes the direction of rotation of the motor and of the motor
feedback unit.
Plug
Pin number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Housing
Signal from motor feedback unit

+15 VDC
0 V GND
Absolute signal rotor position U
Absolute signal rotor position V
Absolute signal rotor position W
Absolute signal rotor position X
Absolute signal rotor position Y
Absolute signal rotor position Z
Tacho winding RA (Start)
Tacho winding RE (End)
Tacho winding SA (Start)
Tacho winding SE (End)
Tacho winding TA (Start)
Tacho winding TE (End)
Screen
Tab. 8.4b (Plug X53 Interface to motor feedback unit)
Plug X52
The pin assignment of the plug X52 is not described in more detail since only
internal signals of the drive module are applied at this plug.
8-17
8.5 AMCOMM
8.5 AMCOMM
The communication interface AMCOMM includes an electrically isolated serial
RS232 interface. The drive module can be configured and can be monitored during
operation by means of a terminal program.
The interface is not usually used. If used at all, it is used only for commissioning.
The various light emitting diodes make it possible to determine the status of the
drive module.
Attention!
A setup switch is also available. This switch makes it possible to limit the
power of the drives to about 10%. It is strongly recommended to use this
switch for manipulations on the machine (adjusting the pinch rollers,
setting the reference, etc.). By using the switch, accidents can be avoided in
the event of an incorrect manipulation.
Fig. 8.5a (Electronic card AMCOMM)
8-18
8.5 AMCOMM
8.5.1 Switches, plugs and LEDs

Pin number
2
3
4
5
Signal assignment
Transmit Data (TxD)
Request to Send (RTS)
Receive Data (RxD)
Ground (GND)
Tab.8.5a (Plug X62, serial interface)
Configuration of the interface 9600 bps/8 data bits/1 stop bit/no parity
Plug X61
The pin assignment of plug X61 is not described in more detail since only internal
signals of the supply module are applied at this plug.
H1 (red) Excess temperature drive module
Temperature at heat sink is higher than 80C
H2 (red) Overvoltage intermediate circuit
H3 (yellow) Undervoltage intermediate circuit
H4 (yellow) Speed zero
The axis is stationary.
H5 (red) Speed error
There is no setpoint value but the axis moves.
There is a setpoint value but the axis does not move.
There is a setpoint value but feedback of the motor feedback unit does not
correspond to the expected value.
H6 (red) Maximum speed exceeded
The information sent back by the motor feedback unit is outside the permissible
tolerance limits.
H7 (red) Effective current exceeded
The effective current was exceeded for too long a time.
8-19
8.6 Overview of LED`s and switches on the drive module

LEDs:
H1
H2
H3
H4
H5
H6
=
=
=
=
=
=
Electronics supply +15 V

Electronics supply -15 V
Electronics supply +5 V
Watchdog
Drive module ready to operate
Not used
Switches S2&S3
Information!
Settings 00 to FE are available for axis parametrizing. The correct setting
for each machine is detailed in the CNC diagram for the machine in
question. The setting FF is used for the manual parametrizing of the
drives.
S1
= Reset key
the drive module can be initialised after a fault.
F1 = Fuse T250 mA / 250 V
X31 = 240 VAC supply
X38 = Drive module enable and error signalling contacts
8-20
Fig. 8.6a (AMCONT)
8-21
LEDs:
H1 =
H2 =
H3 =
H4 =
H5 =
H6 =
H7 =
Overtemperature AMBASE (heat sinks)

Overvoltage intermediate circuit
Undervoltage intermediate circuit
Speed zero
Speed error
Maximum speed exceeded
Effective current too high
Switches:
AMCOMM (10 %)
Motor power to approx. 10%
AMFEED (CW/CCW)
Switch for turning motor rotation direction
Potentiometers:
P1 = Drive module offset
P2 = Tacho adaptation adjustment
Jumpers:
AMADAP
J1 = 1-3 External speed setpoint value 10 V
Measuring monitors:
AMADAP
TP1 = Speed actual value
TP2 = Current actual value
TP3 = Signal GND for TP1 and TP2
AMFEED
TP1 = Speed actual value
TP2 = Signal GND
Plugs:
X62 =
X43 =
X53 =
8-22
Parametrizing interface drive module

Setpoint input
Plug motor feedback signal
Fig. 8.6b (Overview of LED`s and switches)
8-23
For your notes
8-24
Contents of Chapter
Pressure controller
9.1 The pressure controller with Prescon 2 board ................ 9-2
9.1.1 Indicators and setting elements
9.1.2 Plugs
9.1.3 Tuning of control loops (PRESCON2)
9.2 The pressure controller with Prescon 3 board ............... 9-8

9.2.2 Plugs
9-1
9.1 The pressure controller with Prescon 2 board

The pressure controller performs the function of continuously electronically
controlling the cutting pressure or the breaking pressure. It contains the necessary
electronics for regulation and control of two completely independent pneumatic
outputs (cutting tool and breaking tool, edge deleting tool).
S erial S ynchronous I nterface/

RS485)
The pressure values of the CNC are transmitted in digital form to the pressure
controller via an SSI interface. In the pressure controller, the transmitted
information is converted into analogue values. A synchronized current source then
controls the solenoid of the proportional valve on the cutting and/or breaking
tool. A transducer on the cutting and/or breaking tool measures the pressure and
feeds the result in the form of a current (4-20 mA) back to the pressure controller.
If an error occurs and the required pressure cannot be reached, the pressure
controller indicates this via the SSI interface to the CNC, from where it is
transmitted to the Panel PC and displayed there. This function is not available in
all CNC software versions (ROM/RAMx).

H1 = green 5 V TTL supply OK
H2 = green Electronics supply +15 V
H3 = green Electronics supply -15 V
H4 = yellow Output stage control loop 1 switched on (cutting tool)
H5 = red
Error in control loop 1 (cutting tool)
H6 = yellow Output stage control loop 2 switched on (breaking tool, edge
deleting tool ...)
H7 = red
Error in control loop 2 (breaking tool, edge deleting tool ...)
Potentiometers
P1
= Adjustment of proportional valve 1 (cutting tool)
P2
= Adjustment of proportional valve 2 (breaking tool, edge deleting
tool ...)
Test points
TP1
=
TP2
=
TPGN
9-2
Test point for adjusting proportional valve 1 (cutting tool)

Test point for adjusting proportional valve 2 (breaking tool, edge
deleting tool ...)
Test reference point for TP1 and TP2 GND
Fig. 9.1a (PRESCON2)
9-3
9.1The pressure controller with Prescon 2 board
9.1.2 Plugs
Terminal assignment Input signal
X1.1
0 Volt AC
X1.2
23 Volt AC
X1.3
not used
X1.4
0 Volt AC
X1.5
28 Volt AC
X1.6
14 Volt AC
Tab. 9.1a (X1 Electronics supply input)
Pin number
1
2
3
4
5
6
7
8
9
Signal
Master Clock
- Master Clock
Serial Data Channel 1
- Serial Data Channel 1
Not used
Not used
TTL Ground
Tab. 9.1b (X2 SSI interface)
Terminal assignment
X3.1
X3.2
X3.3
X3.4
Signal
Screen
+15 Volt DC
Pressure signal 1 (breaking tool...)
Tab. 9.1c (X3 Connection for the pressure cells on the tools)
9-4
9.1 9.1 The pressure controller with Prescon 2 board
Terminal assignment
X4.1
X4.2
X4.3
X4.4
Signal
Current output for cutting proportional valve
Current return from cutting proportional valve
Current output for proportional valve 2
Current return from proportional valve 2
Tab. 9.1d (X4 Connection for the proportional valves)
Fuses
F1 =
F2
F3
Fuse of the 14 VAC supply 1 AT (1 amp 250 volt slow-blow),

analogue part.
analogue part.
Fuse of the 23 VAC supply 4 AT (4 amp 250 volt slow-blow), output
stages (proportional valves)
9-5

Preparation of the system for tuning
The pressure controller must be under voltage.
LEDs H1, H2 and H3 must light up.
No default pressure value must be present in the CNC. It is also possible to
uncouple plug X2. The LEDs H4 and H6 may not light up.
The proportional valve must be at atmospheric pressure.
Adjustment of cutting tool (control loop 1)
Connect volt meter in 2 V range to test point TBGN and to terminal X3.3. The
measured voltage should be approx. 880 mV.
If the voltage deviates more than 20 mV from 880 mV,
the pressure transducer is not correctly connected or is faulty or
the input circuit of the pressure controller is faulty or
the output stage of the pressure controller is faulty.
The tester is now disconnected from terminal X3.3 and connected to TP1. By
means of potentiometer P1, the voltage is set 10 mV lower than the voltage
measured beforehand at terminal X3.3.
Adjustment of breaking tool (control loop 2)
Connect volt meter in 2 V range to test point TBGN and to terminal X3.4. The
measured voltage should be approx. 880 mV.
If the voltage deviates more than 20 mV from 880 mV,
the pressure transducer is not correctly connected or is faulty or
the input circuit of the pressure controller is faulty or
the output stage of the pressure controller is faulty.
The tester is now disconnected from terminal X3.4 and connected to TP2. By
means of potentiometer P2, the voltage is set 10 mV lower than the voltage
measured beforehand at terminal X3.4.
9-6
9.1The pressure controller with Prescon 2 board
Abb. 9.1b (Block diagram of Prescon2)
9-7

The pressure controller performs the function of continuously electronically
controlling the cutting pressure or the breaking pressure. It contains the necessary
electronics for regulation and control of two completely independent pneumatic
outputs (cutting tool and breaking tool, edge deleting tool).
The pressure values of the CNC are transmitted in digital form to the pressure
controller via an SSI interface. In the pressure controller, the transmitted
information is converted into analogue values. A synchronized current source then
controls the solenoid of the proportional valve on the cutting and/or breaking
tool. A transducer on the cutting and/or breaking tool measures the pressure and
feeds the result in the form of a current (4-20 mA) back to the pressure controller.
If an error occurs and the required pressure cannot be reached, the pressure
controller indicates this via the SSI interface to the CNC, from where it is
transmitted to the Panel PC and displayed there. This function is not available in
all CNC software versions (ROM/RAMx).
It is possible to disable each pneumatic output via a jumper (description of the
jumpers see below).

H1 = green
5 V TTL supply OK
H2 = green
Supply of output stage and of analogue part OK
H3 = green
Communication CNC controller OK
H4 = yellow
Output stage control loop 1 switched on (cutting tool)
H5 = red
Error in control loop 1 (cutting tool)
H6 = yellow
Output stage control loop 2 switched on (breaking tool)
H7 = red
Error in control loop 2 (breaking tool)
Potentiometers
P1 = Adjustment of the proportional valve for cutting pressure
P2 = Adjustment of proportional valve 2 (breaking pressure, edge deleting
tool)
Test points
TP1 = Test point for adjusting the proportional valve for cutting pressure
TP2 = Test point for adjusting the proportional valve of the breaking tool
GND = Test reference point for TP1 and TP2
9-8
Jumpers:
J2 = Jumper installed, pneumatic output 1 disabled *)
J3 = Jumper installed, pneumatic output 2 disabled *)
*) If the pneumatic output is disabled, the solenoid of the proportio
nal valve is switched off and the CNC will not receive any status and
error information from the pressure controller.
Abb.9.2a (PRESCON3)
9-9
9.2.2 Plugs
Terminal assignment Input signal
X1.1
0 Volt AC
X1.2
23 Volt AC
X1.3
not used
X1.4
0 Volt AC
X1.5
28 Volt AC
X1.6
14 Volt AC
Tab. 9.2a (X1 Electronics supply input)
Pin number
1
2
3
4
5
6
7
8
9
Signal
Master Clock
- Master Clock
Not used
Not used
TTL Ground
Tab. 9.2b (X2 SSI interface)
Terminal assignment
X3.1
X3.2
X3.3
X3.4
Signal
Screen
+ 15 Volt DC
Tab. 9.2c (X3 Connection for the pressure cells on the tools)
9-10
Terminal assignment
X4.1
X4.2
X4.3
X4.4
Signal
Current output for cutting proportional valve
Current return from cutting proportional valve
Current output for proportional valve 2
Current return from proportional valve 2
Tab. 9.2d (X4 Connection for the proportional valves)
Fuses
F1 =
F2
F3

analogue part.
analogue part.
Fuse of the 23 VAC supply 4 AT (4 amp 250 volt slow-blow), output
stages (proportional valves)
9-11
9.2.3 Adjustment of the control loops (PRESCON3)

Preparations for adjustment
Light emitting diodes H1 and H2 must light up.
No default pressure value must be present in the CN control. It is also
possible to uncouple plug X2. The light emitting diodes H4, H5, H6 and
H7 may not light up.
Information!
If one of the light emitting diodes H5 or H7 lights up, the following points
should be checked:
Is the pressure transducer correctly connected?
Is the pressure transducer faulty?
Is the input circuit of the pressure controller faulty?
Is the output stage of the pressure controller faulty?
Set the volt meter in the 2 V range and
connect the COM output of the volt meter to test point GND.
Connect the V input of the volt meter to TP1.
Adjust the voltage 0 V by means of potentiometer P1.
connect the COM output of the volt meter to test point GND.
Connect the V input of the volt meter to TP2.
Adjust the voltage to 0 V by means of potentiometer P2.
9-12
Abb. 9.2b (Block diagram of PRESCON3)
9-13
For your notes
9-14
Contents of Chapter
Positioning module UNIPOS

10.1 Technical Data.................................................................. 10-2
10.1.1 Introduction
10.1.2 Characteristics
10.1.3 UNIPOS front view
10.2 Inputs and outputs ......................................................... 10-4

10.2.1 List of inputs and outputs
10.2.2 Supply
10.2.3 Axis switches
10.2.4 Encoder
10.2.5 Speed selection
10.3 Parallel command interface ...........................................10-7

10.3.1 Inputs
10.3.2 Outputs
10.4 CAN command interface .............................................. 10-10

10.4.1 Input
10.4.2 Output
10.5 Light emitting diodes and switches .............................. 10-12

10.5.1 Light emitting diodes
10.5.2 Reset switch
10.5.3 DIP switch
10.6 Parameters ..................................................................... 10-14
10-1
10.1 Technical Data
10.1 Technical Data

10.1.1 Introduction
The UNIPOS is a universal decentral one-axis positioning control with advantages
with regard to uncomplicated realization of movements with the aid of servo drives
and simple commissioning.
The functionality comprises position-controlled positioning of a servo axis.
Manual driving, approaching of reference points, vane driving and positioning
are available.
The commissioning and diagnostics software tool UNIPOS-IDT permits optimal adaptation to the machine as well as fast diagnosis on site.
The data structure envisages the management of parameters, position values and
monitoring values.
The UNIPOS is actuated via a separate command interface. For simple
applications, actuation can be effected via parallel I/O signals. For more extensive
applications (e.g. teach-in), networking via CAN bus is possible.
10.1.2 Characteristics
Travel range, internal
Travel range CAN
Maximum speed
Travel speed
Acceleration distance
Acceleration profile
Hardware switches
Encoder scanning rate
Encoder multiplication factor
Position controller resolution
Position controller amplification
Required value
10-2
15,000,000 increments
1,048,575 increments
10 - 655,350 increments/s
0.392 - 100% of maximum speed
1 - 32767 increments
lin, log, exp, sin2 or n/M table
Limitation+, -, slow, vane
10 MHz
1/2/3/4
0.5 increment / 1 increment
0.6/1.2/2.4/4.8/9.7/19.5/39.2/78.4
mV/increment
+/- 10 V
10.1 Technical Data
10.1.3 UNIPOS front view
Abb. 10.1a (UNIPOS front view)
Legend:
1 Parallel outputs
2 CAN bus interface, stepping motor plug *), reset switch
3 Supply
4 Axis switch
5 Encoder
6 Required value
7 Parallel inputs
8 Light emitting diodes
*) Not yet supported
10-3
10.2 Inputs and outputs

10.2.1 List of inputs and outputs
Supply
X1.1
24VDC
X1.2
0V
Axis switch
X2.1
Switch limitation +
X2.2
Switch limitation X2.3
Switch slow
X2.4
Switch vane
X2.5
Switch 0 V
Encoder input
X3.1
Output channel A
X3.2
Output channel/A
X3.3
Output channel B
X3.4
Output channel/B
X3.5
Output channel 0
X3.6
Output channel/0
X3.7
Supply
X3.8
Ground
Parallel input
X5.1
Manual driving
X5.2
Approach reference point
X5.3
Position
X5.4
Forwards/Reverse
X5.5
Required speed value (1)
X5.6
X5.7
X5.8
X5.9
Enable/Stop
X5.10 Execute/Hold
X5.11
Set actual value
X5.12 Pos. required value/Pos. actual value
X5.13 Required position value (1)
X5.17
X5.18 0 V (common)
10-4
Required value output

X4.1
Required value
X4.2
0V
X4.3
Screen
Parallel outputs
X6.1
Drive running
X6.2
End ramp
X6.3
End vane
X6.4
End limitation
X6.5
Switch limitation +
X6.6
Switch limitation X6.7
Switch slow
X6.8
Switch vane
X6.9
Ready
X6.10 X6.11
X6.12 Required value/Ranges
X6.13 Range 1/Required value (1)
X6.17
+24 VDC (common)
X6.18 0V
10.2.2 Supply
The UNIPOS is supplied with 24 VDC, unstabilized, via terminal X1.
24 VDC X1.1
0V
X1.2
10.2.3 Axis switches

The axis switches are connected to terminal X2.
The switches used may be of any type with a supply voltage of 24 VDC and
positively switching outputs.
Switch limitation +
Switch limitation Switch slow
Switch vane
Switch 0 V
X2.1
X2.2
X2.3
X2.4
X2.5
10-5
10.2.4 Encoder
An incremental encoder is connected to terminal X3, as a distance measuring
system. All incremental encoders with a supply voltage of 10 - 30 V and RS422
output driver can be used.
The maximum line length should not exceed 100 m.
For effective noise suppression in the entire system, encoder lines should be screened
and should be locally isolated from power lines and interference-generating devices.
With simple screening, the screen is connected at one end to the encoder housing.
Although the screening of the entire system is thus interrupted, earth loops are
reliably avoided in this way.
Output channel A
Output channel/A
Output channel B
Output channel/B
Output channel 0
Output channel/0
Supply
Ground
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.7
X3.8
10.2.5 Required speed value

The required speed value of +-10 V is output via a 12 bit D/A converter to terminal
X4.
Required value
Ground
Screen
X4.1
X4.2
X4.3
The cable length should not exceed 5 m. The screen is connected at one end to
the UNIPOS.
The servo amplifier used must have differential inputs.
10-6
10.3 Parallel command interface

The parallel signal exchange with the UNIPOS is via terminals X5.
10.3.1 Inputs
The input signals must be present as positively switched 24 VDC voltage values.
The supply is external.
X5.17
Inputs 0 V (common) X5.18
Function selection
The first four inputs define the function
Manual driving
Approaching reference points
Positioning
Forwards/Reverse
X5.1
X5.2
X5.3
X5.4
The following input combinations are permitted:

Function/Input
Manual travel forwards
Manual travel backwards
Approach reference point forwards
Approach reference point backwards
Incremental positioning forwards
Incremental positioning backwards
Absolute positioning
Vane travel forwards *
Vane travel backwards*
Vane travel absolute *
X5.1
1
1
0
0
0
0
0
0
0
0
X5.2
0
0
1
1
0
0
0
1
1
1
X5.3
0
0
0
0
1
1
1
1
1
1
X5.4
1
0
1
0
1
0
1
0
-
*) Not yet supported
10-7
Speed selection
The maximum travel speed is stipulated with inputs 5-8 (16 configurable speeds).
Required speed value
(1) X5.5
(2) X5.6
(4) X5.7
(8) X5.8
Drive commands
Inputs 9-12 are the actual drive commands.
Setting input 9 activates the position controller and enables the UNIPOS to execute
drive commands.
When input 9 is reset, the position controller is blocked, required value 0 V is
output and any ongoing drive command is immediately stopped.
When input 10 is set, the preselected drive command is executed. On premature
resetting of input 10, the drive command is terminated with a hold ramp.
Input 11 permits setting of a floating actual value. With the positive flank of
this signal, the actual value register is set to the selected required position value.
With input 12, it is possible to switch between required position value output
and actual position value output.
Enable/Stop
Execute/Hold
Set actual value
Required position value/Actual position value
X5.9
X5.10
X5.11
X5.12
Selection of required position value

The required position value is selected via inputs 13-16 (16 configurable required
position values, either absolute or incremental (in steps)
Required position value (1)
10-8
X5.13
X5.14
X5.15
X5.16
10.3.2 Outputs
The output signals are positively switched. The current load per output may not
exceed 0.3 A. The supply is external.
+24 VDC (common)
0V
X6.17
X6.18
Position status
The first four outputs show the position status
Drive running
End ramp
End vane
End limitation
X6.1
X6.2
X6.3
X6.4
Switch status
The output signals 5-8 show the switch status
Switch limitation+
Switch limitationSwitch slow
Switch vane
X6.5
X6.6
X6.7
X6.8
Module status
The outputs 9-11 show the module status
Ready
-
X6.9
X6.10
X6.11
X6.12
Actual position value

If input 12 is not set, the configured actual value ranges 1-4 are output at outputs
13-16 (cam gear function). If input 12 is set, the currently selected required position
value is output at outputs 13-16.
Range 1 or required position value (1)
X6.13
X6.14
X6.15
X6.16
10-9
10.4 CAN command interface

The UNIPOS can be controlled via SELECAN by mounting the intermediate
module DIOCAN.
10.4.1 Input
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Bit 16
Bit 17
Bit 18
Bit 19
Bit 20
Bit 21
Bit 22
Bit 23
Bit 24
Bit 25
Bit 26
Bit 27
Bit 28
Bit 29
Bit 30
Bit 31

Enable/Stop
Execute/Hold
Set actual value
Required position value/Actual position value
Manual driving
Approach reference point
Position
Forwards/Reverse
Speed selection (1)
Speed selection (2)
Speed selection (4)
Speed selection (8)
All inputs of the parallel interface are blocked in this mode!
10-10
10.4.2 Output
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 8
Bit 9
Bit 10
Bit 11
Bit 12
Bit 13
Bit 14
Bit 15
Bit 16
Bit 17
Bit 18
Bit 19
Bit 20
Bit 21
Bit 22
Bit 23
Bit 24
Bit 25
Bit 26
Bit 27
Bit 28
Bit 29
Bit 30
Bit 31
Actual position value (1)

Drive running
End ramp
End vane
End limitation
Switch limitation +
Switch limitation Switch slow
Switch vane
All outputs of the parallel command interface remain active!
10-11
10.5 Light emitting diodes and switches

10.5.1 Light emitting diodes
Four light emitting diodes are present on the front panel:
WDDOG
The watchdog timer is operated only in the line mode. In the local mode,
the LED is lit up continuously.
If the LED lights up in the line mode, a hardware error is present.
UL0M
The LED indicates two states:
The position controller is in overflow
The encoder passes through the zero mark on approaching the reference
position
RUN
The RUN LED lights up if the module is in the line mode. At each start
command, the LED goes out briefly.
ERR
The ERROR LED indicates two error cases:
LED lights up: Error in the encoder signals
LED flashes: Encoder supply faulty
If the FLASH EPROM is empty (first start) and the DIP switch is at line mode,
the ERR and RUN LEDs flash in a continuous loop.
In this case, the DIP switch must be switched off and a reset performed.
The light emitting diodes ERR and RUN are in principle valid only in the line
mode.
10.5.2 Reset switch
The reset switch is located at the bottom of the module, behind the plugs.
After a reset, the UNIPOS copies all parameters again from the FLASH to the
RAM and sets the mode which is preset on the DIP switches.
10-12
10.5.3 DIP switch

The DIP switch is located under the metal cover at the top of the UNIPOS. At
present, only DIP switch 1 is used.
ON:
OFF:
UNIPOS starts up in line mode

UNIPOS starts up in local mode
10-13
10.6 Parameters
10.6 Parameters
The parameters are set via the serial terminal interface under the metal cover at
the top of the module. For this purpose, the special UNIPOS installation and
diagnostics software tools UNIPOS IDT are required.
The following parameters can be set with it:
Command interface
Amplification
Absolute driving
Vane driving mode
4 ranges
Maximum driving frequency
Zero mark
Motor output
Encoder direction
Encoder multiplication factor
16 required position values
16 required speed values
Acceleration profile
Further information can be found in the documentation on the UNIPOS IDT
software (available from the software department).
10-14
For your notes
10-15
For your notes
10-16
Contents of Chapter
Adjustment instructions
11.1 Adjustment of Poscon XYZ, KSM and VSM .................... 11-2
11.2 Adjusting the drive modules ............................................. 11-6
11.3 Adjustment of pressure controller ................................... 11-10
11.3.1 Adjustment of pressure controller with Prescon2 board
11.4 Adjustment of POSCON PSM ......................................... 11-18

11.5 Adjustment of drive module PSM .................................. 11-22
11-1
11.1 Poscon XYZ, KSM and VSM
11.1 Adjustment of Poscon XYZ, KSM and VSM

Proceed as follows:
Shut down Windows 95 and switch off the CN control.
Set the setup switch () in all drive modules, on the AMCOMM board at
the back of the CNC cabinet to 10%.
Fig. 11.1a (10% switch on AMCOMM card)
Switch off motor protection switch Q3 at the front in the CNC cabinet.
Disconnect required value cable (white and brown) () from terminals 3 and
4 on all drive modules (AMADAP).
Fig. 11.1b (Required value cable on AMADAP card)
Information!
This is the cable which brings the REQUIRED VALUE (+/- 10 VDC) from
the POSCON to the drive module.
11-2
Attention!
On no account may the two cables come into contact with one another
(short-circuit). Otherwise, the POSCON cards might be destroyed!
Connect volt meter in the 20 VDC range to the required value cable of the
POSCON card to be adjusted.
Fig. 11.1c (Volt meter at required value cable)
Switch on CN control.
Move the axis belonging to the POSCON (required value cable) very slowly,
millimetre by millimetre, in one direction.
During this it is possible to observe how the voltage on the volt meter
display increases (see Figure below). The voltage may be positive as well as
negative. As soon as the red LED () on the POSCON lights up, stop
moving.
Fig. 11.1d (Diagram showing the voltage)
This value is about +10 VDC or -10 VDC.

This value must be noted (e.g. 9.985 V).
The axis is now moved in the other direction. The voltage on the volt meter
decreases slowly and increases again with the opposite sign (different
polarity).
As soon as the maximum value is reached again, the red LED () on the
POSCON lights up again; stop moving.
This value too must be noted (e.g. 10.075 V).
.
11-3
With potentiometer P2 on the POSCON card (), the voltage can now be
adjusted (see Figure below) so that it has absolutely the same magnitude both
in the minus direction and in the plus direction (e.g. +9.998 V and -9.998
V). In other words, the symmetry of the setpoint voltage on the POSCON
card is adjusted with potentiometer P2.
Fig. 11.1e (POSCON board)
Information!
SW1
LED
LED2
P2
=
=
=
=
Switch 1
Light emitting diode 1 (red)
Light emitting diode 2 (green)
Potentiometer for symmetry adjustment of Poscon
This adjustment should be carried out in the same way for all axes.
Switch on motor protection switch Q3 at the
front in the CNC cabinet.
Set the setup switch () on AMCOMM back to
100%.
Reconnect all required value cables (white and
brown) to terminals 3 and 4 on the AMADAP again.
11-4
For your notes
11-5
11.2 Drive modules XYZ, KSM and VSM
11.2 Adjusting the drive modules

Connect the volt meter in the 20 VDC range, for the axis to be adjusted, to
terminals 3 and 4 on the AMADAP board (parallel to the white and brown
wire) on the drive module to be adjusted.
Fig. 11.2a (Volt meter at AMADAP)
Switch on the CN control. Logging into the MMC program is not

necessary.
Start the HAND menu (HAND key on CNC keyboard).
Start the ADJUST menu (key S7 on CNC keyboard).
Press key [WZ1] or [WZ2] (WZ1 is for the cutting tool, WZ2 is for the
grinding or breaking tool).
By pressing the manual control keys (X, Y or Tool), move the axis to be
adjusted forwards and backwards; during the travel, the voltage is set to the
same value in the plus and minus travel direction by means of potentiometer
P1 () (see Figure 10.2b).
11-6
11.2 Drive modules XYZ, KSM and VSM
By pressing the manual control keys, travel with the axis in one direction;
during the travel, the voltage is set to 1.0 V on potentiometer P2 () (see
Figure below).
Fig. 11.2b (Drive module, AMADAP board)
This adjustment should be carried out in the same way for the X and Y axes.
The adjustment procedure for the auxiliary axes (cutting, grinding and
breaking tool) is identical to the X and Y axes. However, the voltage must be
set as follows:
Cutting tool
= 2.5 V
Edge deleting tool
= 2.5 V
Breaking tool
= 2.5 V
11-7
For your notes
11-8
For your notes
11-9
11.3 Adjustment of pressure controller

Preparations for the adjustment
Light emitting diodes H1, H2 and H3 must light up.
Uncouple plug X2 (). The light emitting diodes H4 and H6 may not light
up.
connect the COM output of the volt meter to test point TBGN ().
Measure the voltage with the V output at terminal X3.3 ().
This should be approx. 880 mV, 20 mV.
The voltage is now measured with the V output of the volt meter at TP1
(). This must be 10 mV lower than that measured at terminal X3.3 ().
Example:
Voltage at terminal X3.3 = 874 mV
Voltage at test point TP1 = 864 mV
If this is not the case, the voltage is adjusted on potentiometer P1 ().
connect the COM output of the volt meter to test point TBGN ().
Measure the voltage with the V output at terminal X3.4 ().
This should be approx. 880 mV, 20 mV.
The voltage is now measured with the V output of the volt meter at TP2
(). This must be 10 mV lower than that measured at terminal X3.4 ().
Example:
Voltage at terminal X3.4 = 874 mV
Voltage at test point TP2 = 864 mV
If this is not the case, the voltage is adjusted on potentiometer P2 ().
11-10
Information!
If the voltage deviates by more than 20 mV, this may be due to the
following causes:
The pressure transducer is not correctly connected.
The pressure transducer is faulty.
The input circuit of the pressure controller is faulty.
The output stage of the pressure controller is faulty.
Fig. 11.3a (Pressure controller, PRESCON2 board)

11-11
For your notes
11-12
For your notes
11-13

Preparations for the adjustment
Light emitting diodes H1 and H2 must light up.
Uncouple plug X2 (). The light emitting diodes H5 and H7 may not light
up.
Information!
If one of the light emitting diodes H5 or H7 lights up, this may be due to
the following causes:
The pressure transducer is not correctly connected.
The pressure transducer is faulty.
The input circuit of the pressure controller is faulty.
The output stage of the pressure controller is faulty.
connect the COM output of the volt meter to test point GND ().
Connect the V input of the volt meter to TP1 ().
Set the voltage to 0 V by means of potentiometer P1 ().
connect the COM output of the volt meter to test point GND ().
Connect the V input of the volt meter to TP2 ().
Set the voltage to 0 V by means of potentiometer P2 ().
11-14
Fig. 11.3b (Pressure controller, PRESCON3 board)

11-15
For your notes
11-16
For your notes
11-17
11.4 POSCON PSM
11.4 Adjustment of POSCON PSM

Proceed as follows:
Set the setup switch () in all drive modules, on the AMCOMM board at
the back of the CNC cabinet, to 10%.
Fig. 11.4a (10% switch on AMCOMM card)
Switch off motor protection switch Q3 at the front in the CNC cabinet.
Disconnect required value cable (brown and white) () from terminals 3 and
4 in all drive modules (AMADAP).
Information!
This is the cable which brings the REQUIRED VALUE (+/- 10 VDC) from
the POSCON to the drive module.
Attention!
On no account may the two cables come into contact with one another
(short-circuit). Otherwise, the POSCON cards might be destroyed!
11-18
11.4 POSCON PSM
Connect volt meter in the 20 VDC range to the required value cable of the
POSCON card to be adjusted.
Fig. 11.4c (Volt meter at required value cable)
Switch on CN control.
Turn the axis belonging to the Poscon, at the motor coupling, very slowly,
millimetre by millimetre, in one direction.
During this it is possible to observe how the voltage on the volt meter
display increases (see Figure below). The voltage may be positive as well as
negative. As soon as the red LED () on the POSCON lights up, stop
turning.
Fig. 11.4d (Diagram showing the voltage)
This value is about +10 V or -10 V.

This value must be noted (e.g. 9.985 V).
The axis is now moved in the other direction. The voltage on the volt meter
decreases slowly and increases again with the opposite sign (different
polarity).
11-19
11.4 Poscon PSM
As soon as the maximum value has been reached again, the red LED () on
the POSCON lights up again; stop turning.
This value, too, must be noted (e.g. 10.075 V).
The voltage can now be adjusted with potentiometer 2 () (see Figure 10.4e)
so that it has absolutely the same magnitude both in the minus and in the
plus direction (e.g. +9.998 V and -9.998 V). In other words, the symmetry
of the required voltage on the POSCON card is set with potentiometer P2.
Fig. 11.4e (POSCON board)
Information!
SW1
LED1
LED2
P2
=
=
=
=
Switch 1
Light emitting diode 1 (red)
Light emitting diode 2 (green)
Potentiometer for symmetry adjustment of POSCON
Carry out this adjustment for the linear and polar axis in the same way.
Switch on motor protection switch Q3 at the front in the CNC cabinet.
Set the setup switch (1) on AMCOMM back to
100%.
Reconnect all required value cables (white and
brown) to terminals 3 and 4 on the AMADAP.
11-20
For your notes
11-21
11.5 Drive module PSM
11.5 Adjustment of drive module PSM

Connect the volt meter in the 20 VDC range, for the axis to be adjusted, to
terminals 3 and 4 on the AMADAP board (parallel to the white and brown
wire) on the drive module.
Fig. 11.5a (Volt meter on AMADAP)
11-22
Switch on the CN control. Log into MMC

User:
EXPERT
Password: EXPERT
Start the SETUP menu (SETUP key on CNC keyboard)
Set the parameter HAND FEED to 5000 mm/min
Start the HAND menu (HAND key on CNC keyboard)
Start the ADJUST menu (key S7 on CNC keyboard)
Start the MAIN DRIVES menu (key S1 on CNC keyboard)
By pressing the manual control keys (Rot, Lin), move forwards and
backwards with the axis to be adjusted; during the travel, the OFFSET
voltage is set to the same value in the plus and minus direction by means of
potentiometer P1 () (see adjacent Figure).
11.5 Drive module PSM
By pressing the manual control keys, travel with the axis in one direction;
during the travel, set the tacho value to 1.0 V on potentiometer P2 () (see
Figure below).
Fig. 11.5b (Drive module, AMADAP board)
This adjustment should be made in the same way for the polar and linear
drive.
11-23
For your notes
11-24
Contents of Chapter
Appendix
12.1 Customer Service information ......................................... 12-2
12.1.1 Bystronic Maschinen AG
12.1.2 Bystronic Inc.
12.1.3 Bystronic Asia
12.2 List of Figures ................................................................... 12-4

12.3 List of Tables .................................................................... 12-8
12.4 Index ............................................................................... 12-10
12.1 Customer Service information

You will help us and yourself if you have the following information ready before
making the call:
F Company name
F Place
F Contact person
F Direct dialling number
F Year of construction ()
F Order number ()
F Machine type ()
F Exact description of the problem (what exactly does not function - answers
obtained on working through the Troubleshooting scheme).
The responsible engineer should have the following documents to hand:
Technical documentation
Circuit diagram
Fig. 12.1a (The identification plate is mounted on every machine)
12.1.1 Bystronic Maschinen AG

Bystronic Maschinen AG
Industriestrasse 5
CH-4922 Btzberg
Telephone +4162-958 77 77
Telefax +4162-958 77 00
E-Mail support.glass@bystronic.ch
http://www.bystronic.ch
12.1.2 Bystronic Inc.
Bystronic Inc.
30 Commerce Drive,
Hauppauge, NY, 11788
Phone +1516 231 12 12
Facsimile +1516 231 10 40
email service@bystronicusa.com
12.1.3 Bystronic Asia
Bystronic Asia
61 Alexandra Terrace
#06-11 Harbour Link
Singapore 119936
Phone +65 278 66 78
Facsimile +65 272 59 78
email BystronicAsia@bystronic.com.sg
12.2 List of Figures

Introduction
Fig. V.1a
Organization of the pages in these operating instructions
Chapter 1
Fig. 1.1a
Fig. 1.1b
Fig. 1.1c
Fig. 1.1d
Fig. 1.1e
Fig. 1.1f
Fig. 1.1g
Fig. 1.1h
Fig. 1.1i
Fig. 1.1j
Fig. 1.1k
Block diagram of cutting machine XYZ97/98

Block diagram of cutting machine XYZF97/98
Block diagram of cutting machine XYZF97/98R
Block diagram of cutting machine XYZF97/98DS
Block diagram of cutting machine PSM-XYZF98
Block diagram of shape cutting machine KSM 97/98
Block diagram of shape cutting and breaking machine KSBM97/
98
Block diagram of multipurpose cutting machine VSM97/98
Block diagram of polar grinding machine PSM97/98 Stand Alone
Block diagram of polar grinding machine PSM97/98 Compact
Block diagram of polar drilling machine PBM97/98
Chapter 2
Fig. 2.1a
Fig. 2.1b
Fig. 2.1c
Fig. 2.2a
Fig. 2.2b
Fig. 2.2c
Fig. 2.3a
Fig. 2.3b
Fig. 2.4a
Fig. 2.4b
Fig. 2.5a
Fig. 2.5b
Fig. 2.6a
Fig. 2.6b
Fig. 2.6c
Fig. 2.6d
Fig. 2.7a
Fig. 2.7b
Fig. 2.7c
Fig. 2.7d
Fig. 2.7e
Fig. 2.7f
Fig. 2.8a
Fig. 2.8b
Fig. 2.8c
Fig. 2.8d
Fig. 2.8e
Electronics rack
Rack supply 2
Block diagram of rack supply 2
CPU 386SX
CPU 386SX
Block diagram of CPU 386SX
ROM/RAM2
Block diagram of ROM/RAM2
CUTCON2
Block diagram of CUTCON2
IMPGEN
Block diagram of IMPGEN
Voltage curve for drive on POSCON
POSCON
POSCON wrap connections
Block diagram of POSCON
SERCOM2
Block diagram of SERCOM2
SERPORT adapter card
SER232 adapter card
SER422 adapter card
SERCUL adapter card
DIOCOM
Block diagram of DIOCOM
DIOPAR interface card
DIOSSI interface card
DIOCAN interface card
Fig. 2.9a
Fig. 2.9b
POSCAD
Block diagram of POSCAD
Chapter 3
Fig. 3.1a
Fig. 3.1b
Fig. 3.2a
Front view of Berger stepping motor rack

Back of Berger stepping motor rack
Stepping motor card D900
Chapter 4
Fig. 4.1a
Fig. 4.2a
Fig. 4.3a
Fig. 4.3b
Fig. 4.4a
Fig. 4.5a
Fig. 4.5b
TERMIF
PARAN
Speed limit monitor SLIM
Block diagram of speed limit monitor SLIM
Module bus S3
I/O module SSI
I/O module SSI
Chapter 5
Fig. 5.1a
Fig. 5.1b
Fig. 5.1c
Fig. 5.1d
Fig. 5.1e
Fig. 5.1f
Front view of panel PC

Block diagram of Panel PC
Serial interface card PCOLA
I/O address on PCTIF
Keyboard interface PCTIF
Voltage and temperature monitor PTCON
Chapter 6
Fig. 6.1a
Fig. 6.2a
Fig. 6.2b
Fig. 6.2c
Fig. 6.2d
Fig. 6.2e
Fig. 6.2f
Fig. 6.2g
Fig. 6.2h
Fig. 6.2i
Fig. 6.2j
Fig. 6.2k
Fig. 6.2l
Fig. 6.2m
Fig. 6.2n
Fig. 6.2o
Block diagram of drive system

AC synchronous motor beam drive
Signal diagram for AC synchronous motor beam drive
AC synchronous motor carriage drive
Signal diagram of AC synchronous motor carriage drive
AC synchronous motor rotary drive
Signal diagram of AC synchronous motor rotary drive
Motor feedback unit, large
Arrangement of large motor feedback unit in motor
Pin assignment of motor feedback plug
Motor feedback unit, small
Arrangement of small motor feedback unit in motor
Pin assignment of motor feedback plug
Incremental encoder
Pin assignment of incremental encoder plug
Chapter 7
Fig. 7.1a
Fig. 7.1b
Fig. 7.1c
Fig. 7.1d
Chapter 8
Fig. 8.1a
Fig. 8.1b
Fig. 8.1bb
Fig. 8.1c
Fig. 8.1d
Fig. 8.1e
Fig. 8.2a
Fig. 8.2b
Fig. 8.3a
Fig. 8.3b
Fig. 8.4a
Fig. 8.5a
Fig. 8.6a
Fig. 8.6b
Supply module, standard version

Power pack of supply module
VMDRIV control unit
Block diagram of supply module
Block diagram of AC drive module

Schematic diagram of the cards in the drive module
Schematic diagram of the cable laying in the drive module
Power pack in drive module
Power control unit in drive module
Block diagram of AMBASE
AMCONT logic control
Schematic diagram of reset switch in drive module
Drive module adapter AMADAP
Block diagram of AMADAP
Motor feedback interface AMFEED
Communication interface AMCOMM
Overview of light emitting diodes and switches in drive module
AMCONT
Overview of light emitting diodes and switches in drive module
AMCOMM/AMADAP/AMFEED
Chapter 9
Fig. 9.1a
Fig. 9.1b
Fig. 9.2a
Fig. 9.2b
Pressure controller PRESCON2

Block diagram of PRESCON2
Block diagram of PRESCON3
Chapter 10
Fig. 10.1a
Front view of UNIPOS
Chapter 11
Fig. 11.1a
Fig. 11.1b
Fig. 11.1c
Fig. 11.1d
Fig. 11.1e
Fig. 11.2a
Fig. 11.2b
Fig. 11.3a
Fig. 11.3b
Fig. 11.4a
Fig. 11.4b
Fig. 11.4c
10% switch at drive module

Required value cable on drive module AMADAP card
Volt meter at required value cable
Schematic diagram of voltage
POSCON
Volt meter at AMADAP
Drive module, AMADAP card
10% switch in drive module
Required value cable at drive module AMADAP card
Volt meter at required value cable
Fig. 11.4d
Fig. 11.4e
Fig. 11.5a
Fig. 11.5b
Schematic diagram of the voltage

POSCON
Volt meter at AMADAP
Drive module, AMADAP card
12.3 List of Tables
12.3 List of Tables

Chapter 2
Tab. 2.5a
Tab. 2.5b
Tab. 2.6a
Tab. 2.9c
IMPGEN switch positions

IMPGEN switch positions, overview according to machine type
Switch positions SW1 POSCON, overview according to machine
type
Wire Wrap Configuration POSCON, overview according to
machine type
Interrupt SW1 SERCOM2, overview according to machine type
Switch positions of bidirectional interface SERCUL
Interrupt SW1 DIOCOM slot STD
Interrupt SW1 DIOCOM slot STE
DIOCAN switch position
Switch positions for encoder input POSCAD
Switch positions for encoder input POSCAD, overview according
to machine type
POSCAD configuration
Chapter 3
Tab. 3.2a
Tab. 3.2b
Dip switch settings on Berger card D900

Rotary switch for motor phase current on Berger card D900
Chapter 4
Tab. 4.3a
Speed setting on speed limit monitor SLIM
Chapter 5
Tab. 5.1a
Tab. 5.1b
IRQ and I/O addresses in Panel PC

Settings for interrupt keyboard interface PCTIF
Chapter 6
Tab. 6.2a
Tab. 6.2b
Tab. 6.2c
Tab. 6.2d
Tab. 6.2e

Signal assignment for large motor feedback plug
Signal assignment for large motor feedback cable
Signal assignment for small motor feedback plug
Signal assignment for small motor feedback cable
Chapter 8
Tab. 8.1a
Tab. 8.4a
Tab. 8.4b
Tab. 8.5a
Power pack connections on AC drive module

Motor feedback variants on AMFEED
Plug X53, interface to motor feedback unit
Plug X62, serial port
Chapter 9
Tab. 9.1a
Tab. 9.1b
X1 PRESCON2 electronics supply input

X2 SSI interface PRESCON2
Tab. 2.6b
Tab. 2.7a
Tab. 2.7b
Tab. 2.8a
Tab. 2.8b
Tab. 2.9a
Tab. 2.9b
12.3 List of Tables
Tab. 9.1c
Tab. 9.1d
Tab. 9.2a
Tab. 9.2b
Tab. 9.2c
Tab. 9.2d
X3 Connection for the transduceron on the tools PRESCON2

X4 Connection for the proportional valves PRESCON2
X1 PRESCON3 electronics supply input
X2 SSI interface PRESCON3
X3 Connection for the transducer on the tools PRESCON3
X4 Connection for the proportional valves PRESCON3
Chapter 10
Tab. 10.2a
Tab. 10.3a
List of the UNIPOS inputs and outputs

Parallel command interface input combinations
12.4 Index
A
Adjustment of drive modules PSM 11-22
Adjustment of control loops (PRESCON2) 9-6
Adjustment of control loops (PRESCON3) 9-12
Adjustment of Poscon PSM 11-18
Adjustment of Poscon XYZ, KSM and VSM 11-2
Adjustment instructions 11-1
Adjustment of drive modules PSM 11-22
Adjustment of Poscon PSM 11-18
Adjustment of Poscon XYZ, KSM and VSM 11-2
Drive modules, adjust 11-6
Pressure controller, adjust 11-10
with Prescon2 board 11-10
with Prescon3 11-14
AC drive system 6-2
AC motors 6-4
AC installation synchronous motor 6-4
AC standard synchronous motor 6-6
Incremental encoder 6-18
Motor feedback unit 6-11
Drive module 8-1
AMADAP 8-12
AMCOMM 8-18
Switches, plugs and light emitting diodes 8-19
AMCONT 8-8
Light emitting diodes, plugs and switches 8-10
Control unit 8-8
AMFEED 8-16
Test monitors, switches and plugs 8-17
Drive module AC 8-2
Power control unit 8-5
Power pack 8-4
Light emitting diodes and switches in drive module 8-20
Drive modules, adjust 11-6
B
Back panel. See CNC rack
Block diagrams 1-1
Block diagram of KSBM97/98 1-8
Block diagram of KSM97/98 1-7
Block diagram of PBM98 1-12
Block diagram of PSM-XYZF98 1-6
Block diagram of PSM97/98 (Stand Alone) 1-10
Block diagram of PSM97/98 Compact 1-11
Block diagram of VSM97/98 1-9
10
Block diagram of XYZF97/98 1-3

Block diagram of XYZF97/98DS 1-5
Block diagram of XYZF97/98R 1-4
Block diagram of XYZF97/98 1-2
C
CAN command interface 10-10
CNC rack 2-2
CPU 386SX 2-8
CUTCON2 2-14
D
DIOCAN. See DIOCOM
DIOCOM 2-36
DIOPAR. See DIOCOM
DIOSSI. See DIOCOM
Pressure controller 9-1
with Prescon 2 board 9-2
Adjustment of the control loops (PRESCON2) 9-6
Indicators and setting elements 9-2
Plugs 9-4
with Prescon 3 board 9-8
Adjustment of the control loops (PRESCON3) 9-12
Indicators and setting elements 9-8
Plugs 9-10
Pressure controller, adjust 11-10
E
Electronics rack 2-1
CNC rack 2-2
RACK SUPPLY 2 2-4
CPU 2-8
CPU 386SX 2-8
CPU jumper 2-10
CPU light emitting diodes 2-9
CPU switches 2-10
CUTCON2 2-14
DIOCOM 2-36
Interface boards for DIOCOM 2-40
IMPGEN 2-18
Impgen switches 2-18
POSCAD 2-44
POSCAD switches 2-44
POSCON 2-22
ROM/RAM2 2-12
ROM/RAM2 jumpers 2-12
SERCOM2 2-28
Adapter cards for SERCOM2 2-32
Outputs 10-9
Parameters 10-14
Technical Data 10-2
Front view of UNIPOS 10-3
I/O module SSI 4-12

IMPGEN 2-18
Incremental encoder 6-18
ROM/RAM2 2-12
J
Jumpers and switches on Panel PC 5-6
L
Light emitting diodes and switches in drive module 8-20
S
Stepping motor cards D900 3-4
Stepping motor rack 3-1
Page organization V-3
Ser232. See SERCOM2
Ser422. See SERCOM2
SERCOM2 2-28
SERCUL. See SERCOM2
SEROPT. See SERCOM2
SSI module bus S3 4-10
Speed limit monitor SLIM 4-6
Panel PC 5-1
Bystronic interface cards in PPC 5-6
Jumpers and switches 5-6
Switch S1 I/O address 5-8
T
Overview of the interrupts and I/O addresses in the PPC 5-4 TERMIF 4-2
PARAN 4-4
V
Peripheral cards 4-1
Supply module 7-2
I/O module SSI 4-12
Power pack for supply module 7-3
Light emitting diodes SSI 4-12
Control unit 7-4
Plugs in module SSI 4-14
PARAN 4-4
SSI module bus S3 4-10
Speed limit monitor SLIM 4-6
TERMIF 4-2
Plugs in TERMIF 4-3
POSCAD 2-44
POSCON 2-22
Positioning module UNIPOS 10-1
CAN command interface 10-10
Input 10-10
Output 10-11
Inputs and outputs 10-4
Axis switch 10-5
Supply 10-5
Encoder 10-6
List of inputs and outputs 10-4
Light emitting diodes and switches 10-12
DIP switch 10-13
Light emitting diodes 10-12
Parallel command interface 10-7
11
For your notes
12

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Electronics Manual CNC97/98

30, Commerce Drive

Telephone +4162 958 77 77

Phone +1516 231 1212

Electronics Manual CNC 97/98

Information on operating instructions

Checked & Approved

Using this Manual

Information on structure of the operating instructions

The header contains the name of Title 1

Block diagram 1-1

Stepping motor rack

Drive supply module

Drive module 8-1

Pressure controller 9-1

10 Positioning module UNIPOS

Block diagram XYZ97/98

Block diagram XYZF97/98

Block diagram XYZF97/98R

Block diagram XYZF97/98DS

Block diagram PSM-XYZF98

Block diagram KSM97/98

Block diagram KSBM97/98

Block diagram VSM97/98

Block diagram PSM97/98 (Stand alone)

Block diagram PSM97/98 Compact

Block diagram PBM98

For your notes

For your notes

2.3 ROM/RAM2 ...................................................................... 2-12

2.6 POSCON ........................................................................... 2-22

2.8 DIOCOM ........................................................................... 2-36

2.9 POSCAD............................................................................ 2-44

2.1 CNC rack

2.1 The CNC Rack

2.1 CNC Rack

Fig. 2.1a (Electronics rack)

2.1 CNC rack

2.1.1 RACK SUPPLY 2

2.1 CNC rack

Fig. 2.1b (RACK SUPPLY 2)

-12 VDC LED

2.1 CNC rack

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

For your notes

Fig. 2.2a (CPU 386SX)

2.2.2 Light emitting diodes on CPU

INTERRUPT REQUEST lights up during execution of an interrupt routine. It

2.2.3 CPU switches

2.2.4 CPU Jumpers

external Non Maskable Interrupt (NMI) connected to internal

Factory settings for all machines

Fig. 2.2b (CPU 386SX)

Fig. 2.2c (Block diagram of CPU 386SX)

Fig. 2.3a (ROM/RAM2)

Fig. 2.3b (Block diagram of ROM/RAM2)

Fig. 2.4a (Cutcon2)

Fig. 2.4b (Block diagram of CUTCON2)

For your notes

2.5.1 IMPGEN switches

Tab. 2.5a (IMPGEN)

Overview of the switches according to machine type:

Master frequency SW2