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c TABLE OF1
h(MELDAS-5000C/51 OOC
CONTENTS
MAINTENANCE MANUAL)
c CHAPTER 1. O U T L I N E O F N C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. NC U N I T CONFIGURATION ................................................................................................. 8
2.1 Main unit configuration ................................................................................................. 8
1) Exterior ...................................................................................................................... 8
2) Interior configuration ................................................................................................. 8
3) Interior configuration (compact cabinet) .................................................................... 1 0
P
4) View of card arrangement in logic board ................................................................... 13
5) Release of door interlock .......................................................................................... 1 4
3. INTERCONNECTIONS ........................................................................................................... .15
3.1 Interconnection diagram of the MELDAS 5000C ........................................................... .15
3.2 Interconnection diagram of the MELDAS 5100C _ .......................................................... 16
3.3 List of input and output signals ...................................................................................... 18
3.3.1 MELDAS 5000C list of input and output signals ................................................... 19
3.3.2 MELDAS 5100C list of input and output signals ................................................... 2 6
4. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1 Block diagram (1) .......................................................................................................... .34
4.2 Block diagram (2) .......................................................................................................... .35
4.3 MCU block diagram ....................................................................................................... .36
5. THE
5.1
5.2
5.3
5.4
5.5
5.6
FUNCTION AND THE HANDLING OF LOGIC CARD (from BNP-A2006) .............. .37
The function of logic card .............................................................................................. .37
Replacing and handling the logic cards .......................................................................... 3 8
Regular inspection of logic cards ................................................................................... .41
Logic card check points ................................................................................................. .42
inside setting on the printed circuit board ...................................................................... 4 7
Logic card maintenance parts ........................................................................................ 5 5
6. FUNCTION A N D HANDLING OF STANDARD BOARD (from BNP-A2007) ................... .56
6.1 Standard board and its functions ................................................................................... 5 6
6.2 Replacing and handling the standard board ................................................................... .57
6.3 Regular inspection of standard board “. ............................................................................ 5 7
6.4 Checking and setting the standard boards ........................... . .........................................5 7
6.5 Parts list of standard board ............................................................................................ .57
7. SETTING AND INDICATION BOARD FUNCTIONS AND HANDLING ............................ .58
7.1 PZ57 board functions and handling (from BNP-A2008) ................................................. 58
7.1 .l PZ57 board and its functions ................................................................................... .58
7.1.2 Replacing and handling the PZ57 board ................................................................. 58
7.1.3 Regular inspection of PZ57 board ........................................................................... 59
7.1.4 Checking the PZ57 board ........................................................................................ .59
7.1 .5 Patts list of PZ57 board ........................................................................................... .60
7.2 DP51 and DP52 board functions and handling (from BNP-A20091 ................................. 62
7.2.1 DP51 and DP52 boards and their functions ............................................................ ,62
7.2.2 Replacing and handling the DP51 and DP52 boards P-.............................................. ,62
7.2.3 Checking and setting the DP51 and DP52 boards ................................................... 62
7.2.4 Parts list of DP51 and DP52 boards ........................................................................ 63’ yb
7.3 DP box 62A and 64A functions and their handling (from BNP-A2010) ...................... .64{
7.3.1 Functions ...............................................................................................................&$
7.3.2 Replacing and handling ............................................................................................ .64
7.3.3 Checking and setting ..................................................................................................64
7.3.4 Parts list .................................................................................................................... 65
7.4 DP box 628 and 648 functions and their handling (from BNP-A2011) ...................... .66
7.41 Functions ............................................................................................................... 66
7.4.2 Replacing and handling ............................................................................................ .66
8. FUNCTIONS AND
8.1 Tape reader and its functions ......................................................................................... 67 ?8.2 Replacing and handling the tape reader .......................................................................... .69
8.3 Regular maintenance and inspection of tape reader ........................................................ 70
8.4 Tape reader check procedure ........................................................................................... 75
8.5 Parts list of tape reader .................................................................................................. 76 t
9. PDWER SUPPLY FUNCTIONS AND HANDLING ................................................................. 77
9.1 PD08A power supply functions and handling (from BNP-A2013) ................................ .77
9.1.1 Functions ................................................................................................................ 77
9.2 Functions and handling of PDOSA power supply (from BNP-A2014) ............................ 79
9.2.1 Functions ............................................................................................................... .79
9.2.2 Replacement and handling ........................................................................................ .80
9.2.3 Check procedure ...................................................................................................... .81
9.2.4 Parts list ..................................................................................................................... 81
7.4.3 Checking
7.4.4 Parts list
and setting ................................................................................................. .66
..................................................................................................................... 66
HANDLING OF PTR-210 TAPE READER (from BNP-A20121 ............ .67
i
r-i
9.3 PMIOA charger functions and handling (from BNP-A20151 ........................................ 8 2
9.3.1 Functions .............................................................................................................. 8 2
9.3.2 Replacement and handling ..................................................................................... 8 3
9.3.3 Check procedure ..................................................................................................... 8 3
9.3.4 Parts list ................................................................................................................... 8 3
9.3.5 List of ratings relating to charger ........................................................................... 8 4
9.4 Battery handling (from BNP-A20161 ...............................................................................8 5
9.4.1 Replacement .......................................................................................................... 8 5
9.4.2 Parts list ................................................................................................................... 8 7
10. DRIVE AMPLIFIER FUNCTIONS AND HANDLING ........................................................... 8 8
10.1 Drive ‘amplifier (3SlO/20/4OB) functions and handling (from BNP-A2017) ................. 8 8
10.1.1 Functions ............................................................................................................... 8 8
10.1.2 Replacement and handling ....................................................................................... 8 8
10.1.3 Regular inspection ................................................................................................... 8 9
10.1.4 Checking and setting .............................................................................................. 8 9
10.1.5 Parts list ................................................................................................................... 9 0
10.2 Drive amplifier (SA20/40A/B) functions and handling (from BNP-A20181 ................. 91
10.2.1 Functions ...............................................................................................................91
10.2.2 Replacement and handling ........................................................... ?. .......................... 92
10.2.3 Regular inspection .....................................................................\........................... 9 2
10.2.4 Checking and setting :.............................................................................................. 9 3
10.2.5 Parts list ................................................................................................................... . 9 4
11. SPINDLE CONTROL DRIVE AMPLIFIER FUNCTIONS AND HANDLING ...................... 95
11.1 Spindle control drive amplifier (S3S50/60A/B) functions and
handling (from BNP-A2019) ..................................................................... 9 5
11 .I.1 Functions ............................................................................................................... 9 5
11.1.2 Replacement and handling ....................................................................................... 9 5
11.1.3 Regular inspection ................................................................................................. 9 7
11.1.4 Checking and setting ............................................................................................... 9 7
11.1.5 Parts list ................................................................................................................... 102
11.2 Spindle control drive amplifier (S3S50/60A/B) functions and
handling (from BNP-A20201 ...................................................................... 1 0 3
11.2.1 Functions ................................................................................................................ 1 0 3
11.2.2 Replacement and handling ........................................................................................ 1 0 5
11.2.3 Regular inspection .................................................................................................... 1 0 6
11.2.4 Checking and setting .................................................................................................. 1 0 6
11.2.5 Parts list .................................................................................................................... 1 0 8
3
12. MOTOR HANDLING (from BNP-A20211 ................................................................................ 1 0 9
12.1 Cup motor ........................................................................................................................ 1 0 9
12.1.1 Regular inspection of cup motor .............................................................................. 1 0 9
12.1.2 List of commutator brushes for cup motor ............................................................. 1 0 9
12.2 HD motor ......................................................................................................................... 1 1 0
12.2.1 Regular inspection of I-ID motor ............................................................................... 1 1 0
12.2.2 List of commutator brushes for HD motor ............................................................. 1 1 0
12.3 Low inertia motor. .............................................................................................................. 111
12.3.1 Regular inspection of Low inertia motor ...................................................................1 1 1r
12.3.2 List of commutator brushes for Low inertia motor.. ................................................. 1 1 1
13. DETECTOR GEARBOX FUNCTIONS AND HANDLING (from BNP-A20221 . . . . . . . . . . . . . . . . . . . . 1 12 I
13.1 Functions ......................................................................................................................... 1 1 2
13.2 Replacement and handling ............................................................................................. 1 1 4
13.3 Regular inspection ........................................................................................................... 1 1 4
13.4 Parts list ......................................................................................................................... 11 5
14. MANUAL HANDLE (HD51) FUNCTIONS AND HANDLING (from BNP-A20231 .............. 1 1 6
14.1 Functions ......................................................................................................................... 1 1 6
14.2 Replacement and handling ............................................................................................. 1 1 8
15. ROTARY ENCODER FUNCTIONS AND HANDLING (from BNP-A20241 ........................ 1 1 9
15.1 Functions ......................................................................................................................... 1 1 9
15.2 Replacement and handling ............................................................................................. 121
15.3 Regular inspection ........................................................................................................... 1 2 4
15.4 Parts list .......................................................................................................................... 125
16. TAPE HANDLER (TH-400) FUNCTIONS AND HANDLING (from BNP-A20251 .............. 1 2 6
16.1 Functions ......................................................................................................................... 1 2 6
16.2 Replacement and handling ............................................................................................. 1 2 8
16.3 Regular inspection ........................................................................................................... 129
16.4 Checkpoints .................................................................................................................... 1 2 9
16.5 Parts list .......................................................................................................................... 1 2 9
17. SERVO ADJUSTMENT METHOD (from BNP-A20261 .......................................................... 130
17.1 General outline of NC servo .............................................................................................1 3 0
17.1.1 NC servo ................................................................................................................... 1 3 0
17.1.2 Types of NC servo systems ..................................................................................... 131
17.1.3 MELDAS servo system .............................................................................................1 3 6
17.2 NC servo system diagram ................................................................................................. 1 3 8
17.3 Servo adjustments and regular inspection ..................................................................... 1 4 0
18. PARAMETER SETTINGS
18.1 System parameter tape loading ........................................................................................ 142
19. SELF-DIAGNOSIS .................................................................................................................... 1 4 4
19.1 Alarms and states indication ........................................................................................... 1 4 4
19.2 ALARM contents check .................................................................................................. 1 4 4
19.3 Interface check ............................................................................................................... 144
20. TROUBLE-SHOOTING (from BNP-A20271 ........................................................................... 145
21. TROUBLE-SHOOTING WITH SOFTWARE (from BNP-A20281 .......................................... 165
21.1 LC2, LC120, LC23 logic cards ........................................................................................ 165
21.2 Action when there is something wrong with LC2, LC120 or LC23 logic card ............. ..16 9
21.3 Trouble-shooting ............................................................................................................. 1 7 0
22. MAINTENANCE PARTS LIST (from BNP-A202911
.................................................................171
22.1 Spare parts ................................................................................................. ..: .................. 171
22.2 Printed circuit board (Logic card) ................................................................................... ,171
22.3 Board .............................................................................................................................. 172
22.4 Power supply .................................................................................................................... 1 7 2
22.5 Battery .............................................................................................................................. 1 7 3
22.6 Tape reader .................................................................................................................... 1 7 3
22.7 Rotary encoder ................................................................................................................ 173
22.8 Detection gear box .......................................................................................................... .I 7 3
22.9 Drive amplifier ............................................................................................................... 1 7 4
22.10 Motor ............................................................................................................................. 1 7 4
22.1 1 Motor brush .................................................................................................................... 175
22.12 Thermal relay .................................................................................................................... 1 7 6
5
CHAPTER 1. OUTLINE OF NC SYSTEM
The MELDAS51OOC is a numerical control unit which is designed especially for lathes, and the MELDAS-5000C
is a numerical control unit which allows combinations with other machine tools.
Figs. 1.1 and 1.2 give the arrangement of systems using the numerical control units.
M 5ooocmain unit
M51ooCmain unit
j
X-axismotor
Y-axis3motor
Z-axismotor
1 L-_______ ____.__________JConnection cables
Fig. 1.1 View of ME LDAS5000C configuration
r - - - - ----- ---- ------_-Operation Power Limit
I 7 panel controller switches,etc.1
I c X - a x i sm o t o r 7
II c Z - a x i s
I m o t o r -
I zc \ z
I iiI
I Rotary encoder IJ J J /
I
L-_______ 7_------ -_--__ J
r _----Operationpanelr - - -
1
J
-- --Powercontroller
l -- - -
-l
-Limit- -switches,etc.
J7
Machine
‘-1
i
.Connection cables
fMachine
Fig. 1.2 View of MELDAS51OOC configuration
The system is composed of the numerical control main unit, the operation panel, the power controller and the
main machine unit. The main machine unit is provided with servo motors (also rotary encoder for lathes) for
the X axis up to the 4th axis (X axis and 2 axis for lathes).
The construction of the MELDAS 5OOOC/51OOC can be broadly divided into the following five sections.
i
Power supply section
Logic section
Paper tape reader section
M ELDAS5000C/51 OOC Servo drive section
MELDAS
F/l-
! Setting and indicating section
(Spindle motor drive section)
(Machine operation setting and
indicating section)
Setting and indicating section L(Machina operation settingand indicating section)
Paper tape reader
S e r v o d r i v e saction _ _ _(Spindle motor drive section)
.--I Logic sectionI
Iy-:
Power supply section
’ L.-f._J 4-k
Fig. 1.3 MELDAS-5000C/51OOC
h
7
CHAPTER 2. NC UNIT CONFIGURATION
2.1 Main unit configuration
1) Exterior Refer to Fig. 1.2 and Fig. 1.3 of the MELDAS5OOOC/51OOC Instruction Manual
2) Interior configuration
(1) Exterior with front door open
D.C. power supply_
SCR AMP ------&-
i
Tape reader
Logic section Board
3-phrw transformer -
/
‘_g Front door
No-fuse breakor
8
(2) Exterior with rear door oDen
Logic board rear
D.C. powu supply
Exhaust fan
Relay unit
3-phase transformer
Connecton for externalconnections
9
b.-$c
.
10
I
I0 I
11
I Rear view)
Battery box
X-axisno-fuse breaker
Space for additionalaxis or spindle AMP
Limit switch for _door interlick
,. ._... .,s..,
Logic sectionDC powersupply section
7--.?.-
. Ad---
X-axis SCR AMP Z-axis SCR AMP
r - - - - - - - - - - 1
1 I
II
II
I
I
II
I
II
L _-__-----_ -I
1
AC 1OOV line.fuse (lOA)
- Card
+24Vfuse (3A) -
Frequency se-_lector switch
CANNON con-nectors for ex- -ternal connection
1 Z-axisno-fuse breaker
Terminal blockfor tap switching-of control powertransformer
Space for powercontroller -
a-phase trans-former switch- -ing tap
Logic sectionDC powersupply section
IDCll
DC12 *’
Relay unitocllDC12 -1
I 2 3 ---- 12 rGZ
r - - - - - - - - - - - -I
1
III
I II I
II II II IIL__________1
(
fTB 2
T
_Terminal block
’ for X-axis motorconnection
_ Terminal blockfor Z-axis motorconnection
Limit switch fordoor interlock
Terminal blockfor input power
Fig. 2.5 Main unit interior arrangement (ME LDAS-51OOC) Supply connec-tion
\ j. .
n_.‘p.Yw
Uame of card
LC 4_, cn--kLC 3 a
LC 10 -a
LC 1 a,ILC 2 I ,a
Name of card
LC 2 2 -
LC 2 1 h)
L C 1 2 0 w
LC 10 a
LC 1 cn
LC 2 0,
LC 3 4
LC 4 co
t_-
n_.‘pNt
Jame of card
IF01 -
LC23 N
LC 21 w
LC 4-I VP
LC 4_, m
LC 3 Q,
LC 10 q
LC 1 00
LC 2 D
LC 120 g
LC22 =
Jame of card
L C 2 3 +
LC 21 N
LC 1 0 w
LC 1 P
LC 1 2 0 m
LC 2 Q,
LC 3 4
LC 4_, 03
5) Release of door interlock
MELDAS5000C/51OOC has a door interlock construction for a safety measure. When the front or rear
door is opened, the main input no-fuse breaker is opened automatically so that all the power supplies in
the N/C controller are cut off for preventing the trouble due to an electric shock.
Make sure to close the front and/or rear doors before turning on the main input no-fuse breaker. (If the
breaker is turned on while the door is open, the breaker opens immediately.)
When it is forced to turn on the N/C power supply while the door is open, release the door interlock
system according to Fig. 2.10. (Refer to Fig. 2.1 -Fig. 2.5 as to the locations of the door interlock limit
switches for the front and rear doors.)
Limit switch fordoor interlock
(a) Normal state
plate
Ib) Released state ofdoor interlock
Fig. 2.10 Release of door interlock
(1) Loosen the setscrew in the state shown in Fig. 2.10(a).
(2) Turn the lock plate 90 degrees as shown in (b) and tighten the setscrew while pushing the limit switch
with the lock plate. Then the main input no-fuse breaker can be turned on manually in this state.
Note that the door cannot be closed in the (b) state. Be sure to return the lock plate to its original
position before closing the door.
(3) Since the limit switch for the door interlock is provided each for the front and rear doors, the above
procedure should be done for both the limit switches when the power is turned on while both the doors
are open.
14
CHAPTER 3. INTERCONNECTIONS
3.1 Interconnection diagram of the MELDAS 5000C
onnector NO. HELDIS 5U”“C-Y,,,
TB2(M8 screw)
Interconnection diagram of the MELDAS 5000C (for relay output)
15
3.2 Interconnection diagram of the MELDAS 5100C
MS3102.\28 -2lSI
:\lSJO57--16.\
(InlIe connecte” to be attuhd toabbs (oppaite skte of NC) we notbtcluded In the MELDAS SIOOC.
(2) Ihs able8 l d thn conmton Jllll
(4)Cablu connected to tke controlquipmmt halt not be grouped in Iswne bundb with the pma cablesto tbe machine.
WPtew prepare I lapante AC IOOVPO* wppty *hen externllcounterr or punchers are innJled.
(6)In TB121 and 11122. please con-nect DC1 I to PA. and DC12 to NBof the nlota.
i
VS3lO?\?H 2lS\E---J ,
\lb31Otili2X 2lI’\\lS3lJ57 I6 \
1
r \+i3102\2u “YsrT
.\1S31081128 21SXSIS3057-16A
\IS3102A28 2ll’X
- I
I,IS3 1 O&II120 29sI\lS3057- l2A
IS3102\2lJ 291’
\Is:~lntill?o 041’YS305i 12\I”--: ;
L-\lS3102\20 ?YS%
us3 I u(i1+20 2Yl’%\Is30 Si
L
I ‘? \
- - -
\Is:!lo2\?o ?YS%
motorside A (A2) or PA
motorside B Al) or Nl
(7) The abler CNA 3.4 are prosidedfor the sisnals from the detectors.Pbar cc.““ect these able, directlyto the NC mntrotler without ajunction in the mmhtne.
OJAs for the particulara of the EC.“-nccttons for TB121. TBl22. pteau
3refer to the instruction Manual.
(9) Sidr for the extr. exe, (No. 3 &4 axes) we shown in the bracketf ).
handle ked
J J
/
\L%.l lOti 29s\I53057 1 2 4
/-\lS31lJ2\10- 291’
/
\IS3 I Otil120 29s\I53057 12\
as3 102?\20 291'7 r-
power supply
grounding
Interconnection diagram of the MELDAS 51OOC (for relay output)
16
CNDB
CNA5
(M4 screw)
- MS3102A20-29s
MS31O~B20-29Ph&33057-12A
- MS3102A20-29%
l-MS3106H20--29PzMS3057-12A
otor side ACA2) or PAotor side B(A1) or NE
otor side A (A2)or PAotor side B (Al)or NE
r Ms3106826-21s MS3057-16A
r MS3102A26-21P
ground1-w AC 10 O/l 1 OV
asVn/l Axis
f&i3106H20-29sMS3057-12A
NS3102A20-29P
No.3 axis motor
No.4 axis motor I I
Interconnection diagram between the MELDAS 51OOC and itemsspecified by the optional specifications
17
3.3 List of input and output signals
The meaning of the symbols used in the following lists are:
(1) l . . . . . . . . . . . . . ...*.. means a normally closed contact.
(2) - -I I -- . . . . . . . a circuit receiving input signals in the MELDAS 5OOOC/51OOC, as shown in the follow-
ing drawing.
4+21vr __---------- - - - - - - 1 I
(3) ---.-jj-- -..- . . . . . . .
(note) (1)
I -I-
-5 2.2 ,uF !!
4
I I
LI I
_ __ - __-__-----_1 -..---J(N/C wx2~
means a relay contact output from the MELDAS 5OOOC/51OOC.
The maximum allowable current for a relay contact is 200 mA for DC24V and 100mA
for DC 4SV.
18
3.3.1 MELDAS5000C list of input and output signals
-___ _._ _
MELDAS 5OOOCCND 1 /
Cycle start
Automatic halt (feed hold) -- -fl- .!i- 0 :;I,, ~iy _. .._ _._
Tape command select .__. _-__a_ .i‘_
Manual handle ‘step feed selection _. __.. +.
Manual feed selection . .._.
Manual data input salact -..__. --I) ..!’
Manual handle feed axis selectton (X) - ---#-I!
Manual joa feed
Return to the zero select ------I)--!-.
Feed hold indication - --. 1 FL!- SI’I.
Cycle start indication - -- -1 /--.--
The zero point indication X - -.-.---f ). 1-4 ;I 111 _ _1
Manual rapid select
The contact is opened forthe feed-hold state
----a CSDf; - :M
- CND3 - iT)
The contact is opened forthe emergency stop state
1 HSO
J O
1 i!k.Y p
RT
Automatic operatron__.{ 1”
1 s
1
,JP,
_ _-.- OP’ mte 1 I If * marked signal is not used.connect it to grounding.
_.__.._..._ -- .- -.
Interconnection diagram for CNDl of MELDAS 5000C (for relay output)
(‘\I):, ! <’ )
6--lll’lf
19
(CNDZ)
MELDAS 6OOOC CND 2- 1
M function outpot ; M 1 1” Ml 2
” Ml 4
” Ml a
” M2 1
” M22
c M24
” M28
Ml 1
Ml 2
Ml 4
Ml 8
M2 1
M22
M24
M28
M command &art MF
M function output common
Traverse command completed
I
S function output S 1 1
I s 1 2
)I s 1 4
” S18
” 521
I s 2 2
z 524
” s20
S command start
S function output common /
T function output T i i
I T 1 2
” T 1 4
n T18
MF
OM
DEN1
DEN2
Sll
s12
s14
Sl8
s 2 1
s 2 2
S 2 4
S28
SF
OS
Tll
T 1 2
T14
T18
n T 2 1
” T 2 2
I T 2 4
” T 2 8
T command start
T function output common
MST compkted
NC ready completed
*
, ;;e
T 2 1f
I,II 0 T22
gb ” <) T24
I, ,, hI, OT28
4, ,I J 01 TF
k
Interconnection diagram for CND2 of MELDAS 5000C (for relay output)
20
(CND3 i
MELDAS 5000C CND 3 -
Pitch error compensation t X p+x
P --x
Ps-Y
I,
,,
I,
Interlock X
I,
0
The zero point detection X
I,
External deceleration +
I,
I,
II
Auxiliary function output M 3
,,
I
Output common
Input groundng
NC reset output
I
External reaet output
Overtravel + X
I,
I,
0
I
,I
.P --Y
PfZ
P - Z
I T X *
ITYa
ITZ*
DECX*
DECY*
DECZ*
EDXPf
EDYPf
EDZP*
O J
M30R
M02R
M O O R
OMR
O R
RSTl
RST2
E R S
+LX*
-Lx*
+LY*
-LY*
+Lz*
-Lz*
OL
Tape editing E D T
Spindle gear selection input ’
2,I
GRl
G R 2
I When open, significant
Mode selection switch
note) If * marked signal is not used, connectit to grounding.
Interconnection diagrams for CND3 of MELDAS 5000C (for relay output)
21
(CNDI)
Manual jog feed + 4--rJ
Af4T d-7
” -
Manual handk fead axis selection (4 th)
Tha zaro point indication (4 th)
- 4 T 3
H4T 4 Manud handb faad axis selection switch
k +24V CN-Dl -c
Pitch error compnsation ( f4 th)
” (---4th)
Intarlock (4 th)
Tha zero point detection
External de&oration i- 4When open, significant
” - 4
input grounding
Overtravel + 4Z
I - 4q “” a’n o t . ) I f * markedsignalis
--L4* not used, connect it to
Input grounding
Baxis r&o off
B3 ( T5 , S4 ) digit function outputcommon
B F
# Bll(T31, S31)
* B12(T32, S32)
I B14(T34, S34)
I B18(T38, S 3 8 )
I B 2 1 ( T 4 1 , S41)
I B22(T42, S42)
, B 2 4 ( T 4 4 , S 4 4 )
N B28(T48, S 4 8 )
N B 3 1 ( T 5 1 )
” B32(T52)
, B34(T54)
, B38(T58)
OL
SVFB*
B F
Bll ( T 3 1 , S 3 1 )
B12(T32, S32)
B.14 (T34, S 3 4 )
B l 8 ( T 3 8 , S 3 8 )
B21 ( T 4 1 , S41)
B22(T42, S42)
B 2 4 ( T 4 4 . S 4 4 )
B28(T48. S48)
B 3 1 ( T 5 1 )
B32(T52)
B34(T54)
B38(T58)
grounding.
lnterconnggtion diagram for CND4 of MELDAS 5000C (for relay output)
22
(CNDG)
MELDAS 6WOC CND 6 -
Manwi Jog food spwd selaction 1
I 2
I 3
# 4
I 6
Handk bad rrcodr A phan output
” B phase output
f12V
- 1 2 v
Grounding ( rt 12V)
Handk food multiple 1
* 2
Optional stop
Input grounding
Auxiliiry output MO1
Feed override 1
” 2
” 4
H 8
I 16
Ovwide cancel
NC power ON
NC powor ON/OFF common
NC power OFF
NC alarm output
Memory operation
Manual absolute
Extornsl docabration - X
” - Y
I - Z
Bonro romiy complettd
1001 length measure
Tod roforonco point return
FSTl
FST2
F S T 3
FSTI
FST5
HA
H B
+12Vh
- 1 2 V h
O h
MPl
M P 2
OSP
ONMO 1 R
OVRl
O V R 2
O V R 4
0VR6
O V R 1 6
O V R C
P O N
C O M
P O F
A L 1
A L 2
MEM
A B S
EDXM*
EDYM*
EDZM*
S A
S B
T L M
H P R
not.1 If * marked signal is
notd Rofor to next page tabe1-3 for further detailsabout FSTl-6, OVRl,
lntgrgonnection diagram for CND6 of MELDAS 5000C (for relay output)
23
Table 1. F step setting.__
‘,;P Feed -IFs?~~~i? FST FST1 2:314 5
0 o/o G o-0 0 0
1 2/0.2I
Cl ’ 3 (3 0
2 4/0.4 0 IO c' 0
3 6/0.6 '0 0i
0
4 6/0.6
5 IO/l.0
6 12/1.2
7 14/1.4
6 16/1.6
9 2Of2.0
10 40/4.0
11 60/6.0 0 0
12 60/8.0 0 c, 0
13 100/10.0 0 0.---_.14 120/12.0 0 0-_15 140/14.0 0
16 i 160/16.0 0 T-7 0 0 0 )
not0 21 table 1 F step: upper mm/min.
lower inch/min.
Table 2. Override
Step/Handle multiple selection
x 1 0 0 0 / x 1 0 0 0I
0 1I
note 1) 0 mark means that the connectiongo6a to grounding (ON).
note 3) When both Ml and MP2 aregrounded, in -0 of step, x 1000
in casa of handle x 100
2 4
CNAl-4
MELDAS 6OOOCCNA 1 --4 --.
Resolver excitation 1
If 2
Resolver output 1
I 2
A0 Rd i r----’
B IbRd2 ----.
COOdl 4
D boa2 __+___I1
Pi 12v +12vA
Analog signal groundingR
A N G i
- 1 2 vS --12vk
I
whiteI
AB\ b r o w n
C
D red
??a_I;I
Tachogenerator 1
I 2
Shield grounded
The detector gear boxfor motor side
(note)
white
r - - - - - - l
Tachogenerator
E
(1) CNAl is for analog cable of X axis.
CNA2 11 Y axis.
CNA3 $1 Z axis.
CNA4 11 4th axis.
(2) In interconnection diagram, above Q is indicated
in case of CNA 1, X is marked.
I, CNA 2, Y 11
I, CNA 3, Z 11
I, CNA 4, the 4th 11
tnterconnection diagram for CNAl - 4 of MELDAS 5000C (for resolver detector)
25
3.3.2 MELDAS5100C list of input and output signals
CNDl
cycle start
automatic halt (feed-hold)
tapa editing select
memory oparation selact
manual data input select
tape command salect
manual (handle feed)/(step faad) selection
manual fed selection
manual handle feedaxis selection (X)
,, (2)
manual rapid traverse
return to the zero select
manual jog feed
I,
emergency stop
single block
block delete
vrlnritv intrwunt (drv run)_“._W.., . ..__.._ r- .--,
P*-
input grounding m
+24V
feed hold indication
cycle start indication
the zero point indication(X axis)
the zero point indicationI2 axis)
(the contact is opand for thefwd-hold state)
(the contact is opened for theemergency stop state)
Interconnection diagrams for CNDI of the MELDAS 51OOC(for relay output) . . . . . extra axes are excluded
26
CND2
MELDAS 5 1 OOC
feed override 1 VRlh
I, 2
,, 4
,, 8
,, 16
display lock
machine lock
error detect
chamfering
multiple by 10 select
absolute ON
jog feedstep 1
(IO mmlmin),, 2
(100 mm/min),, 3
(1000 mm/mini
ABS -Oh’
FS2 _O
FS3 -
input grounding
constant
ON A
GRl -{
GR2 ___I
GR3 -1
CR4 .-I
input grounding OJ -
external power nsupply ON IJ
P
input grounding small
external powersupply OFF -4r
PON *
COM
POF ___o
(The points indicated by 0 shall begrounded to (ON) 1
Interconnection diagram for CNDP of the MELDAS 51OOC (extra axes are excluded)
27
CND3
MELDAS 5 10 OC
M function output
n M l 4 14
f~ M 2 4 (v--j
U? command start
traverse commend
S command start
S functionoutput common
T function outputTll
” T 1 4
N T 1 8
fl T21
I/ T24
11 T28
T command startTF
T function ou\putcommon
M.S.T. completed
NC ready completed
c,, c o m m o n -
Interconnection diagram for CND3 of the MELDAS 5100C
(for relay output) . . . . . extra axes are excluded
28
MELDAS 5 1 0 0 C
auxiliaryfunction o;t&t
NC alarm output
auxiliaryfunction o;tl;t
auxiliaryfunction out ut
MB3the zeropoint detectgn
,# z
input grounding
NC reset output
MOO
ALA
MO2
M30
DCX*
D C Z *
O N
RST 1
each of these contacts (normally closedcontacts) shall be opened when thecorresponding limit switch is pressed
overtravel+ x
,, - x
#, + z
#, - z
input grounding
7
+Lx*
-Lx* each of these contacts (normally closedcontacts) shall be opened when the
+Lz*
31
corresponding limit switch is pressed
--Lz* -v
OL
servo readyS A
external reset
interrupt
E R S --it---,
STLK --_I+
Interconnection diagram for CND4 of the MELDAS 51OOC(for relay output) . . . . . extra axes are excluded
29
CNAl
MELDAS
rotary encoder A phase pulse
rotary encoder B phase pulse
rotary encoder one pub perrevolution output
,, lamp grounding terminal
rotary encoder +5W powerSUPPlY
power supply -12V
power supply groundingterminal
power supply +12V
shield grounded
handle feed encoderB phase pulse
handle feed encoderA phase pulse
spindle rotation analogoutput signal
PA
PB
SC
PLG
+5H
HB
---- A
1?- _-_-_--- C
I . B_-_-----I_------- M
II _-_-_--- HII
; i.L_______ f
I I I----fdSPSC ;_-___-____q ~ 1
Interconnection diagram for CNAI of the MELDAS 51OOC
30
CNA3
MELDAS 5lOOC
resolver excitation 1A
resolver excitation 2B
resolver output 1C
Dresolver output 2
P+12v
analog signal grounding Rterminal
-12vS
tachogenerator output
tachogmerator output
shield groundedE
Rx1 r__--_--(
Rx2 &___--1I
0x1 +__-----’
I0x2 )__-_--1
III
t12VI’AN0 et- 1 2 v
I 4I
PXl !-_-__-_t
PX2 f - - - _ _ - _ I
I
IOG !
P
R
S
K
L
(note) CNA3 is a cable for X axis analog signal.
(note) Refer to MELDAS 5000C CNAl - 4 interconnection diagram concerning to the diagram of detector
gear box.
Jnterconnection diagram for CNA3 of the MELDAS 5100C(X axis resolver detector)
31
CNA4
MELDAS 5100 C
resolver excitation
rasolver excitation
resolver output
resolver output
Pl-
E2-
Cl-
Iz-
I+12v -
Ianalog signal grounding -terminal
I-12v -
1tachogenerator output 1 -
Itachogenerator output 2 -
shield grounded E
RZl r---___,~
RZ2 ;_--____
OZl ;_--____
022 :__--___IIII
+12v.y
ANO.-
-12v ]
I
Ipz] !__--_--
pz 2v----
lOG I
A
B
C
D
(note) CNA4 is a cable for i! axis analog signal.
(note) Refer to MELDAS 5000C CNAl - 4 interconnection diagram concerning to the diagram of detector
gear box.
Interconnection diagram for CNA4 of the MELDAS 51OOC(2 axis resolver detector)
3 2
CND8 axis command readoutindicator (extrrhall
MELDAS 5 1 0 0 C
metric/inch select A ) fjfj,O 1
return
X axis data
return
X axis strobe E
r e t u r n
X axis reset
Z axis data
return
2 axis strobe
return
2 axis reset
No.3 axis data
return
No.3 axis strobe
return
No.3 axis reset
No.4 axis data
return
No.4 axis strobe
return
No.4 axis reset
common
i
VW
ef
Z axis
._-__‘__---l- 1
III
No.3 axis III
I II IL___-----Jr -------- 1I II III I
I No.4 axis II II II II IL-_-_--_-J
e&-w___________ 6s;RGbus - “p RG
interconnection diagram for CND8 of the MELDAS 51OOC(for external axis command read-out indicator)
33
CHAPTER 4. BLOCK DIAGRAM
4.1 Block diagram (1)
MEMORY
R A M73CPU
Machine Control Unit
Line Receiver
Relay OutputI IPaper tape reader
MCL!
Setting and indication board
Read-out counter
I
clPaper tape puncherrL____-
l--o%- 1,-op-- IL-A--, JclBuffer register
D P MTMultidata display
Rput Bus Line
Drive motor
Machine sequence-
M
;
L ~ ,,Machine
R sequence
control
Lpanel
Rak
9L I
-1
Output Bus Lina
a1
34
4.2 Block diagram (2)
(LC3)
FY-Jq
(x22 j
note) Numerals of ( ) :Printed circuit board name
TfvEc P u,
(LC2)Standard spec.rmemory
R O M
#l-+&I NC standard input signals
I I
(LC4)
++jJf+ NC input signals relation to axis
I I
(LC21)
L
-KU
AR
T LNC standard output signals
1( L C 2 3 )
I
M Lc LJ-g; R
L R-.
TA -)L
- -
--a
-0 I Machine sequence control input 81 output
(Z Machine sequence control panel)
+ S analogue output
( -+ Spindle drive
SCR amplifierl
3 5
4.3 MCU block diagramIT ___-7
I l- I Ii II I r .--- --- --~ -
CNA
.
36
CHAPTER 5. THE FUNCTION AND THE HANDLING OFLOGIC CARD (from BNP-A2006)
5.1 The function of logic card
C A R D N A M E FUNCTIONS REMARK
CPU (central Processor Unitl input & output controlClock generator relation to CPUAuto restart function of CPU
LClControl switch (to let CPU RUN/STOP by using
toggle switches mounted on the logic card)Sequence instructions controlVarious kinds of ROM (Read Only Memory)4 bits ALU (Arithmetic Logic Unit)
LC2
Standard specification memory (ROM)The memory (C MOS) for parameter, zero shift setting,and various kinds of offsetCalculation memory (RAM-Read access memory)Memory parity error generatorBattery charging/discharging circuit
LC3
Operation ready sequenceSystem clock generatorTiming generatorPaper tape reader controlManual handle controlSpindle revolution detection (*I
1Encoder Pulse buffer Circuit
NC standard input signal I/FControl words decoder for input & output I/FSetting and indication board I/F
1) (*I MBlOOC only2) When Multidata
display unit is con-netted, a settingand indication
board can not beavailable.
LC4
Pulse distribution circuit, Smoothing circuit,Digital Phase Modulation circuit, Resolver exciter,Resolver output filter, Settings of servo system, ’Input interface relation to axis
Two axes are mountedon one logic card.
(LC20)
LC120
Flexible memory (RAM)
Memory to memorize a processing tape ( BkW RAM 1Program for option (Memory cycle, Tape editing,
Punch out, Special fixed cycle, Nose R compensation)Battery backed up circuit
Battery charging circuit
Optional card
LC21
Memory parity error generator
Relay interfaceRead-out display (Four axes)S analogue outputD/A converter
Optional card
LC22Tape puncher controlMultidata, display control OEMTlWJ BD JPJEKWE (‘fi LA- (CLy9
Optional card
LC23Memory for machine sequence control (ROM)Machine sequence interface
Optional card
3 7
5.2 Replacing and handling the logic cards
Switch off the NC power, and replace the card after opening the front door or pulling it out.
a\Large-sized cabinet
Location where card basketis drawn out
Card and card retainer
Loosen the two screws and removethe card retainer before drawingthe cards out.
Compact cabinetI I
This cable is easily damaged A
Take care that the cable doesnot get entangled with thefixtures, etc., When drawingout the basket or replacing it.
3 8
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Card connector - __.__
(Touching this by hand may\ (LC 3 card)
result is a defective contact)
\7
Mini bus
IC plug
AMP MODU connector f!- AMP BLADE connector
Mini bus (power supply bus)
The base of the mini bus is very easily bent and so take care not to touch it.
It will break easily if force is applied to it when the cards are draw out.
AMP MODU connector
When connecting or disconnecting this, rotate the screws at both end uniformly to loosen or to tight-
en them.
AMP BLADE connector
Take hold of this with both hands and pull to disconnect it.
The reverse procedure is adopted for connection.
Card connector
Signals are exchanged when the card connector touches the receiving side connector and so when it
becomes dirty, this will result in a faulty contact. Therefore, do not touch it directly.
C MOS memory (LC2). RAM memory iLC1201, plasma display (LC22)
When one of these is added, each of the C MOSS is employed and so after removing the card, it is
necessary to cover it with aluminum foil and take sufficient care of static.
The ROM memory, RAM memory and IC plug, etc, may work loose due to the vibration sustained dur-
ing transportation. To forestall defective contact, an effective method is to push these parts in by hand.
When removing the cards, take hold of the card in the corner position, and take out.
After a card has been inserted, it is necessary to check whether the card has been inserted properly
by observing the connector section of the card.
39
(LC 2 card)
RAM memory
C MOS memory
Handle this C MOS with care
A single card has 160 contacts which are connected by connectors at the receiving side with contact
pressure. This means that it may require a great deal of force to remove and insert the cards manually.
Note) Handling the AMP MODU connectors
When connecting or disconnecting these connectors for exchanging the cards, etc., loosen the
left and right screws in the photo alternately or tighten them alternately, and never force them.
Loosen these screws alternately a littleat a time and then detach them.
40
5.3 Regular inspection of logic cards
Apart from the relay mounted on the LC 21, the logic cards do not use consumables and so there is no need
to conduct daily inspections. Nevertheless, after a year has elapsed, it is important for long-term use to
clean the logic card connectors with alcohol, remove the dirt and dust adhering to the face of the cards, and
check that there are no loose connect/ens in the ROM, RAM and the IC plugs (the setting plugs).
Cleaning the cardconnectors
Pushing in a ROMon the LC 120 cardby hand
41
5.4 Logic card check points
Card no.
LC4
Checkpoint
TPl
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
Function
X-axis error output
Z-axis error output
Phase difference (droop)
between command DPM
and resolver feedback
signal
11FXaxisD= 150 x 2
mZaxisD= ,50
D = droop (/&.ec)
F = feed rate (mm/min)
So X axis x 2
= 0.5j.llP
X axis resolver feedback
signal
2 axis resolver feedback
signal
These signals are turned
into square waves at the
Schmitt circuit for TP5,
TP6
X axis feedback signal
2 axis feedback signal
X axis command DPM
Z axis command DPM
Command pulse is re-
ceived and phase
changes.
DPM reference
Used for resolver exciter
Waveform
I+) ‘““““““n F-J--I-) command
J--LAPulse width = droop (calculated according to left)
(704 /..&ec with a Z axis rapid traverse of 9600mm/min)
L e v e l +lOV
. . . . Only with radius command (lathe)
Frequency = 4.5kHz
Level = 12V 2: VP-P
Amplitude fluctuation = less than 1.5%
I LFrequency = 4.5kHz
Duty = 1 : 1
Level = logic level
t With (+I c o m m a n d
I I IFrequency = 4.5kHz
Duty = 1 : 1
Level = logic level
I I IFrequency = 4.5kHz
Duty = 1 : 1
Level = logic level
4 2
The check points given on the previous page are used for regular inspections. It is also possible, however, to
use the connector pins at the rear of the logic boards and check the signals. This method of checking requires
a very high level of expertise and a thorough knowledge of the whole machine system, and so it should be
performed only by specialist maintenance personnel.
Front of logic card
-III
y;ftnngith ICs mounted
(Side Al
- Upper A 01 address (known as UAOl)
- Upper A 40 address (lJA40)b
/------- Upper B 01 address
WBOl)
1II
I=III ---.I
Side with patterns(back) (Side B)
-Y
- Upper B 40 address
WB40)
L - Lower 01 address (LB011
Eadc of logic card\L Lower B 40 addrass
(LB401
L Lower A 01 eddress (LAO11
Lower A 40 address (LA401
Card no.
Same
for
all
cards
Pin # Signal name Description
UAOl
UA40LG DC +5V return
LAO1
LA40 iI--
UBOl 7
UB405 v DC 5V power supply
* LB01
LB40 !I-
t”,:“, > 12V DC +12V power supply
DC -12V power supply
(Cant
43
Card no. Pin # Signal name Description
L A 1 3
L B 1 3A G DC? 12V return
L A 1 4
L B 1 4 E-
Et z “, > 2 4 V DC24V power supply
L A 3 8R G DC24V return
L B 3 8
LC 1 L A O 4 DA3F output CPU designation
L A O 5 DAlF N MCU designation
L A O 7 DABB ” LC2 designation
L A 0 6 DAlB u PTR designation
LB04 STRBP I’
L A 2 8 RDA N Having a function to read in data of 16
L A 2 9 RDB ubits from an input 81 output device(correspond to the address) designated
L A 3 0 RDC 0by Device Address.
L B 2 8 WRA IJ
WRB ’ ”The contents of register designated (16 bits)
L B 2 9 is transfered to an input 81 output devicespecified by Device Address
L B 3 0 WRC I’
L B 3 1 SNSO ‘I
L B 3 2 SNSl ‘1 States that an input & output devicedesignated by Device Address has are
L B 3 3 SNS2 J’ desired to search
L B 3 4 SNS3 ‘I
L A 3 2 CNTO u
L A 3 3 CNTl I’The function that a control signal istransfered from CPU to an input &
L A 3 4 CNT2 fl output device designated by DeviceAddress
L A 3 5 CNT3 N
L A 3 1 C L K O Input 9 MHz crystal oscillator
L J A 2 3 CPCL output CPU clock_.
L A 0 8 M P E R Input Memory parity error
U A O 5 C A L M output CPU stop
UA18 L I T R Input I T
LC 2 L A O 2 M P E R output Memory parity error
U A 2 4 P B I T 0 H output Parity bit ON
44
(Cont.)
U B 0 7 DPMl N Digital pulse minus (1 st axis)
UBO8 DPPl N ,* I, plus (1st axis)
U B 0 2 DPM2 ” ,I I, minus (2nd axis)
U B 0 3 DPP2 u ,* N plus (2nd axis)
U A 2 2 DVAL 1’ Drive alarm
LC120 U A 2 4 P B I T O H ” Parity bit ON
L A O 2 MPER ” Memory parity error
45
l When adjusting this output signal, volume 1 (lower side) is for zero adjustment and volume 2
(upper side) for output voltages on this printed circuit board.
46
5.5 Inside setting on the printed circuit board
The location of IC chips (Address of IC chips on PCB LCl/LC3/LC4)
IC chips are mounted on the printed circuit board as following.
Vertical lines are indicated numeral and horizontal alphabetical.
The location of IC chips
IC location on memory board (LC2)
I1 M 01 J UAOlL.lI2 L02 M I2 K
03 M 13 13K1 03 J
I5 M
06 M
I7 M
15 I5 K 05 J
I7 J
I8 J
(7-qpr-q16 16 GI 16 FI
17 (718 LI 18 KI
I-E-I 09 J
111 Gl 111 FI
K J H G F E D C B A
48
Pin number of IC chips
UAO 1
14
13
12
11
10
9
8
In case of 14 pins
L A 4 0
1 16
2 15
3 14
4 13
5 12
6 11
7 10
8 9
In case of 16 pins I---UA40
49
SETTING OF SERVO CONSTANT AND OTHERS
These settings are only for machine manufacturers because the settings are set to the optimum values before
shipment from the factory. The settings can be done by changing the connections of the IC sockets on the
printed cards mounted on the logic board in the controller.
(a) Setting of time constant
A servo time constant can be set by selecting required one system among the three systems of “A” on card
LC3 (A 81 B) and setting its detail value on card LC4 (A & B). The rapid feed system for each of the axes
can be selected on card LC4 as shown in Table 3.
Identical values for axes 1 to 4 (X, Z axes for M5100C) should be set for the cutting feed. The rapid feed
can be set for each of the axes within the same system. The setting procedure is shown in Table 1.
(b) Setting of encoder type (only M5100C). switching of tape store and power controller
These are for the switching encoders 1024P/rev. and 204B/rev., and switching of tape store and power
controller necessity. The procedures are shown in Table 1.
5 0
zardVame
LC3
LC4 4-3M(A,B) XIC3
krangemen4004A
2M
LC4(A,Bl
4-2MXIC3
IC location
seal)
2G
3-2GXlCl
rrrangemenl4003A
3M
Arrangemen4004A
Setting
1 16
!!
B
a
1 16
F
a 9
1 16
Switch bf tape store necessity
Necessary 3-14
Nil No connection
IM5100C only)
X-axis
Encorder
I 2048 No connection
IX-axis)(Z-axis)
-_
Z-axis
!Y-axis)L
I 1024I
4-13
>I Time constant setting I Ttme constant system setting I
1 -- 13 2 13 30ms 40ms 50ms
1 - 12 2 - 12 15ms 20ms 25ms
14.axIsI - - - T( ) indicates for M5000C - Not with M5000C (parameter setting)
l l The time constants of the cutting feed should be set to the same values for the X-and Z-axes
Table 1 Servo time constant setting list
(c) Setting of stop method at stroke end
This is for setting a stop method at the stroke end, either the linear decelerationstop or the step stop.
The setting procedure is shown in Table 2.
(d) Setting of command polarity switch
This is for setting the rotary direction of the motor when a command is given for CW or CCW. The setting
procedure is shown in Table 2. The polarity switch in the servo loop can be selected by the procedure in
Table 3. This setting is required when the polarity of a command is opposite to that of the feedback
signal in cases where the detector is mounted separately and the motor is connected directly.
52
axis1
I cStop method at stroke end
Direction of motor rotation(with (+I command whenviewed from load side)Card
nameC locatiorseal 1 Setting
L axis X
xis jT-.
! axis 2
Gis)
axis)
axis)--i
--l---- Second LC4ItI CardI lame
tI
I
C locationseal 1
5J
-t- .
Servo looppolarity
Z-axis X-axis
1-16~2-15~3-14~4-13 5-12~6-11~7-10~8-91-axis
Setting
Positivedirection OXXOOXXO
Negativedirection XOOXXOOX
4C5J4-9M
1 16
!a 9
Y-axis I
(4 axis) - - - JLC
4
(A,B)
LC4 c ‘0’ denotes connection
‘X’ denotes cut
Table 2 Setting list of stroke end and command polarity
-
0
-
-
m
-
P
%
nQa
Emc-4
-
z0
-
Er-
ii2
-
iR
gd
EF:
-
2I
N
i8
-
Em
hl
I
c-4
-_
c-4
m
I
N
P
Ic-4
I
N
P c-7
I
54
5.6 Logic card maintenance parts
The only consumable part on the logic cards is the relay on the LC21. However, providing logic cards
themselves as maintenance parts is an effective way of improving the machine tool operation rate.
Maintenance parts
Part name Standard Q’ ty used Remarks
Logic card LC1 (A,B,C)
___._-_
N LC 2 (A, B)
_ _ _ _ _ _ _
N L C 3 (A,B.CJ
_
1 for M5100CII L C 4 (A,B,C)
2 for M5000C
,, LC120 (A, B , C >
N L C 2 1 ( A , B)
I, L C 2 2 ( A , B) 1 Option
___-
N L C 2 3 ( A ‘ , 1 Optlon
- - -
Miniature relay 5 1 Used for LC21 relay I/F
The ‘A’, ‘B’ and ‘C’ after the card name are symbols which denote that the physical arrangement of the board
has been changed. Their performance is identical.
55
CHAPTER 6. FUNCTIONS AND HANDLING OF STANDARDBOARD (from BNP-A2007)
6.1 Standard board and its functions
Board for MELDAS-5100C (Board SC511
Setting and indication board,*
J
Board for MELDAS5000C (Board SC57)
POWERON
Functions
1. Control unit power ON/OFF
2. Control unit reset
3. Command indication (universal readout)
4. Manual data input setting/indication
5. Tool position offset, tool radius offset setting/indication
6. Parameter setting
7. Sequence number search
8. Present position indication
9. Alarm content indication
10. Input/output interface check
11. Tape load and tape punchout
12. Editing . . . . . . . . . . . . . additional specification
13. Erase . . . . . . . . . . . . . . . . . additional specification
For details on how to use the functions, refer to the Instruction Manual.
5 6
6.2 Replacing and handling the standard board
The SC 51 and SC 57 boards are connected to the interior of the NC unit with the 12-pole MR connector
and the 38-pole AMP MODU connector. They are mounted on the main control unit by eight setscrews.
6.3 Regular inspection of standard board
The power ON/OFF switch, reset button, a rotary switch for functions and the numeral and alphabet buttons
contain parts that wear. If regular inspections are therefore conducted, it is possible to check whether these
buttons and switches are defective by using the function switch to display the various modes.
6.4 Checking and setting the standard boards
The SC1 (or SCl-1) logic card is mounted on the SC 51 (or SC 57) board, and the rotary switch and buttons
are in turn mounted on this card. Furthermore, the two ROMs are plugged into the card by means of sockets,
and if there are any defective contacts in these ROMs, trouble will be caused in the character display section
at the left end of the board. Each of the character display and numeral display elements is plugged into
sockets, and so these elements may work loose or their contacts may become defective.
There are no special settings on the logic card inside the board.
6.5 Parts list of standard board
Name of part
Rotary switch
Push switch
Diode LED
Diode LED
Diode LED
Diode LED
Push switch
Push switch cap
Seesaw switch
Rating
GRS 2, 40. 1, 12, 6, 7
FPS 6720526 KBH-A
TIL 305 or DL-57
T L R 3 0 6
T L R 3 0 7
D-502
01-121
01 -901 (R)
LW-3128 (white) bezelAT-206 black attached
Remarks
Function
Numerals, alphabet, etc.
Character
Numeral
Code
Lamp indication
Reset button
Reset button cap
Power ON/OFF
5 7
CHAPTER 7. SETTING AND INDICATION BOARD FUNCTIONSAND HANDLING
7.1 PZ57 board (multidata display) functions and handling (from BNP-A2008)
7.1.1 PZ57 board and its functions
1 fN I23 G I7 G 02 ‘I
Key switches I_- Power switch
_ Mode selectorrotary swit?h
/- . .
Multidata display unit
[Functions]
1. MDI data setting/indication
2. Offset data setting/indication
3. Sequence number search
4. Tape editing and punch-out
5. Parameter setting/indication
6. Constant indication
7. Command position indication
6. Command indication
9. Buffer indication
10. Alarm indication
11. Input/output interface check
For details on how to use the display unit, refer to the multidata Instruction Manual (BNP-A20321
7.1.2 Replacing and handling the PZ57 board
The PZ57 board is connected to the inside of the NC unit by means of three 38-pole AMP MODU con-
nectors and a 12-pole MR connector, and an AC 1OOV power line is connected from the inside of the NC
unit.
The MR connector is connected to the connector to the DC power supply, and the three AMP MODU
connectors are connected to the receiving side of the LC 22 logic card.
58
Note) Handling the BECOJU connectors ( BECON : made by TELEDYNE KINETICS (TKC) 1
When connecting and disconnecting the BECON connectors when replacing the cards, etc., use
a small Phillips head screwdriver to loosen the three section alternately, or to tighten them up.
Do not force them. When attaching the BECON connectors to the card again, first wipe the card
connection tabs which come into contact with the BECON connectors with a clean cloth
(gauze, etc.) dipped in a little alcohol.
This board contains a high-voltage circuit with a maximum voltage of DC 300V. Therefore, when inspect-
ing or replacing the board, be absolutely sure to switch off the NC unit’s power first.
7.1.3 Regular inspection of PZ57 board
The power ON/OFF switch, the reset, key operation, puncher start, reader start and data send buttons,
the mode selector rotary switch and the keys (alphabet, numerals, etc.) as well as the indication lamps and
plasma display unit all contain parts that wear, and for this reason it is necessary to check whether there
are any defects in the keys, lamps and rotary switch.
It is also possible to clean the glass surface of the plasma display unit with a piece of gauze dipped in some
alcohol.
7.1.4 Checking the PZ57 board
The LZ 07 logic card is mounted on the PZ57 board, and the plasma display unit is incorporated onto the
top of the card by means of sockets.
Inside the board is a glass-sealed fuse for the high-voltage DC circuit and so when this fuse blows nothing
is displayed on the screen.
Most of the board signals are connected to the LC 22 logic card and so it is possible to check for defective
contacts in the three AMP MODU connectors and in the IC (character generator/keyboard encoder
element) inserted into the IC socket on the top of the LC 22 logic card.
There are no special settings for this board.
59
7.1.5 Parts list of Pi!57 board
Name of part Location Rating Remarks
.
Fuse Glass-sealed fuse 0.3 A
Seesaw switch s 1 LW-3128 (white) bezel AT-206 black
Push switchs 2
S’60 1 - 1 2 1 CODlX
Switch caps 2
S’6
I,0 1 - 9 0 1 Green/Orange/White/Red
Rotary switch RSWl MS-40PL40412A3015 Saga 30 degree endless
LampPL2
PL6O L - 3 2 7 Oshino
LampPL7
PC100 L - 5 5 2 8 5 0 Oshino
Lamp holder PLS2 F - G A / C L / G Oshino Green
Lamp holderPLS3
P&4F - G A / C L / R Oshino Red
PLS5.”
PtS6F - G A / C L / A Oshino Orange
Plasma type display R D M D 5 7 3 2 4 X Y G Okaya
A
6 0
~__-------_-- ----- ---,Q 10,
‘01: = = :_ = = = = = = = J_______ =_=_ = = _JQ II”
61
7.2 DP51 and DP52 board functions and handling (from BNP-A2009)
7.2.1 DP51 and DP52 boards and their functions
Command indication board DP51 [Y- 2 for M5100C (2 axes) 1
The DP52 board illustrated above is for only one axis out of two axes.
Command position indicator (internal)
This function indicates the tape and manual command movement amount for each axis (X, 2 for M5100C,
and X, Y, 2 and 4th axis for M5000C). It indicates the counted command pulses to the drive section.
This is a coded decimal 8-digit indicator, and the decimal point is positioned to mark off three digits from
the right with a millimeter system and four digits from the right with an inch system. The indicator is
mounted on the NC operation panel.
l Display lock function
The above command value display is locked with an external input signal (DLK) ON, and even if a
command is fed out, the same display will be held.
7.2.2 Replacing and handling the DP51 and DP52 boards
With two axes (or one axis) the DP51 board (or DP52) is constituted. The board is mounted with four
setscrews and connected inside the NC unit by a 12-pole MR connector. With two axes, the SC 02 logic
card is used for the board, and with one axes, the SC 02-l card is employed.
7.2.3 Checking and setting the DP51 and DP52 boards
Unlike a reversible digital counter, this command value indicator displays the command value stored
inside the memory for each and every time interval. The digital pulse and strobe signal for the indicator are
sent from the LC 21 logic card.
There is no need for daily inspections but it is important to inspect to see whether the elements of the
indicator are broken. In particular, the leftmost display digits are not used very often and it is often the
case that broken elements are discovered when these digits are used.
62
The indicator’s elements are mounted with IC sockets and a display defect is sometimes mistaken for a
loose contact.
DECIMAL POINT SELECTION OF COMMAND POSITION INDICATOR
Apart from general machine manufacturers it is not necessary to set the decimal point display of the
command position indicator to one of the digits. However, it can be set by connecting the center point
to the digit pins with a short pin in accordance with whether the system is millimeter or inch.
rrI I11
Point digit
Millimeter canter point
Inch cantor point
When the point digit and thecanter point are shortad, thatdigit point will light up.
z + 3 3 3 !I0 3, 3, 3. 3_---__-------- -f AI t I
1c-- -dd B0. -’__-------- ----- -4
I+_ ____ --------- ----- -- I !l
a I-I I
_-m-w- --------- _-----
~‘_=___--------------_______I
r-;--i\q
to 0;I 0 Ilo 01
Lo_ __.J
Command position indicator card
Commend position indicator card and its setting
7.2.4 Parts list of DP51 and DP52 boards
Light-emitting diode TLR307 (code) Toshiba
Light-emitting diode TLR306 (numeral) Toshiba
Push switch MSPE-106F
63
7.3 DP box 62A and 64A functions and their handling (from BNP-A2010)
7.3.1 Functions
These indicators are used when an indicator is to be installed on the exterior of the NC unit unlike the
DP51 command position indicator (or DP52) which is mounted on the front panel of the NC unit. (It is
installed when an indicator cannot be mounted because the standard board and machine operation board
are mounted.)
This function indicates the tape and manual command movement amount for each axis (X, 2 axes for
M5100C; X, Y, 2, 4th axis for M5000C). It indicates the counted command pulses to the drive section.
This is a coded decimal 8-digit indicator, and it is possible to select the position of the decimal point by
means of an internal setting.
The indicator is installed in a different location from that of the main NC unit.
* Display lock function
The above command value display is locked with an external input signal (DLK) ON, and even if a -
command is fed out, the same display will be held.
7.3.2 Replacing and handling
This indicator is composed of the DP61 (or DP62 used together) board, and a DC 5V powersupply(input
A C 1OOV).
The board is connected to the signal line with an MR connector and the power line (DC 5V) is connected
to the DC power supply. This means that even if there is something wrong with the indicator, repair
work can be performed quite easily by replacing the DP61 (or DP62) board, or the DC power supply
without having to replace the DP box 64A (or 62A).
A glass-sealed fuse (5A) is used for the AC 1OOV line inside the DP box, and so when this blows, nothing
is displayed on the indication section.
7.3.3 Checking and setting
When none of the indicator lights up, it is necessary to inspect whether the AC 1OOV power switch at the
rear of the DP box is set to the OFF position and also whether the glasssealed fuse has blown. Furthermore,
it is important to remove the DP box lid and check whether a DC 5V voltage is being made available by
using a tester. For other details, refer to the section dealing with the checking and setting of the DP51
and DP52 boards (7.2.3).
Decimal point position setting
The indicator card LZ 02A-1 (for one axis), the LZ 02A-2 (for two axes) and the LZ 048 (used for both
one and two axes) which drives the indicator are connected to the DP61A (or DP62A) board by BECDN
connectors.
The decimal point is positioned by changing over the setting pins of the card at the indicator side.
The position of the decimal point can be changed with the LZ 02A-1 or -2 setting pin at the rear of
the board.
Axis 1 Connect ? - 4 Decimal point : 1st digit from right
Connect $- - a Decimal point : 2nd digit from right
Connect ? - /\ Decimal point : 3rd digit from right
Axis 2 Connect b - Z Decimal point : 1st digit from right
Connect b - /* Decimal point : 2nd digit from right
Connect b - c\ Decimal point : 3rd digit from right
+, a, I\, 1 .I........ : the square form of the Japanese syllabary
7.3.4 Parts list
Glass-sealed fuse
DC power supply
Toggle switch
Push switch
Light-emitting diode
Light-emitting diode
5A
MC3D-05 Voltek 5A
ST205N52
MSPE-106F Fujisoku
TLR307 (code) Toshiba
TLR306 (numeral) Toshiba
7.4 DP box 628 and 64B functions and their handling (from BNP-A2011)
7.4.1 Functions
These indicators are used when an indicator is to be installed on the exterior of the NC unit unlike the
DP51 (or DP52) command position indicator which is mounted on the front panel of the NC unit. (It is
installed when an indicator cannot be mounted because the standard board and machine operation board
are mounted.)
This function indicates the tape and manual command movement amount for each axis (X, 2 axes for
M5100C; X, Y, 2, 4th axis for M5000C). It indicates the counted command pulses to the drive section.
This is a coded decimal 8-digit indicator, and the position of the decimal point marks off three digits from
the right with a millimeter system and four digits from the right with an inch system.
The indicator is installed in a different location from that of the main NC unit.
l Display lock function
The above command value display is locked with an external input signal (DLK) ON, and even if a com-
mand is fed out, the same display will be held.
7.4.2 Replacing and handling
This indicator is composed of the DP51 (or DP52) board and a DC 5V power supply (input AC 1OOV).
Both the signal line and power line are connected to the board by an MR connector, and this means that
even if there is something wrong with the indicator, repair work can be performed quite easily by replac-
ing the DP51 (or DP52) board, or the DC power supply without having to replace the DP box 626 (or 648).
A glass-sealed fuse (3AI is used for the AC 1OOV line inside the DP box, and so when this fuse blows,
nothing is displayed on the indication section.
7.4.3 Checking and setting
When none of the indicators lights up, it is necessary to inspect whether the AC IOOV power switch at the
rear of the DP box is set to the OFF position and also whether the glasssealed fuse has blown. Further-
more, it is important to remove the DP box lid and check whether a DC 5V voltage is being made available
by using a tester. For other details, refer to the section dealing with the checking and setting of the DP51
and DP52 boards (7.2.3).
7.4.4 Parts l ist
Voltek 3A
3 A
MC3C-05
ST205N22
MSPE-106F
TLR307 (code) Toshiba
TLR306 (numeral) Toshiba
Glass-sealed fuse
D.C. power supply
Toggle switch
Push switch
Light-emitting diode
Light-emitting diode
6 6
CHAPTER 8. FUNCTIONS AND HANDLING OF PTR-210 TAPE READER
8.1 Tape reader and its functions (from BNP-A2012)
This is the device to read in informations from a paper tape into NC unit.
As all information can not be read at once, it is formed of magnets for start and stop control, light source
in order to read informations from a paper tape and photo-cell to change an electrical signal.
9 PCS.
ITk-----WChannyl 1
I
L- -p-p< DCBV
Light soure
Start magnet
Stop magnet
AC1 OOV
Drive circuit
<
OE=+ <
MOTOR
Fig. 8.1 Configuration of tape reader PTR-210
6 7
Lamps .__.~ ,/,, OptiT
Brake armature
Photo-cell
Drive magnet
Fig. 8.2 Mechanical configuration of the tape reader
Impedance-
converter
= --G- TransistorE -B-0
p’
. 2- - 3
a 4> 5
___) 6
1 71 6- Sprocket output
Fig. 8.3 Signal reading section
68
8.2 Replacing and handling the tape reader
Card
&la clampReader connector
AC lOOV, DC 5V, 24VTape handler connector ground terminal boards.~
IT1 terminal) Fixed screws
Fig. 8.4 Rear of tape reader
Note) When the tape handler does not conform to the specifications, it will not be connected anyone to
the tape handler connectors.
Removing the PTR-210 tape reader
i)ii)
iii)
iv)
Detach the cable clamp.
Detach the externally connected wire connected to the Tl terminal.
Detach the P5 connector (See Note 1).
Remove the four tape reader fixed screws.
After following steps (i) to (iv), it is now possible to remove the PTR-210.
69
Note I) Removal of connector P5
Depress
i/ Lock button
With the lock button depressed,pull the connector firmly in thedirection of the arrow,
Fig. 8.5 Removal of tape reader connector P5
Note 2) There are no settings for the PTR-210 tape reader, and so it can be replaced as it is.
8.3 Regular maintenance and inspection of tape reader
(1) Lubrication
Since a shield type ball bearing and oilless material are used for the bearing section of the capstan motor,
no lubrication is required except for overhauling. If the tape lid becomes stiff, apply a little motor oil and
grease to the toggle spring.
Motor oil\‘1 Grease
spring
(2) Cleaning
Dust and dirt adhering to the reading face are liable to be a cause of misreading. Clean the tape path
occasionally with the supplied blower brush.
A swab dipped in isopropyl alcohol is useful for wiping off debris attached to the capstan, pinch roller,
and photo sensor with the oil of the tape when not blown away with the blower brush.
Furthermore, if the surface of the optical plate becomes dirty, the attenuation with respect to the light-will increase and this is the cause of erroneous read-out. Therefore, wipe the surface of the plate, and
especially the ends and curved sections with a swab dipped in a small amount of isopropyl alcohol._-
70
Optical plateCurved section
roller
\ Photo sensor
1
’ Clean the parts with thisswab dipped in a smallamount of isopropyl alcohol.
(3) Reading lamp section
Remove the lamp cover and slide the optical plate to the right and left, and back and forth with the screw
so that the light beam focused by the lens comes to the center of the photo cell and its width is 2 to 3 mm
on the cell.
Photo sensor\
Focused beam
‘!
Photo cell
(4) Lamp replacement
When the inside glass face of the lamp becomes black, replace the lamp even if it is not burnt out. The
average life of the lamp is 2,000 to 3,000 hours.
_--- --- Pair of tweezen orsimilar instrument
Pull out
71
(5) Belt replacement
Two belts of the same type are looped over the capstan and motor pulleys for securing the drive when one
of the belts stretches, wears or breaks. In cases like this, the defective belt should be replaced with a new
one. Two belts are necessary for ensuring the reliable operation of the drive. The average life of the belts
is 4,000 to 5,000 hours.
Capstan pulley
(6) Tape reader tape and sprocket channel adjustments
1) First slip the all marked tape in the tape reader over the ring (endless).
Next, detach the reader connector and attach the tape reader channel checker. Set the tape reader
operation switch to MANU. The tape should now start to run continuously. In this state, connect
the sprocket signal to channel 1 of a synchroscope and attain synchronization with the same signal.
Then observe the data output on channel 2 of the synchroscope, all the while comparing it with the
sprocket signal. If the waveform of the signal resembles that in the figure below, the signal is satisfac-
tory. If there is no resemblence, rotate the variable resistor at the rear of the tape reader and adjust.
Make sure the reading lamp section is checked beforehand.
Belt
--- Motor pulley
all marked tape
.
72
- 1 period (100%: about 5 ms)-
H
Sprocket
L
- 25 -45%-
H-
Data 1 to 8
L
More than 5%_ _ _ _ _
(center
value : 35%)
I I
- 50 - 8 0 %
(center value: 85%)
Data channel 8 Data chennel 4
Sprocket channel\ I I
Data channel 3
. . / , Data channel 2
Data channel 7Data channel 1
Data channel 5
Data channel 8
Tape reader channel checker
73
2) Adjust the tape reader data output by rotating the adjustment variable resistor, all the while observing
the waveforms on the synchroscope as in the above adjustment. The pulse width increases when the
variable resistor is rotated to the right, and the width decreases when the control is rotated to the left.
Adjust the variable resistors for each channel to produce the required waveforms.
VRl is for channel 1, VR2 for channel 2 . . . . . . . . . . VR8 is for channel 8. VRQ is for sprocket adjustments.
\Sproc
. Da
channrl
Note) The variable resistors are set before the NC unit is shipped from the factory and SO they should
not be adjusted unless absolutely necessary.
R31 Data channel 1
R32 Data channel 2
R33 Data channel 3
R34 Data channel 4
R35 Data channel 5
R36 Data channel 6
R37 Dara channel 7
R38 Data channel 8
R39 Sprocket channel
74
8.4 Tape reader check procedure
Tape reader trouble-shooting chart
Symptom Cause Remedy
1 Drive magnet is not excited 1: Failure in drive circuit Repalr.
even when RUN signal is
supplied2. Disconnection in drive magnet Replace magnet.
3. Defective tape guide lever Adjust tape guide lever or replace
switch micro switch.
4. Defective connector contacts
in any of above three circuitsRepair or replace.
2 No tape feed even when drive
magnet is excited 1. Gap between pinch roller and Adjust the position of the drive
capstan roller is too wide. magnet.
2. Tape seam has caught on brake Correct seam.
magnet or another part.
3 Defective tape feed
I, Gap between pinch roller and Adjust the position of the drive
capstan roller is too wide. magnet.
-
2. Worn capstan roller Replace capstan roller.
3. Failure in capstan motor Replace motor.
4 Brake magnet is not excited 1. Disconnection in brake magnet Replace magnet
even when stop signal is
supplied2. Disconnection in brake magnet Replace magnet
3. Defective tape guide lever Adjust tape guide lever or replace
switch micro switch.
4. Defective connector contacts in
any of above three circuitsRepair or replace.
5 Output width of all channels 1. Failure in photo cell Replace photo cell.
is below regulated values
with a holed tape 2. Failure in photo cell bias
circuitCheck circuit and repair.
3. Disconnection in lamp Replace lamp.
4. Defective connector contacts
in any of above two circuitsRepair or replace
..yIII~L”III bO”JC “r;,,,r;“)r
1
6 Output width of all channels / 1. Failure in photo cell / Replace photo cell
is above regulated values ~___ __----c_-_
with a hole-less tape /2. Failure in readout circuit Check circuit and repair.
._..__-_-.. .._--
7 One or more of the channels’ , 1. Failure in photo cell i Replace photo cell.
signals are supplied only k-- _ _ - . _--+_.____-----__
1 2. Defective punched tape holesi Replace with tape having corr
intermittentlyi
/ punched ho,es---- t----3. Dirty focusing lens / Clean lens.
8. Defective data seam
8 End of optical plate at lamp
side heats up and melts Defect in constant-voltage circuit Replace the transistors for thefor lamp power supply (normal voltage circuit or replace the Y\Ivoltage of lamp 1s DC 18V)
--
ectly
_
constant-
Ihole unit.
,
8.5 Parts list of tape reader
Lamp unit
Gum belt
Optical plate
Capstan roller
76
_-
CHAPTER 9. POWER SUPPLY FUNCTIONS AND HANDLINGThe MELDAS5000C/51OOC contains a main power supply (PD08 or PDO9) which serves to supply power to
each of the units.
9.1 PD08A power supply functions and handling (from BNP-A20131
9.1.1 Functions
Output terminal blodc
InputAClOO/llOV50/50Hz - Converter \
/
AClOO/llOVselector
1-
1Battery alarmoutput
I I
-7
50l60Hzselector
+24V coarse \/
+6V 30Aswitchingregulator
PM3A card+12V constant-voltage circuit
Power switch-onsequence auxiliarycircuit
+12v+24V
5 v
Fig. 9.1 Block diagram of circuit
77
1’ DJ 2I
Tl9
f-J
1
204-l-QF l
3 ‘p4
5
6
7
D8
9Gt 24v
RG
+ 12v
AC
- 1 2 v
LC
+ 5v
REBLL
AC 1OOVIN ’
AC 1M[
AC loo
E
E
DJ 2To paper.tape reader
To logiccard section
I Card PMBA
Charger circuit
Lwk2
6
7
8
9
1 0
11
1 2
Ok’
1p
2&_
1Relay drive
circuit
Fig. 9.2 PD08A power supply diagram
9.2 Functions and handling of PDOSA power supply (from BNP-A2014)
9.2.1 Functions
ON 0
G O
OFF 0
FuseH-
AC1 WV
N -
Ii i
5V 20ASW powerSuPPlY
I----
+ 12v 0.8A
l-
/--- +5v
IGND
+24V
GND
I---+ +12v
SW powerSuPPlY
I I
I0 GND
0 - 1 2 v
Fig. 9.5 Block diagram
79
9.2.1 .l Power switch-on sequence
When the NC power switch is set to ON/OFF by the relay drive circuit, a sequence is formed under
which a 5V ?12V, 24V DC voltage is made available. The output voltage detector circuit serves to
generate a power failure signal (when either the 5V +12V or 24V voltage is not made available), and
this sets the NC unit to the same state as when the NC power switch is set to OFF.
9.2.2 Replacement and handling
VAOJ0$5
Fig. 9.6 PDOSA power supply unit
9.2.2.1 Power supply unit removal
(i)(ii)
Detach all the lines which are connected to the TB23, T624 and TB25 terminal boards.
Remove the four power supply setscrews.
The DC power supply can now be removed.
9.2.2.2 Power supply unit replacement
The terminal board connection lines have the terminal board number and terminal number marked on
them. Take note of these numbers to connect the wires properly.
This power supply is not provided with frequency (50/60Hz) or lOOV/llOV selection functions.
80
9.2.3 Check procedure
Input/output voltage check
The input/output voltage check is performed at the TB23, TB24 and TB25 terminal boards.
AC input 1OOV TB24, across pins 7, 8
AC output IOOV T’B23, across pins 8, 9
TB25, across pins 8, 9
DC +24V TB25, across pins 1 (or 2) and 4 (or 5)
DC +5V TB23, across pins 1 (or 2) and 4 (or 5)/
10 and 12
DC +12V TB24, across pins 3, 4
DC -12V TB24, across pins 4, 5
Refer to the table below for the output performance.
Rated output voltage
Total voltagefluctuation
5 v 1 2 v - 1 2 v 24V
+ 2% +15%+ 2% + 2% - 1 0 %
Ripple voltageless lessthan than50mV 50mV
lessthan50mV
lessthan2.ov
The values in the above table are to be referred to as a general guideline.
In order to feed out the constant DC voltage, variable resistors are provided on the circuits for adjusting
the voltages. However, do not use these resistors for adjustment since the operation requires the use of
a number of measuring instruments.
9.2.4 Parts list
Glass-sealed fuse GMB125V 10A Asahi
o r MF51NR 10A Toyo Fuse
81
9.3 PMlOA charger functions and handling (from BNP-A20151
93.1 Functions
Terminals for battery leads
BT (+I BT (-1
MR connector(power supply)
MR connector(logic board)
Charger mounscrew ss Iction
Fig. 9.7
Output terminal blodc(MR connectorl
Battery charger circuit
Battery alarm outputcircuit
Input AC voltagedetector circuit
BT (+J BT (-)
Block diagram of circuit
Other circuits are also included for charging, when the NC unit power passes through, the battery which is
used to back up the tape editing memory.
82
0 Battery charger circuit
This circuit serves to convert the AC 13V input voltage into a DC 5.3V to 6.7V voltage and feed it out.
There is a selector switch to select between nickel-cadmium (NiCd) and lead (Pb) batteries in accordance
with the battery being used.
When the battery voltage decreases, the contents stored in the tape editing memory may be destroyed
and so a function is provided which generates battery alarm signals.
9.3.2 Replacement and handling
Disconnect the two MR connectors indicated in the photo under 9.3.1, remove the two screws which
anchor the charger, and the charger can then be removed.
Be careful of static on the printed circuit board and take care not to touch it since it uses CMOS ICs.
9.3.3 Check procedure
In order to check as if the battery voltage is over 5.45V (NR6F-4 NiCd, Japan Battery), check first that the
above battery is supplying the rated voltage by measuring the voltage at the BT(+) and BT(-) terminals il-
lustrated in the photo in 9.3.1. (Measure both when the NC unit power is on and off.)
To check whether the battery is charged, disconnect the same ET(+) (or BT(-) 1 terminal (by loosening the
screw), insert an ammeter (0 to 1 OOOmA) and check that a current ranging from 0 to 300mA is flowing.
9.3.4 Parts list
NiCd battery NR6F-4 Japan Battery 6AHr
Pb battery PE20-6A Japan Battery 20AHr
A pan head iron screw (3 x 0.5 x 8) is used for the terminal board at the charger side and so it is necessary
to mount an EJST 2-53 blue AMP terminal made by AMP which matches the screw after first pressuring
(clamping) it to the battery lead end.
9.3.5 List of ratings relating to charger
LC /20
uI tern NiCd battery (6AHr) Pb battery (20AHr) Remarks
Model NRGF PE20-6A1 Specifications
Manufacturer Japan Battery Japan Battery
0% 3.3v 5.1v2 Battery voltage
100% Min. 5.45V at 45’C 6.75 to 6.9V max
3 Usable tem- Operating -5e to +45C o’c to 45C
peratureStorage ,I ,,
Over 3 years 3 years
5
6
Precautions for use Set switch to NiCd
Storage precautions None
Set switch to Pb
Set switch to centerposition in order toprevent discharging,load locally and setto Pb side.
7 Storage precautions Store flat in a cold, Maintain charge atdark location. 6.2V every 2 months.
8 Charging current max Cl20 + 260 to300mA 0 to 1.2A mex
Charging time(from 0% to 100%) 24 hours 24 hours
T/ ~~Charge recovery rate
11 Charging/discharging ratio( a t 16kW)
12 1 Battery error detection voltage
90 to 95% (5.4A)
5 hours’ power with a1 hour charge (at 0%)
Less than 4.OV
100%
15 to 20 hours‘ powerwith a 1 hour charge
5.4 to 5.6V
Memory capacity16kW = 50mA
/ / / I
13 Overdischarge prevention voltage None 5.4 to 5.6V Recoverywith 6.1V
14 / Battery leak current (charging side) / Less than 4mA Less than 4mA I15 Discharge stopping voltage 3.3v fl.lV/CL) 5.25V (1.75OlCLI
16 Charging voltage Max 300mA with 6.9V 6.8 to 6.9V
40% in 6 months if17 Storage characteristics 45 days, 0% at 2O’C fully charged battery Period left
is left in 459:
18 Life cycle 500 times 500 times 50% capacitanceof initial period
.
84
9.4 Battery handling (from BNP-A2016)
The batteries which are used with the MELDAS can be broadly divided into two types. One is the small-sized
battery (4/450RS) which stores the system parameters, and the other is the large-sized battery (NR6F-4,
PE20-6A) which backs up the tape editing memory.
When replacing the small-sized battery, it is necessary to remove the LC2 logic card first, and when replacing
the large sized battery, it is necessary to remove the LC120 logic card.
The photos show the mounting positions of the batteries.
9.4.1 Replacement
Battery(4/450RSl
Fig. 9.8 Position of battery with large cabinet
Fig. 9.9 Battery 4/4501X
85
Battery(NR6F-4)
Fig. 9.10 Position of battery with large cabinet (rear of cabinet)
A
Fig. 9.11 Battery NR6F-4
Battery4/450RSNR6F4
Fig. 9.12 Position of battery with compact cabinet
9.4.2 Parts list
NiCd battery NR6F-4
NiCd battery 4/45QRS
Pb battery P E20-6A
87
CHAPTER IO. DRIVE AMPLIFIER FUNCTIONS AND HANDLING
10.1 Drive amplifier (3S10/20/406) functions and handling (from BNP-A20171
10.1 .l Functions
T”” \““I
3.phaser-----
Grounding plate047
Axis SCR AMP Relay unit
transformer Axis reactor :NF~ - - - - -- - - - --1 r---7~ II 1
Spindle motor+ detector gear boxr - - - - - - - - 1
r - - - - - --_l-? I-
i!I L______~-G i___; [y Logic board 5
I-_____-__
System diagram of drive amplifier (3810/20/408)
The drive amplifier serves to amplify the error voltage (command voltage) which is a comparison of the
operation result output and the position detector output, and to drive the DC motor mounted on the
machine tool.
The drive amplifier unit is composed of the control card (THABS-A/B) and SCR stack as well as the
no-fuse breaker (NFB), and thermal relay (for overload alarm applications).
10.1.2 Replacement and handling
The amplifier is connected externally with the APl and AP2 MR connectors and the cables protruding
from the thermal relay and no-fuse breaker.
The actual unit is mounted on the NC cabinet with four setscrews.
API
M R connector
control card to
4
AP2
Control CardTHA3S-A/B
LJ6 V6 W6
.
out when it isactivated)
- Thermal relay(This is actuated whenan abnormally highload is applied to themotor.)
’ No-fuse breaker
h
Exterior view of 3S-10/20/40A/B
8 8
Mounted on the control card of the unit is an IC plug for frequency selection. Therefore, when replacing
the unit, set the frequency to that of the plant’s power supply and set as shown in the figure below.
F50Hz”
T 60Hz
(a) For 50Hz (b) For 60Hz
Frequency setting
10.1.3 Regular inspection
There is no particular need for inspection except when the positioning accuracy is poor and it cannot be
compensated for even with backlash offset, and when there are other similar problems.
10.1.4 Checking and setting
The control card of the unit is provided with variable resistors and check terminals. The variable resistors
are adjusted before the unit is shipped from the plant or when it is installed. This means that adjustments
should be lefe to the NC serviceman or a properly trained maintenance engineer.
The positions of the variable resistors and check terminals, together with their functions, on the control
card are shown in the figure for reference.
When replacing the unit, it is important to check that the direction of the IC plug for frequency setting,
the setting of the brake across fi and 7 , and across _(- q , -f-j\ and 4-z are the same as before
the unit was replaced.
89
10.2 Drive amplifier (SA20/40A/B) functions and handling (from BNP-A2018)
10.2.1 Functions
Transformer”
E0”n
.!!
4
“1
,.-ve-ran+n, _ TG
I I’-i-v, BhlI--l !IL--------:
I !LMR
Iconnector which connects th
control card to the thyristor stadce
SCR amplifierSA?“A 8. SAl”A B
_.-I
System diagram of SASOAIB, SMO/A/B drive amplifier
The drive amplifier serves to amplify the error voltage (command voltage) which is a comparison of the
operation result output and the position detector output, and to drive the DC motor mounted on the
machine tool.
The drive amplifier unit is composed of the control card (TH30A) and SCR stack, as well as the no-fuse
breaker, thermal relay (for overload alarm applications) and brake resistor.
9 1
10.2.2 Replacement and handling
The drive amplifier is externally connected with the ZPl and ZP3 MR connectors and the TB121 terminal
board. The actual unit is mounted on the NC cabinet with four setscrews.
Control cardt THJOA
\MR connector which ‘\connects the controlcard to the thyristorstack
‘\\\
Brake resistor
Reset leverThis lever flies outwhen it is reset.
\
dial scale
Thermal relayThis is actuated when anabnormally high load isapplied to the motor.
’ Thyristor stack
1 No-fuse breaker
(~~1311
\\ Relay
Terminal blocks(TM21 1
Exterior view of SA20/40/A/B
Mounted on the control card of the unit are two switches for frequency selection. Therefore, when
replacing the unit, set the frequency to that of the plant’s power supply.
.
10.2.3 Regular inspection
There is no particular need for inspection except when the positioning accuracy is poor and it cannot be
compensated for even with backlash offset, and when there are other similar problems.
92
10.2.4 Checking and setting
The control card of the unit is provided with variable resistors and check terminals. The variable resistors
are adjusted before the unit is shipped from the plant or when it is installed. This means that adjustments
should be left to the NC serviceman or a properly trained maintenance engineer.
The positions of the variable resistors and check terminals, together with their functions, on the control
card are shown in the figure for reference.
When replacing the unit, it is important to check that the direction of the frequency setting switches (21,
the setting of the speed feedback resistance selectors ( b , ;f, ‘I, Jb and 4 ), the setting of 9, ‘Y. b, 3,
z , and t , as well as the setting of 4, a, ~1, *, 3, a, 7 and h are the same as before the unit was
replaced.
Speed faadback resistance selectorF
CurrantManual spmd input Position loop gain
C u r r a n t l i m i t servo Offset lC21 output
faadback gain adjust P o s i t i o n loop/ Tzdback
s?sZ%:p
S p e d IC21 zero
\ \,command/
adjust
\ \ \ \ / I/ / /
uancy Servo offset
CPl, Ll+,CPlZiU
Firing angle CP 13 j v+ ;CPlliV ’cp15,w+ 1CP16IW 1
ut comparison adjustIC51 zero adjust
IC41 input comparison adjust
Exterior view of TH30A control card
Setting
The frequency must be set to the power line of the plant, as mentioned under (21, on the control card.
93
10.2.5 Parts list
Circuit breaker (No Fuse breaker)
Thermal relay
Thyristor stack
Relay MC1
RL3
RL4
A
94
CHAPTER 11. SPINDLE CONTROL DRIVE AMPLIFIERFUNCTIONS AND HANDLING
11.1 Spindle control drive amplifier (S3S50/60A/B) functions and handling
(from BNP-A2019)
11.1.1 Functions
Main no-tuoo brukorTB2 NFBl I 1 Rrctor
Domactic 2OOV,,22OV 50& 6CHz
}3-phau
To TB13,ground
terminal blodc 2OOV. 22OV: 24OV, 38OV, 4OOV’42OV 4 4 0 V . 46OV 48OV, SlOV, sSOV, ‘55uV
To NFB 101
System diagram of spindle control drive amplifier
The spindle control drive amplifier serves to amplify the output which has been converted into analog
voltage from the S command by the D-A converter and to drive the spindle DC motor mounted on the
machine tool.
The spindle control drive amplifier unit is composed of the two control cards, SCR stack (sometimes
including that for field systems), the no-fuse breaker and the thermal relay.
11 .1.2 Replacement and handling
The drive amplifier itself weighs more than 20 kg and it may take more than one person to replace it. As
mentioned above, the unit is composed of two control cards and two thyristor stacks and so it may be
possible to deal with defects by replacing the control cards or the stacks.
95
I No fur breakorNFRlOl
Grol
30
200v
1TF2
80
Bl
A0 t
I
I
01
Main motor SDN-BA
E
Ii Intrrpolo-I
Thrmostat*6----lCP 1
96
Spindle control drive amplifier S3S6OA/B
TB13
1
Ground
AJ 2
7,s
Y If990zoov b
11 ,l20
Main currentAP 2 detection
rwistor
Spindle motor
DC12 IB0
D
$cklp
UC11 A0
THA3S-BSO
Card
THAS3S BO
Mounted on both the (1) and (2) control cards of the unit are the IC plugs for frequency selection.
Therefore, when replacing the unit (or control card), set the frequency to that of the plant’s power supply.
11 .1.3 Regular inspection
There is no particular need for inspection except when the frequency shifts or there is rotational drift.
11.1.4 Checking and setting
The control cards (1) and (2) of the unit are provided with variable resistors and check terminals. The
variable resistors are adjusted before the unit is shipped from the plant, or when it is installed. This
means that adjustments should be left to the NC serviceman or a properly trained maintenance engineer.
97
111 I U6 V6 W6
MRP3
LJ
Control card (2)
Control card (11
THA3S-ES0
AF’104 AJ104
a
0OFF
--Ill0 NFBlOl
Exterior view of spindle control drive amplifier S3S50A
99
This switch should be always P side
Synchronous signal
Current limit 2
Frequencyselector IC plug
Ground terminal
mt )(u-)(V,)(V-)(W-)(W-)RV RV RV RV RV RVaz&S&
u- v- v- _ -
$@pj@@Cp22 C P 2 3 C P 2 4 C P 2 5 Cp26@ Q Q Q Q--
Current feedback
IC 1 output
(TG feedback)The measurement of TGfeedback : Use CPll on thecontrol card (2)
Speed command
Current limit 1
IC 1 zero adjust
IC 11 zero adjust
IC 11 outputServo compensation
Firing angle adjust
Firing angle
Spindle control drive amplifier card (1) ~~~$:$~0 exterior view
CPl
CP2
CP3
CP4
CP5
CP6
CPll
CP21
CP22
CP23
CP24
CP25
S analog autoinput
S analog clatchchange output
ICl output
IC2 output
IC3 output
IC6 output
TG feedback
IC21 output
IC22 output
IC23 output
Rated fieldcur! ent
IC24 output
CP26
CP27
CP31
CP32
CP33
CP41
CP42
CP43
RVl
R V 2
R V 3
R V 4
Field currentfeedbackWeak field startpoint (onlyTHAS3S6)Synchronoussignal U
Synchronoussignal VSynchronoussignal W
Firing angle U
Firing angle V
Firing angle W
Spindle override{option)
Inching speed
L clutch speed
M clutch speed
R V 5
R V 6
RV7
RV8
RV9
RVlO
RVll
RV21
R V 2 2
R V 2 3
RV31
R V 3 2
-. Frequency selection IC plug
H clutch speed
Manual input setting
ICl zero adjust
IC2 zero adjust
Zero adjustmentof CP6Acceleration/decelerationtiming setting
Not used
Meter correction
Zero speed
Zero speessetting
Armaturefeedback
IC21 zeroadjustment
IC21 zeroadjustment
Weak fieldstart point
Field controlcompensation
R V 3 3
R V 3 4
R V 3 5
R V 3 6
R V 3 7
RV38
R V 3 9
R V 4 0
RV51
R V 5 2
R V 5 3
IC23 zeroadjustmentMinimum fieldcurrent
Rated fieldcurrent
Field currentloop compensation
IC24 zeroadjustment
Firing angle U
Firing angle V
Firing angle W
Spindle control drive amplifier card (2) ~~~~~~:~~~ exterior view
101
The positions of the variable resistors and check terminals, together with their functions, on the control
cards (1) and (2) are shown in the figure for reference.
As mentioned in 11 .1.2, it is necessary to set the frequency in accordance with the power line of the plant
on control cards (1) and (2).
11.1.5 Parts list
No-fuse breaker
Thermal relay
Thyristor stack (main circuit)
Thyristor stack (field circuit)
Relays MCI
MC2
RLYl
RLY2
RLY16
102
11.2 Spindle control drive amplifier (SSGOA/B/C-MA/NO) functions and handling
(from BNP-A20201
11.2.1 Functions
- from
Main no fuse breakerYKHI I 3.phase main transformer
Reactor
Primary tap selectorterminal block’ i
toTHI I
t oTRI:iEarthtoTRI I
,,;I L!+“J .--~~II Main current detector
resistor_. .~_ ~-
rator
CardI !
CardTHA3S-BS THAS3S-BB I I
I I
Fig. 11.1 Block diagram of spindle control drive amplifier (I)
103
from
from TB2
No fuse breaker
Main thyristor sta
Earth J
/Thvrictnr stack far field
TBI36
05. .&A I I I /\
R3 f%ld current detector resistoi /06--.. MC2 u Thermal relay for fan motor07. & CrJ^
v A “OCR2 ) I08 ,I n h
M‘? w I 1 I09 I ! s?c
CardTHA3S-BSO
I I_CardTHASBS
- B B M
)I Spindle motor
I
Fig. 11.2 Block diagrati of spindle control drive amplifier (2)
Tachogeneratol
104
The spindle control drive amplifier serves to amplify the output which has been converted into analog
voltage from the S command by the D-A converter and to drive the spindle DC motor mounted on the
machine tool.
The spindle control drive amplifier unit is composed of the two control cards, SCR stack (sometimes
including that for field systems), the no-fuse breaker and the thermal relay.
11.2.2 Replacement and handling
arrangement I
Control card (2)THAS3S-00MlBB
Control card (I)THA3S-BSIBSO
TBlOl SHT 1
TH 1 :i
,’ OCR1
I lll1llllll
TBII’
//
TBll terminal arrangementI
Reset lever(This lever flies out when it is reset.)
Thermal relay(This is actuated when an abnormally high load is applied to the motor)
SSGOA/B/C-MA/NO spindle control drive amplifier
The drive amplifier itself weighs more than 20 kg and it may take more than one person to replace it. As
mentioned above, the unit is composed of two control cards and two thyristor stacks and so it may be
possible to deal with defects by replacing the control cards or the stacks.
105
11.2.3 Regular inspection
There is no particular need for inspection except when the rotation is not settled or rotations commanded
can not be got.
11.2.4 Checking and setting
The control cards (1) and (2) of the unit are provided with variable resistors and check terminals. The
variable resistors are adjusted before the unit is shipped from the plant, or when it is installed. This means
that adjustments should be left to the NC serviceman or a properly trained maintenance engineer.
Keep this switch at [PI __-- Armature current feedback
S p e e d s e t t i n g - - - -ICl output
\‘\ I / lr- (TG feedback)
I / Measure the TG feedback atCPll of the control card (2)
Synchronous signal
Current limit 2
Frequency
selection IC plug
Ground terminal
(Lb)
E
8
(1' ) (V 1, ,'(V-1 (W-J w 1
3
)--
_-_
- - S p e e d c o m m a n d
~ Current limit 1
- ICl zero adjust
- ICll zero adjust
~ ICll output
__ Servo offset
~ Firing angle adjust
~ Firing angle
THASS-BSExterior view of THA3S_BS0 ps indle control drive amplifier control card
106
CPI
CP2
CP3
CP4
CP5
CP6
CPll
CP21
CP22
CP23
CP24
CP25
F. SF:I,F:(:T
S analog autoinput
S analog clatchchange output
ICl output
IC2 output
IC3 output
IC6 output
TG feedback
lC21 output
IC22 output
IC23 output
Rated fieldcurrent
IC24 output
CP26 Freld currentfeedbackWeak field start
CP27 point (onlyTHAS3.S6)
CP31 Synchronoussignal lJ
CP32Synchronoussignal V
CP33Synchronoussignal W
CP41 Frring angle U
CP42 Firing angle V
CP43 Firing angle W
RVI osp;yz;)override
R V 2 Inching speed
R V 3 L clutch speed
R V 4 M clutch speed
R V 5 H clutch speed
R V 6 Manual input setting
R V 7 ICl zero adjust
R V 8 IC2 zero adjust
RV9 Zero adjustmentof CP6Acceleration/
RVI 0 d,ecelerationtrmrng settrng
RVll Not used
RV21 Meter correction
RV22 Zero speed
R V 2 3 Zero speessetting
RV31 Armaturefeedback
R V 3 2 IC21 zeroadjustment
Frequency selection IC plug
R V 3 3IC21 zeroadjustment
R V 3 4 Weak fieldstart point
R V 3 5Field controlcompensation
R V 3 6 IC23 zeroadjustment
R V 3 7Minimum fieldcurrent
R V 3 8Rated fieldcurrent
R V 3 9Field currentloop compensation
R V 4 0IC24 zeroadjustment
RV51 Firing angle U
R V 5 2 Firing angle V
R V 5 3 Firing angle W
THAS3S-BBFig. 11.5 Exterior view of THAS3S_BB&, spindle control drive amplifier control card (2)
1 0 7
The positions of the variable resistors and check terminals, together with their functions, on the control
cards (1) and (2) are shown in the figure for reference.
Setting
As mentioned in 11.2.2, it is necessary to set the frequency in accordance with the power line of the plant
on control cards (1) and (2).
11.2.5 Parts list
Circuit breaker (No-fuse breaker)
Thermal relay
Thyristor stack (main circuit)
Thyristor stack (field circuit)
Relays MC1
MC2
RLYl
RLY2
RLY16
108
12.2 HD motor
12.2.1 Regular inspection of HD motor
(1)
(2)
(3)
Inspection of brush
Inspect the brush about every 500 hours for wear and abnormality of the commutator. Blow off brush
powder with compressed air of about 5 kg/cm2.
Replacement of brush
The length of the brush is about 18 mm and it can be used until it wears down to about 3 mm in length
(more than 3000 hours).
Remove the brush retainer with a slot screwdriver and replace the brush with a new one.
Fig. 12.2 Brush replacement of HD motor
Treatment after brush replacement
Idle the motor for five or six hours after the brush replacement for fitting the brush and the commu-
tators.
12.2.2 List of commutator brushes for HD motor
Table 12.2 Brush dimensions
0.75kW
Size (mm) Material Maker
1.5kW
2.2kW
4.7 X 16 X 16 EG319 Fuji Carbon Co.,Ltd.
110
12.3 Low inertia motor
12.3.1 Regular inspection of low inertia motor
(1)
(2)
(3)
Inspection of brush
Inspect the brush about every 500 hours for wear and abnormality of the commutator. Blow off
brush powder with compressed air of about 5 kg/cm2.
Replacement of brush
When the length of the brush becomes 13 mm, replace with a new one. To replace, open the inspection
window of the motor, pull up the brush retainer spring and then replace with a new brush. There is no
need for adjustment since the contact pressure of the brush does not fluctuate much.
Treatment after brush replacement
After having replaced the brush, check the fit between the sliding surface of the brush and the com-
mutator surface. Refer to 8.2.1.1 item (3) and improve the fit.
12.3.2 List of commutator brushes for low inertia motor
Table 12.3 Brush dimensions
I Type Size (mm) Material
UGMMEM-5OAAl 6 X 20 X 25MG9RB-0
UGMMEM-1AAAl 10X20X25
-
111
CHAPTER 13. DETECTOR GEARBOX FUNCTIONS ANDHANDLING (from BNP-A2022)
13.1 Functions
The detector gearbox is mounted at the opposite side to that of the motor load (it is sometimes directly
mounted on the ball screw in accordance with the machine tool), and so in order to detect the rotation
angle of the motor (or ball screw), it is connected to the shaft of the resolver (detector) via a constant gear
ratio. This mechanical rotation angle is converted into an electrical angle by the resolver and it then enters
the NC unit. In order to enhance the positioning precision, a tacho-generator is mounted via a 1:l gear.
The signals from the tacho-generator are sent to the drive amplifier inside the NC unit.
Gear ratio 1:l
The gear ratio differs according tothe detector gearbox.
Fig. 13.1 Configuration of detector gearbox
Stator exciting coilStator output winding
II
Matching transformer
Machine axis -.
Rotor transformu
Fig. 13.2 Resolver phase composite circuit
Motor
L Gearbox
Fig. 13.3 Detector gearbox
Resolver
I Cover support arm
C.
Fig. 13.4 Inside of detector gearbox
Cover removalSCTOWS
113
13.2 Replacement and handling
Replace the detector gearbox as follows:
(1) Loosen the screws that anchor the detector gearbox.
(2) Loosen the setscrews of the bellows coupling, and remove.
The mounting screws and setscrews are coated with a special paint, and so they cannot be removed
unless this paint is dissolved in thinner, etc.
Note 1) When the detector gearbox has been replaced, it is necessary to perform zero point adjust-
ment.
Note 2) Handling precautions
(1) Do not subject the gearbox to sudden shock.
(2) Do not allow cutting oil or other oils to come into the gearbox.
(3) Use in an ambient temperature range of O’C to 45’C.
(4) The gearbox is capable of withstanding vibrations up to 3G.
13.3 Regular inspection
It is possible to inspect the gear wear visually by removing the detector gearbox cover and the gear cover
(Fig. 13.4). There is no need to inspect the resolver since it is brushless.
The tacho-generator is a DC type and so it contains parts which wear. (Refer to ‘cleaning the tacho-generator’.)
The detector gearbox is protected when it is temporarily covered with oil. However, if it is covered with oil
for prolonged periods of time or if it is surrounded by oil, this oil will seep inside and damage the resolver
and tacho-generator. Therefore, open the detector gearbox cover regularly and check that oil has not seeped
inside.
Cleaning the tacho-generator (TG)
If the ripple voltage of the TG exceeds the prescribed value, this will cause feed fluctuations and other
problems while the NC unit is operating.
In cases like this, the rule is to replace the TG and as far as possible not to disassemble and clean the TG.
However, if there are no parts at hand and action must be taken quickly, the TG may be disassembled and
cleaned as a makeshift measure.
(1) Cleaning the TG
1)
2)
3)
4)
5)
When the screw of the TG top terminal is removed with a Phillips head screwdriver and radio
plier, the brush with spring will jump out.
Loosen the setscrew on the TG top cover and remove the cover.
(When replacing the cover after its removal, the output voltage will fluctuate if it is not returned to
its original position. Therefore, when disassembling, make marks between the cover and main unit.)
Wipe the commutator lightly with gauze dipped in alcohol.
Wipe the sliding surface of the brush with gauze dipped in alcohol.
Attach the cover, insert the brush from the terminal opening and anchor with the screw.
(Re-assembly)
114
, Bearing
Tachogenerator main unit
Fig. 13.6 Tacho-generator
* The ripple voltage is prescribed as follows:
Less than 5% for 10 to 200 rpm
Less than 3% for 200 to 3000 rpm
(actual values)
13.4 Parts list
Tacho-generator
115
CHAPTER 14. MANUAL HANDLE (HD51) FUNCTIONS ANDHANDLING (from BNP-A2023)
14.1 Functions
(1) General
This manual handle is rotated by hand, and two types of pulse signals proportionate to the rotation angle
are generated.
(2) Electrical specifications
1) Input/output terminals
.Terminal block no. Signal
1 Phase A signal output
‘
2 Phase B signal output
3 +12v
4 - 1 2 v
5 Ground
2) Power supplies
The required voltages are as follows
+ l2V
- 1 2 v
3) Signal output
Phase A and phase B output signals are fed out, and the following outputs are available with respect to
the rotation angle of the handle.
Output waveform and phase relationship (when handle is rotated in the (+) direction)
Phase A output
-J
jlPhase B output
V H : 5v + 10%
a : P/2 +_ 30%
b: Pl4f.40%
116
4) Maximum output frequency
Over 100Hz
THE ENCODER FOR MANUAL HANDLE
Exterior view
h
Front view Rear view
14.2 Replacement and handling
When a DC 12V or -12V voltage is applied to GND, signals are automatically made available from phase A
and phase B. This means that if the signals are not made available, the manual handle needs replacing.
After replacement, it is necessary to connect the DC 12V and -12V voltage wires properly. If the wires
are not properly connected, damage may occur.
118
6) Adjacent pitch error
of signal Less than l/3 of signal period
7) Phase between each
channel Refer to waveform figure
8) Usable temperature range 0°C to 50°C
9) Output terminals CANNON connector
Receptacle MS31 02A20-29P
Plug MS31 06A20-29s
Cable clamp MS3157-12A
Pin arrangement
Pin no.
A
0
C
D
E
F
/Signal I Pin no. Signal
Ch 1 A( K i
OV (for amp)
Ch 2 A L +12V (for amp)
Ch 1 B M OV (for amp)
N
ICase ground P /
IR
/
G
H +5V (for amp)
S!
T ,
J -12V (for amp)
(Note) OV is common
Mechanical performance
1) Dimensions See 15.2 (2)
2) Input axis inertia 2.3 x 10e3 kg/cm sec2
3) Input axis torque Less than 1000 gem
4) Allowable angle acceleration
1 O5 rad/sec2
5) Allowable speed 3000 rpm
6) Bearings Oil-less for over 100,000 hours
7) Allowable input axis load
Thrust load Less than 4009
Radial load Less than 1 kg
8) Weight Approx. 3.1 kg
120
15.2 Replacement and handling
To replace, first switch off the power to the NC unit and detach the CANNON connectors.
(1) Coupling
Make sure the coupling between the rotary encoder input axis and the external force (rotation axis of
lathe, for instance) matches the following specifications:
Outer diameter of input axis 15 g6
Input axis key groove width 5 +oo.O’*
Seat for mounting positioning 80 g6 (refer to figure of dimensions)
Take special care not to apply shock or an excessive load to the input axis.
h
121
ROTARY ENCODER
122
(2) Exterior dimensions
Kay war dimensions
-0.0 10R6-0.029
-
i-N
i00
1 IF
CANNON plug
1I
MS31 02A20-29P / 136’“lI I
T
123
15.3
(1)
Regular inspection
Trigger level adjustment
The photoelectron output signals are connected to the printed circuit which is contained in the encoder,
and they are converted into square wave signals.
The square wave signals are adjusted to a I:1 duty with a lamp voltage of 12V and so there is no need
for re-adjustment. Proceed as follows if the 1: 1 duty has undergone any change.
Ch 2 Phase A
Ch 1 Phase B
1) Remove the rear cover
2) After checking that the lamp voltage is 12V, monitor the signals on a synchroscope, rotate the signals’
variable resistor and adjust.
_.
(2) Lamp replacement
The service life of the light source lamp is quite long.
Nevertheless, if there is a disconnection inside the lamp due to an abnormal voltage or vibration, replace
it with a new lamp according to the following procedure.
124
h
1) Remove the rear cover first, and then detach the lamp from the light source mounting fixture.
2) Remove the lamp from the small connector, join the new lamp and the small connector together and
mount on the light source mounting fixture.
Note) A spare lamp is contained inside the main unit.
Remove the screw for use.
3) Check that the lamp lights up with a 12V voltage rating and check the output signal.
If it is necessary to adjust the duty, proceed as outlined under the trigger level adjustment in item 5.
15.4 Parts list
Lamp For R F2048M-22-1 rotary encoder
125
CHAPTER 16. TAPE HANDLER (TH-400) FUNCTIONS ANDHANDLING (from BNP-A2025)
16.1 Functions
This tape handler is equipped with a standard panel and it is designed for the extension, wind-up and rewind
of the paper tape of the tape reader.
Configuration
The tape handler is broadly composed of the following:
(1) Drive section
(2) Circuit section
(3) Tension arm
(4) Panel
(5) Reels
Refer to Fig. 16.1
126
FrameI
S P O O L E R S witch
I1 SPOOLERS
4 - 6.5 Table center\
I ‘.x I
----_--Iy)
I\
Rewind reel 1 \ REWIND s w i t c h ’\ \ SUPPlY redI I
2213
1-__- __
T’ 183
,’
/_ ,;”L- __._~_______.__~~ _ --.-+ 2
Fig. 16.1 Tape handler T H - 4 0 0
16.2 Replacement and handling
The TH-400 tape handler is connected to the PTR-210 with a 12.pin connector. It can therefore be removed
by removing this connector and also the setscrews which support the tape handler.
Signals of 12-pin connector
Connector 1pin no. Destination ! Connector
pin n o . Destination
1 A C 1OV._. . /
2 o v I
3 DC 27V_--__-_----_t-------_-~~_--_._+~ ~_~.~_ ..--.-.
12-pin connector Glass-sealed fuse
Fig. 16.2 Rear of tape handler
128
16.3 Regular inspection
About once every six months apply a little #BO spindle oil td the six frame guide rollers and four tension arm
guide rollers.
The application of lubricants and grease is performed during overhaul.
16.4 Checkpoints
’ Diagnosis of TH-400 trouble spots
Trouble Cause Remedy
1 Motor does not rotate even 1. Tape is not set. Set the tape.
when SPOOLERS switch 2. Blown fuse Replace fuse.is set to ON.
3. Defective SPOOLERS switch Replace switch.
4. Defective contact in junction Reconnect connector or replace.
connector
5. Defective RS, LS micro-switch Replace micro switches.
cll....~~~~~~~ches. -~
Re-adjust based on adjustment
value.
3. Defective thyristor Replace thyristor.
3 No tape rewind 1. Defective MANU REWIND Replace switch.
switch
2. Defective thyristor Replace thyristor.
3. Defective C relay Replace relay.
4 Reel is late in stopping 1. Defective motor brake Re-adjust based on adjustment
(hunting) value.
2. Defective tension arm spring Replace spring.
5 Too short time taken from 1. Defective A relay Replace relay.
REWIND, STOP operations 2. Defective capacitor C5 Replace capacitor.to START operation
16.5 Parts list
129
CHAPTER 17. SERVO ADJUSTMENT METHOD(from BNP-A2026)
17.1 General outline of NC servo
First, a general description of NC servo mechanisms is given from the NC beginner’s text book which is used
at the MELDAS training school.
17.1.1 NC servo
A servo mechanism for an NC unit can be defined in terms of automatic control whereby the moving
position of the machine tool’s moving table, the rotary angle of the rotating table and other mechanical
positions are made the objects of control.
Automatic control is defined by the Japan Machine Society as “the automatic revision operation which
must be performed to detect quantity C of an object, process or machine and to control in accordance
with the comparison value (r - x) with the target value r so as to match quantity C with the target value
r applied from an external source.” Furthermore, the object that “performs the automatic control of the
mechanical position or angle” is the “servo mechanism”. The automatic control system is given in the
block diagram (Fig. 17.1) below. The target value is the command from the NC,tape, the adjustment
section is composed of the DC amplifier and drive amplifier, the operation section is the drive motor, the
control object is the moving section of the machine tool, and the detection section is the position detector.
Together, they may be called the servo mechanism of the NC unit. (Refer to Fig. 17.2)
I ’ ’ C‘_ Operation _ Control _ z
section objectoutput
Detection_section
Fig. 17.1 Block diagram of automatic control system
In Fig. 17.2, the command value Ei of the table position from the command tape (e.g. X axis 10 mm move-
ment) and the feedback Ef from the resolver which detects the actual table movement are compared, the
error 6 (Ei - Ef) is amplified by the DC amplifier and drive amplifier and it is then applied to the drive
motor (DC motor). The motor then lets the ball screw via the gearbox rotate, and when the table is moved,
the resolver at the end of the ball screw turns at the same time.
As the table advances 6 mm with a single rotation of the ball screw, the phase of the resolver output
voltage varies 360”. This means that when the phase variation is taken out as a reverse polarity, or
negative feedback, as feedback Ef compared with the polarity of the command value, the DC motor
rotates. When Ef is varied and & becomes zero, the voltage which is applied to the drive motor becomes
zero and the DC motor stops.
130
Command signal DC amplifier
X axis 10lmmError signal
Resolver detect
motor
Fig. 17.2 Model of servo mechanism
17.1.2 Types of NC servo systems
(1) Closed loop and open loop systems
The usual kind of servo mechanism is based on closed loop principles. The output signals are detected
by the detector, they are compared with the input command as a feedback command, and the resulting
operation is performed. By balancing these two factors, this system is provided with a self-regulating
function.
There are three types of closed loop servos, one fully closed type and two semi-closed types.
a. Closed loop servo
Fig, 17.3 shows a fully closed loop system. The final position of the moving table is detected by
the direct-driven detector (e.g. linear inductosyn, magnescale or optical scale), and feedback control
is performed to match this quantity with the target value, Under this system, the motor is actuated,
the machine is moved while there is an error between the command value and the movement but
when these two values coincide, the machine is automatically stopped. This means that the system is
characterized by highly accurate control. However, contained in the control loop are non-linear con-
stants peculiar to the machine such as backlash, friction resistance, machine rigidity and machine
resonance. If these constants are not within the prescribed values, adjustment of the servo system
is performed only with difficulty, with the result that the precision does not meet the prescribed
value and hunting occurs. When adopting this system, therefore, it is necessary to identify the
machine constants that perform the control and to give sufficient consideration to matching these
with the drive system. The system illustrated in Fig. 17.3 is often known simply as the closed loop
system.
Dirrctdrivrn detector (inductown)
yziq~otoJlhcing tab’eBell screw
I I
Fig. 17.3 Cloyed loop system (fully closed loop system)
131
b. Semi-closed loop servo . . . . . . . . . . 1
Fig. 17.4 shows a type of semi-closed loop system which uses a rotary detector such as a synchro
resolver rotary encoder. This is installed in a position opposite to the side where the feed motor is
located. The rotary deviation in the feed screw is detected and feedback control performed.
Under this system, the feed screw pitch error, backlash and other mechanical errors are produced
outside the loop system and so these directly affect the control precision. At the same time, the
machine rigidity based on the inertia of the moving section, the ball screw rigidity and other factors
are produced outside the loop system, and so stability can be maintained more easily than with
the closed loop system illustrated in Fig. 17.3.
Moving table
C.
Fig. 17.4 Semi-closed loop system
Semi-closed loop servo . . . . . . . . . . 2
Fig. 17.5 gives another type of semi-closed loop system.
Under this control system, the rotary detector is installed at the mounting position of the motor (at
the opposite side to that of the motor load), the feed screw rotary deviation is detected and feedback
control performed. Compared with the system in Fig. 17.4, the backlash in the gear mechanism and
the ball screw torsion are produced outside the loop system, and so while the control precision
deteriorates, it is easy to maintain the stability of the servo system. This system is sometimes known
as the quasi-closed loop system although it is usually referred to as the semi-closed loop system.
Moving table
Rotating detector (resolver)
Fig. 17.5 Semi-closed loop system
132
(2) Analog and digital servosC
d. Open loop servo
An electrical pulse motor or an electrical hydraulic pulse motor is used for the open loop servo
with NC units and so this system is known as the pulse motor servo, too. Fig. 17.6~shows its con-
figuration. This system is characterized by the fact that it is unnecessary to provide for stability since
the pulse motor tracks in step form with command pulses. This means that as long as there are no
irregularities in the operation, no unstable phenomena like hunting will be caused. However, since
the mechanical error and non-linear mechanical rigidity are outside the control, it is difficult to
maintain control precision.
Moving table
cl-NC
Wr ew
Fig. 17.6 Open loop system
As mentioned above, there are three types of closed loop systems. It is common for small-sized and
medium-sized machine tools to adopt the semi-closed loop system in Fig. 17.5, and for machines, that
require precision machining, to adopt the fully closed loop system in Fig. 17.3. Furthermore, large-
sized machine tools which require a high level of precision adopt a type of hybrid servo system, the
dual feedback system, which combines the merits of the semi-closed loop system’s stability and the
control precision of the closed loop system.
a. Analog servos (amplitude servd and phase servo)
The commands from the NC unit are given in digital amounts of electrical pulses. When the input
commands to the servo mechanism are given in analog quantities, the servo system is known as
an analog servo of which one type is the amplitude servo.
Figs. 17.7 and 17.8 give examples of the principle of amplitude servos. The input command pulse
from the NC unit passes through the D-A converter and is applied to the coarse, medium and fine
stator windings of the synchro resolver as analog voltage at a level with corresponds to the input
numerical value.
The output voltage of the rotary windings of the resolver becomes zero only at a certain rotary angle.
In Fig. 17.7, the electronic switches operate with an input command so that the coarse resolver is
configured as a closed circuit. Next, the control error is reduced, and when the signal enters the
detection range of the medium resolver, the electronic switches operate so that the medium resolver
is configured as a closed circuit. When the control error is reduced even further, switching occurs
so that the fine resolver closes,
An amplitude (such as synchro voltage) is used as the input command, and this is compared with the
amplitude value (feedback synchro voltage) corresponding to the movement from the detector, the
133
amplitude difference is amplified as the error signal and the servo mechanism drives the drive motor
until this error is reduced to zero. Generally, this system is not very resistant to drift and it is
difficult to obtain a high level of precision. This is why it has not been used recently as the servo in
NC units.
Command Multi-speedsynchroresolver
Coarse synchrofeedback signal
Medium synchro feedback signal
Fine synchro feedback signal
, . .~,..“_
Fig. 17.7 Explanatory figure of multi-speed synchro resolver system
Coarseresolver
E&ronic E l e c t r o n i c --’Driveswitch *switch -z
(2)amplifier
I
Each command unit with respect
to rotating angle 1
Fig. 17.8 Principle of multi-speed synchro resolver detection system
On the other hand, the phase servo accepts command pulses as the input, it generates phase modula-
tion signal by digital methods, compares this signal with the phase modulation signal that corresponds
to the movement from the detector in the phase discriminator, amplifies the phase error as the
error signal, drives the motor until this error is reduced to zero, and causes the machine to stop at the
spot where the command and the feedback phases tally perfectly. This phase servo mechanism is
used in the MELDAS series, and an example of this system is given in Fig. 17.9.
In Fig. 17.9, the digital phase modulation (DPM) serves to feed out the reduced frequency of the
reference clock pulse like the reference pulse generator. It is provided with another pulse input
terminal for pulses from the gate circuit. When positive or negative pulses enter this terminal,
the DPM output phase either advances with respect to the output of the reference pulse generator,
or is delayed. This phase shift is proportionate to the number of input pulses from the gate circuit,
and the shifting speed is proportionate to the density of the input pulses.
134
h
For instance, if the mechanism serves to shift the phase exactly 360’ with a table movement of
4 mm and 400 pulses for a single rotation of the resolver, the phase will be the same if 400 pulses
are applied in one direction only when there are no input pulses.
The phase discriminator compares the output phase of the resolver with the phase from the DPM,
and it discriminates the phase difference. A positive error signal is generated when the resolver output
phase lags behind that of the DPM output phase, and a negative error signal is generated when it
advances. The error signal is rectified, DC amplified and the motor is driven. When the difference
is reduced to zero, the machine is stopped. Fig. 17.10 illustrates the phase difference signal.
When a + command pulse is applied once to the DPM input terminal, the DPM output phase ad-
vances 360/4000 only compared with the output phase of the resolver. Therefore, a + error is
generated in the phase discriminator, and the motor is driven in the direction in which the output
phase of the resolver advances. The machine then stops at a position where the resolver is rotated
0.09 times. Compared with the previous position, this
0.09 times and the table has moved 0.001 mm.
In this way, the number of positive and negative input
ment of the machine table and their repeat frequency
is the position where the resolver has rotated
pulses to the DPM correspond to the move-
also corresponds to the movement speed of
the moving table. Compared with the position servo which is composed of a phase discriminator,
drive amplifier, drive motor and resolver, the phase servo system controls the speed by giving posi-
tion commands from time to time in the form of the phase signals from the DPM. This means that
unlike speed control by speed feedback, it is possible to increase the allowable speed range to
infinity.
Under this system, the arithmetic processes are dealt with digitally and so there are no adverse
effects of noise and drift, and the signal transmission is extremely accurate.
Reference clock pulse 4.5 kHzr .
1 AMHZI._.Reference phase
4.5 kHzIM,d”” d.I,1&9 i
Fig. 17.9 Example of phase servo system
Command pulp, 1
rReference clock pulse
1.. 8 hIH z
Rotary angleI+ -Q
Fig. 17.10 Explanatory figure of phase difference signal of phase servo
135
b. Digital servo
A digital servo features digital signals based on pulses generated from the data of the major
parts. An example of this system is given in Fig. 17.11.
In Fig. 17.1 1, pulses are generated from the pulse generator for every unit angle in the output axis,
the command pulses and the number of feedback pulses are compared by the reversible counter,
the difference (in digits) is converted into analog voltage by the D-A converter, it is amplified and
the motor is driven. The feedback pulse generator must be provided with a function that discriminates
the rotation direction and it is necessary to install asynchronous circuits so that the command
pulses and the feedback pulses do not enter the reversible counter at the same time.
Under the digital servo system, there are no problems in the size of the signals and it is possible to
transmit the signals in the simple form of identifying whether there are or are not pulses. This
means that there are no adverse affects of noise and that the signals can be transmitted very ac-
curately. The pulse motor system mentioned in the explanation of the open loop servo in section
17.1.2( 1) d. may be described as a type of digital servo in the way that the signals are transmitted. h
Photoelectric pulse
Moving generatortable.
+ - ronized~ d
Axis cpmmand pulseS,$f
D-Aconverter.
H b&Drive
2 zamplifier motor
+ direction feedback
Feedback pulse
- direction feedbackcircuit
pulse ?Synchronous pulse
Fig. 17.11 Example of digital servo system
17.1.3 MELDAS servo system
Semi-closed loop system
This system features a resolver mounted on the motor shaft at the opposite side to that of the load for
detection. It is exactly the same as the so-called open loop system.
Under this system, the machine characteristics are produced outside the closed loop system and so a high
level of stability is featured. However, on the other hand, its main demerits consist in the fact that the
feed screw pitch error, backlash and other mechanical errors are not corrected.
In Fig. 17.12, the input command pulses from the tape are phase modulated, and the signals are converted
into signals whose phase is shifted by angle 0 which is proportionate to the number of input pulses, with
respect to the reference phase. As the output of the resolver phase shifter, signals are produced whose
phase is shifted by angle 8, which is proportionate to the rotary angle of the resolver axis, with respect
to the reference phase after the waveforms of those output signals are shaped. Therefore, both phases
are discriminated, the error Be = Bi - B. is amplified and the motor is driven. The closed loop system
is configured until the error Be is reduced to zero.
136
11111 J-u-L--lLJLI Machine side
N/C M o v i n g t a b l e
Phase ‘r Phase 8, Drive a- m o d u - ----+ discrim- --+ ampli-
later inator fier
A00
A
Vr - - - - -l
IDrivemotor
Waveform
shaper
r
Detector gearbox
(x, R e s o l v e r p h a s e s h i f t e r1
Fig. 17.12 Block diagram of semi-closed loop system
Note 1. The limitations on the machine constants are given below :
(1) Load GD*,_ (converted to motor axis) Depends on drive motor specifications
(2) Maximum static friction torque Less than rated motor torque
(3) Maximum dynamic friction torque ,,
(4) Maximum cutting torque
(dynamic friction torque cutting) ,I
(5) Backlash 127 pulses maximum offset
(6) Machine stiffness No particular limitation
137
17.2 NC servo system diagram
Command DPMError output
PP Analoguo error voltago
Command(to 9CR amplifier)
PMDPM circuit DIA converter )
DPM circuit ER
1
@ Resolver feedback
0 Resolver feedback
Feedback signal (sine wave) Feedback signa! It&are wave)
Reference DPM
fr
Reference DPM
4 No feedbacksignaldetection
1 circuit11st axis: 9M
2nd axis : 9M
Drive alarm
signal
3rd axis (2nd logic card) : 9M
4th axis (2nd logic card) : 8M
r-L-1;za;ez;, -FiFi Amplifierk ] t o R e s o l v e r e x c i t e r
Fig. 17.13 Printed circuit board LC4 system diagram
138
,
TG feedback
Analog error voltageEl3
. . . . ..-circuit
L”
E?!;0 v---I FZng angle
commandSynchronous signal
Manual speed inputPosition/Speedloop selection
TG output
Analog error voltage
Fig. 17.14 Drive amplifier (3810/20/4083
TG feedback
Servo compensation
i IC21 o u t p u t
+12V Position loop
P gain command 0
IC51 output
Manual speed input
1 1 E;ionon;pe;d , 1 Svnchronous signai
d7Current feedbackgain adjustment
IC31 input comparison
IC31 input comparison adjust
Fig. 17.15 Drive amplifier (SA20/40A/B)
8-12v
Current feedback
IC41 output
IC41 input comparison
SCR gate
to SCI? gate
139
17.3 Servo adjustments and regular inspection
There are no adjustable locations at the logic card (LC 4) side, but
(1) If synchronization is attained with the DPM reference, and if the command DPM or feedbacR DPM
(square wave) signals are observed, it is possible to check whether the commands are being made
available and whether the machine is moving.
(2) If the command DPM and feedback signals (square waves) are viewed on the synchroscope ADD, it is
possible to measure the droop (phase shift error), and so if the droop at a certain speed is measured in
advance, this can be used as a reference for regular inspections and trouble-shooting.
(3) The amplitude variations in the feedback signal (sine waves) have a great effect on the detection
accuracy, and so if the machine is moved at a low speed and the amplitude variation rate is measured,
it is possible to use this value as a reference to check whether the accuracy of the detector (resolver
+ phase synthesizer) is succumbing to aging.
The control cards of the drive amplifier (3S10/20/408, SA20/40A/B) have check terminals and variable h
resistors :
(1) If the TG feedback voltage at a constant machine speed (motor speed of about 1000rpm) and the
waveforms are observed and the ripple is measured, it is possible to use these data when the TG output
waveforms are the cause of increased roughness in the cutting surface. (Measure the waveforms with
both (+) rotation and (-) rotation directions.)
(2) When adjusting the linear IC zero adjusts and firing circuit, switch off the power supplies of the NC unit,
detach the MR connectors which connect the thyristor stack and the control cards (refer to the exterior
views of the drive amplifiers), and set so that the machine does not move. Now switch the power on
again.
(2)-l Linear IC zero adjust
Ground each of the check terminals at the IC input side, observe the signals at the check terminals on
the output side using a synchroscope, and set to zero.
(2)-2 Firing circuit adjustment
First ground the check terminals of the firing circuit input (analogue input) and then observe (U+,
U-) (V+, V-) (W+, W-) with. respect to synchronous signals U, V, W (use a 1O:l synchroscope
probe). If the firing angle is not set to 9” , use the variable resistor for adjusting the firing angle
to set it to this value. (The numbers of the variable resistors correspond to the check terminals.)
The following figures show the synchronous signal and switching waveforms.
140
Synchronous signal U phase
V phase
W phase
Switching u phase (+I ’waveforms U pham (-) ,
V phase (+I
V phase (-1 ’W phase (+I ’
W phase (-1 ,
)Level 560 VP_p
50/60Hr
t
9’ firing angle
(3) When it is desired to use a discrete drive amplifier to move the machine, set the position loop/speed
loop selector switch to speed loop, and the machine can be moved with the manual speed input by
variable resistor. At this time, the feedback signal will move with the command DPM at a standstill.
This means that the excessive error detector is actuated when preparing to operate, a drive section alarm
is issued and the NC operation preparations are shut down. Therefore, move the machine after removing
the IC plug, corresponding to the axis which is to be moved, on the logic card.
Note: If the logic card IC plug k removed and the position loop/speed loop selector switch is set to
speed loop, the machine will move in the same direction with a very small voltage caused by a
very low manual speed input (the variable resistor is not necessarily set to the center position)
or by a shift in the IC zero drift. This means that it is necessary to monitor the movement at
the machine side and that somebody who can depress the emergency shutdown button stand
on the machine side.
(4) Included in the servo system are the logic cards, drive amplifier as well as the motor and detector
gearbox. The latter two contain parts which are subject to mechanical wear (motor brush, tacho-
generator) and so refer to the sections for each of the units and check and clean the parts regularly.
141
CHAPTER 18. PARAMETER SETTINGS
The most representative parameters which determine the specifications of the NC unit with MELDAS are given
below (they differ according to the type of machine tool). .
Parameters : (1) Low speed feed speed with zero point return
(2) Absence or presence of optional and special optional specifications
(3) Absence or presence of machine control sequence
(4) Timer constants relating to machine control
(5) Backlash offset
(6) Zero point setting
(7) Pitch error offset
(8) Rapid feed acceleration/deceleration time constant setting
h
18.1 System parameter tape loading
Reading the system parameter tape into the memory determined inside the NC unit is known as ‘loading’.
The system parameter tape attaches with the NC unit. Load it, therefore, when necessary, when inserting or
taking out the logic cards and when the battery alarm has been issued.
Loading
a) Switch off the power to the NC unit.
b) Open the front door of the NC unit and release the door interlock.
c) Switch on the power to the NC unit.
d) Logic card LCl is mounted in the logic section of the NC unit and two switches are arranged on the
card.
Operate these switches in the following sequence :
(I) Set the top switch SW1 down to ON.
The control unit stops and the CPU alarm lamp comes on.
(2) Load the system parameter tape which comes with the NC unit into the tape reader.
(3) Set the bottom switch SW2 up to ON.
The reader starts operating and the tape is read through.
(4) When the top SW1 is set up to ON, the NC unit returns to normal.
Note 1) Operations (I) and (2) may be performed in any order.
2) The power may be cut off after operation (4). However, the battery will overcharge, and so it
is recommended that the power be cut off after power has been flowing to the NC unit for one
hour and after the battery recovers.
142
1
Logic section DC powersupply section
EI
Inside of main unit
SW1
SW2
@ Set SW1 down to ON
($ SetSW2uptoON
@ Sat SW1 up to ON
Fig. 18.1 Tape loading switches and their operation
Once the system parameter tape has been loaded, it is now necessay to set the other parameters.
For the settings of these parameters, refer to the section 7 on ‘Internal Settings’ of the Instruction Manuals
of the MELDAS-5000C and the MELDAS-5100C.
h
143
CHAPTER 19. SELF-DIAGNOSIS
The setting and indication board has the following selfdiagnosis functions, it gives the following alarms and
displays.
19.1 Alarms and states indication
(1) READY
(2) ERROR
(3) BATTERY
(4) ALARM
(5) BUFFER This comes on when the next block data of the tape is stored in the buffer.
(6) EDIT This comes on during tape editing.
This comes on when the operation preparations for the NC unit are completed.
This comes on when there is something wrong with the computer inside the NC unit. Re-
start is performed with the start button (mounted on the LCl logic card) inside the
NC unit. (Switching the power to the NC on and off is performed in the same way.)
This comes on when the memory battery has overcharged and the NC is set to the
READY OFF mode.
This comes on when the NC unit detects any of the alarm states below.
(a) OT (overtravel)
(b) SERVO (servo error)
(c) TH (parity H)
(d) TV (parity V)
(e) P/S (program setting error)
The contents of the ALARM are displayed on the numeral display when the function
switch is set to ALARM.
h
When the CPU, BATTERY and ALARM lamps have come on, all the (AL) alarm signals are sent to the
machine side.
19.2 ALARM contents check
When the ALARM lamp on the setting and indication board has come on, it is possible to find out its
contents by using the setting and indication board. When the ALARM lamp has come on, set the function
switch to ALARM, and the contents of the alarm (section (1) 4) are displayed. With a program setting
error, the error number that indicates the cause is displayed and so refer to ‘alarm contents indication’
under the section on ‘Setting and Indication Board Handling’ in the Instruction Manual of the MELDAS-
5oooc/51 ooc.
19.3 Interface check
Interface refers to the input and output signals that bridge the gap between the main NC unit and the machine
tool (or power controller, machine operation board). The main NC unit operates in accordance with the
interface conditions. Set the function switch to I/F CHECK and check on the setting and indication board.
The name of the signal corresponding to number H differs with the MELDAS5000C/51OOC and so refer
to the section on ‘Interface Checks’ in both the Instruction Manuals.
CHAPTER 20. TROUBLE-SHOOTING (from BNP-A2027)
1) I No NC power1
NO YES
Side or rear panel is open. Or doors
are not closed properly and so door
interlock limit switch is not com-
pletely ON.
Check .+,rether main no fuse breaker
in main NC unit has failed and wheth-
er this is cause of no power.NO
Blown AC 1OOV or 24V fuse in DC
power supply section (~~08 or PD09) ?When NC power switch is set to ON, NOobserve tape reader lamp and setting
and indication display. Do they come
on if only for an instant ?I - - - - - -1 1 YES
YES
rsupply in NC power supply section is
IrtesI~pP,:.g51 ZtFi ~ZeIower 1
to main no-fuse breaker ?
NO
NO I
1 1 NO
..-Find out why. If no voltage applied
here, voltage is not being supplied to
transformer.
. J
If normal up until now, unit is defec-
tive and should be replaced. If defect
after repair or inspection inside NC,
DC output may have shorted.
Check whether voltage is being applred to AC 1OOV
input of DC power supply section (PDOB or
j PD09,. ,I----=
YES
Inspect for defective contact in MR connector
which connects NC power supply switch and DC
power supply as reason that NC power is off.
Check MR connector connections.
145
Power is on but no READY (preparation for operation) state.
No ALARM lamps on.SERVO alarm lamp is on. Is BATT alarm lamp on 7
YES
4I I
(1) Axis drive amplifier no-fuse breaker has been tripped.
(2) Axis drive amplifier thermal relay has been tripped.
(3) Position detector cable is not connected.
(4) Spindle drive amplifier no-fuse breaker has been tripped.
(5) Spindle drive amplifier thermal relay has been tripped.
I - Emergency stop stateI
Battery power has fallen below
prescribed level.
V
Leave in this state for several hours and then depress
reset button after having recharged battery.
Now it is necessary to re-load system parameter tape.
Special care is required since tape editing memory may
be damaged.
(However, when system parameter tape is loaded, the tape
editing memory area is cleared.)
146
3) The ALARM lamp comes on
Set the function switch on the setting and indication board to ALARM, display the contents of the
alarm, and determine and remove the cause.
Alarm contents
OT
Adjustment method Remedy, countermeasure
Move the axis which has overtraveled in
Find the axis which has overtraveled. the opposite direction with handle feed OI
manual feed.
SERVO
(1) No-fuse breaker of axis
(or spindle) drive amplifier has
been actuated.
(2) Thermal relay of axis for spindle)
drive amplifier has been tripped.
(3) Position detector cable is not I
After remedying cause, depress reset
button of thermal relay.
Or set no-fuse breaker to ON.
connected or has come loose.
Connect cable (CNA14 or CNA3-6) or
tighten COnneCtiOn
(1) Tape itself is set to parity H
or parity V state.
(1) Re-inspect tape. If there is a mistake ir
the tape, correct.
TH, TV (2) Tape sprocket hole (feed) has
shifted.
(2) (3) Re-inspect puncher which is beinf
used. If there is something wrong witl
the puncher, repair or replace.(3) There are many fibers around
sprocket hole
(4) Tape reader photo cell or optical (4) Inspect tape reader.
plate is dirty. Clean tape reader.
Refer to the ‘alarm contents indication’
PIS Check the number of the error.under the section on ‘Setting and
Indication Board Handling’ in the
Instruction Manual.
147
4)
ALARM lamp comes on during operation
and SERVO section goes to ‘1’.
Lamp remains on Lamp goes offDepress reset button
(1) Overload has tripped thermal relay_ of axis (or
spindle) drive amplifier.
(2) No-fuse breaker of axis (or spindle) drive ampli-
fier has been tripped.
(3)
tion detector cable.
(4) Oil has seeped into position detect01 (normally
on the opposite side to that of the motor load),
and there is something wrong with the resolver
and phase synthesizer.
J
Excessive errorc_Perform disengaged
operation-under same
conditions and check
whether same phenome
non occurs.
h
148
5) No tape reader start
I
Tape advances only one character
or one block.
V ,Tape reader switch is set
(1) Parity error
(2) Program error
(3) Incorrect advance direction
of paper tape
L
r J not set to RUN ?
I Check ALARM.I I
switch to MANU.
Defective contact of tape
(1) Inspect tape reader.
(2) Inspect tape.1
it NO
-i
(1) Defective tape reader
(2) Defective LC3 logic card
Note) It is possible to perform an interface check to check whether ‘automatic start’ signals are being fed out.
149
I
V waveforms agree with those
on the data sheets.(1) Output waveforms and sprocket
waveforms not adjusted with vari- ,able resistors.
(2) Check whether lamp voltage is DC
18V.
(3) Check whether optical plate is I
Tape reader does not stop 9
Does not stop even with error stop
(parity H, V, program error).
Does not stop even -when end of blockis read.
----) Check tape reader.
* 6
Use a synchroscope to check
Something that output waveforms of tape
wrong reader with all mark endless
tape as well as sprocket
Replace tape reader
Try replacing LC3 logic card.I
150
7)
YES
(+I f-) polarities are,
reversed or axis iswrong.
Defective switch or related part
at machine side stroke end.
8)
MELDAS-BlOOC?
Moves (1) Override is set to 0.
(2) Feed hold is set.
V (3) Stroke end is set.
(1) No feed speed command F
(21 No rotation of rotary encoder for
spindle does not rotate)
Present position display counter only
moves but machine does not move ?
J1
Something wrongwith LC4 or axisdrive amplifier
YES
Machine lock ?
, Servo actuated ?
NO
Movement with GOcommand 7
I NOBr
Problems withsetting of LC3,
LC4 IC plugs ?
151
9)I”““‘“’
(1) Battery has overcharged.
(2) Logic card (especially LC2, LC120)has been inserted or taken Out.
Use the switch on logic card LCl and reload
the system parameter tape.
Note 1. After loading the system parameter tape, it is necessary to set the backlash offset, zero point,
pitch error offset, rapid feed time constant, power sequence timer constant and other values
peculiar to the machine tool again.
2. If it is thought that the battery has discharged extremely, it is desirable to run power through it
for continuous 4 hours or more.
10)
Notreleased
NO
Try reloading system
p a r a m e t e r t a p e
Logic card:Check connections of ROM,RAM, micro CPU plug typechips mounted on LCl, LC2,LC120, LC23 for looseness bypushing them in.
Q
Try re-loading system parame-ter tape
c
1
Try replacing in turn of LCl,2, 120 and 23 logic cards.
Defective LCl logic cardpreventing CPU fromstarting from fixed address
Check method of use of control unit when ERROR lamp
comes on, and check whether there is reproducibility.
Note) ROM (read only memory)A memory where fixed commands arestored.
RAM (random access memory)This is a tape store memory that canbe freely written into or read out.
153
11) I No manual feed
NOhandle feed and zero point
NO
No movement in onlyone mode
No movement with
cutting feed only
Use interface check tocheck which mode doesnot come
Is axis selected 7
Override is set to 0%.
OK
Use interface check tosee whether axis has beenselected
I O K
If fault is related to axis,try replacing LC4 logic card.
JInspect with interface check tosee if JOG or handle/step modehas come.
Has not come
(1) Check connections betweenpower controller and NC unit.
(2) Try replacing LC3 logic card.
Use interface check tosee whether overridesignals are available.
If signals come as far
as NC unit but can
not confirm at
interface check, try
replacing LC3 logiccard.
h
154
12)
Emergency stop Auto1
No stopping even when manual
cutting, rapid feed buttons are
depressed and released,or when
OFF button isdepressed.
1Use interface check mode and check
.ON/OFF operation with JOG (+)
(-) as button input.
!
Check that line U P
to CNDl-T, which
is entrance to NCunit, opens andcloses with buttonON/OFF operation.
No ON/OFF L
V,
Inspect JOG (+) f-) signal line from but-ton input up to operation board, powercontroller
I
I OK
READY lamp doesnot go off even whenemergency stop ibutton is depressed.
\uI
Try replacing LC4 logic card (1 cardwith 2 axes; with more than 2 axes,view from front and left side LC4 corres-ponds to 1st and 2nd axes, and secondLC4 card corresponds to 3rd and 4th
Iaxes.
O K
No stopping even when feedhold button is depressed.
Use interface check mode tocheck that feed hold signalsare set ON/OFF.
Check signal line of feed hold frombutton input in order of operation
board and power controller.
V
Buttons must be set to OPEN.
O K
I 1
Try replacing LC3 logic card.1
155
13-3)Movement speed differs from that
1 1I I
NO0 +M-51 OOC 7Something wrongwith override ?
Something wrong with LC3 logic
14)
h
I Manual data input doesnot function.
Check machine
3operation boardand powercontroller related
A
Check machine
(CNDl-G) signal come ?and powercontroller relatedparts.
1 z;zL;g wrong with LC3
157
15) Something is wrong with zero point returnI
15-l)
15-2)
15-3)
No movement with rapid feed speed evenwhen zero point return mode is selectedand manual JOG button is depressed.
Zero point return mode 7
1 NO
Something wrong with LC3logic card
No low speed even when zeropoint detection dog is kicked
Is zero point detectionsignal available ?
(“““““i”l”“““‘“l”’
Low speed after zeropoint is detected 7
I NO
Is JOG signal available ?
\1 NO
158
15-4)
NO
Try varying zero
16) No precision
16-l)
h
Defective detector precision
\
Check that amplitude variationsof detector output signal are with-in rating (less than 1.5%)
Inspect and determinewhether dog length is
Note) The test points on the LC4 logic card for checking the amplitude fluctuations are:
TP3 . . . . . . . . . . 1st axis (or 3rd axis)
TP4 . . . . . . . . . . 2nd axis (or 4th axis)
First measure the peak-to-peak voltage (VP-p) of the sine waveforms, and then enlarge the voltage
range as far as possible. Move the machine slowly and measure the voltage (A V) which is
fluctuating)
Check that fluctuation is:2 AVVP-P
x loo(%) ri 1.5(%)
159
16-2)
Defective coupling with detector
I
V
Inspect bellow coupling which connectsdetector gearbox to drive motor.
h
Note I) When the detector gearbox is behind the drive motor, the bellow coupling can be seen from
the outside if the cover is removed.
21 If the bellow coupling works loose, it will not be possible to maintain the repeat accuracy.
3) Because of its construction, the bellow coupling may be considered a consumable and so it is
recommended to have a spare available for maintenance purposes. Contact a MELDAS serv-
iceman to find out what type is used.
7
160
16-3)
High machine friction torque1\1/
(1) High starting current
(2) ALARM lamp (SERVO) comes on
Note) When the machine is assembled (or under normal conditions), measuring the torque at the motor
load, when the machine starts up and when the machine is moving, produces results which are
used as appraisal references (trouble in the electrical system, failure in the mechanical system) to
deal with trouble. It is therefore a good idea to proceed with these measurements.
16-4)
Method by which ball screw is being usedis extreme, and the error increases to (+).
161
16-5)
16-6)
Measure backlash at total
stroke 2 or 3 locations.
Re-set backlash offset
High residual current whendrive amplifier is stopped.
16-7)Lack of precision due toball screw pitch error
VMeasure precision for singlerotation of ball screw.
,
(1) Use pitch error offset ifavailable.
(2) Repair at machlne sideif no pitch error offsetis available.
162
17) Hunting
1 7 - l )
Defective TG feedback
V
inspect TG feedback voltage.,
(1) Inspect wiring inside detectorgearbox.
(2) Inspect wiring route from de-tector gearbox to NC unit.
Note) Measure the TG feedback voltage at the CPl of the drive amplifier corresponding to the axis.
D C 7V/lOOO r p m
17-2)Defective TG characteristics53
J/
(1) Besides ripple in TG feedback waveforms,disturbance in other waveforms is high.
(2) Defective rotational speed voltage specifi-cations.
1Clean TG or replace TG
163
17-3)
I Defective TG couplingI
V
inspect coupling inside detector
I Repair trouble spots or replacedetector gearbox.
Note) If the polarities of the TG (tacho-generator) are reversed and signals enter the NC unit, the
machine will move in the one direction as soon as the NC enters the ready state (this is due to
positive feedback), and the machine will stop with the SERVO alarm (due to excessive error).
h
164
CHAPTER 21. TROUBLE-SHOOTING WITH SOFTWARE(from BNP-A2028)
‘Software’ in connection with the MELDAS 5OOOC/51OOC refers to the memory program arrangement in which
the standard specifications, optional specifications including tape editing, special optional specifications, power
controller sequence and the functions of these three sections are housed. With the MELDAS 5OOOC/51OOC,
the contents of the software are stored in a fixed type of memory known as a ROM (read only memory), and
so with trouble in the software, the fault lies with the ROM IC.
Following is a description of the action to be taken when there is something wrong with the logic cards, on
which the ROM ICs are mounted, or with the ROM ICs themselves.
21.1 LC2, LC120, LC23 logic cards
There are three logic cards, LC2, LC120, LC23, on which the ROM ICs are mounted. These cards are con-
figured so as to accommodate a maximum of 88, 48 and 16 ROM ICs, respectively.
The positions of the ROM ICs mounted on each of the logic cards are shown in the following figures.
165
rIII
IIIIIIIIIIII
- III
IIIIII
IIIIII
IIII-
LC 2 UAO 1.-----------
(LEEIIX~ 22liner x4rowsL
8 8 p i e c e s
IIIIIIIIIIIII
IIIIIIIIIIII
IIIII
I .III
IIIIIIIIII
_- ------ --__.J
M L K J H G F E D c B A LA40
h
ROM(Read Only
Printed circuit board LC2
LC120
17lines x2rows --_--- -----l
I II II II
III
I
I I
I I
I I
II
I II II II II II II II II II I
I II II II II II I
I I
I I
I II I
I II II II I
In II
I II
I I I I I
I E I I I I
I I I I I
I FI I I I
I I I II
I I I II I
I
IG I I
I II II I
I HI I
I I II I I I
I II
I J I I II I I I
IK I I I II I I I
I I I II L
II I I
I I II I IIM ;
I II I I
‘N I I I II I II~el~li_l
L_-_--_-__-_T-- - -
- - 34 pieces (RAM)
12 lines x 4 rows 48 pieces (ROW~~~~~~~__~~- - - -__
II LAO I
ROM(Read Only Memory chips)
RAM(Reed Access Memory chips)
Printed circuit board LC120
167
LC23A
4 lines x 4 roWs - - 16 pieces ( R O M )
r---------1
L
t L K J HI
Connector
UAO 1
-
-
G F E D C B
LC23A - ROM(Read Only Memory chips)
Printed circuit board LC23e
168
Note) The RAM memory on the LC120 logic card refers to the random access memory which allows free
writing and reading and which is used for tape editing.
21.2 Action when there is something wrong with LC2, LC120 or LC23 logic card
When something wrong occurs with these cards, in most cases the parity check function is applied during
operation, memory parity is set, the CPU stops and a CPU error is recorded. When the memory parity is
not set, CPU rotates the routine in the software, and external interruptions can no longer be accommodated.
Possible causes of this are:
(1) ROM IC has worked free of socket
(2) Defective characteristics of ROM IC
(3) Defective characteristics of other IC, resistor or capacitor
(4) Defective soldering
(5) Defective pattern
(6) Defective soldering at both ends of jumper wires
(7) Defect in mini bus supplying DC 5V, ground to each row
When an identical spare is available, try replacing the logic card and observe the variation from the trouble.
Mounted on the LC2, LC120 and LC23 logic cards are the following memories:
Standard specification memory on LC2 logic card
Optional specification and special optional specification memory, and tape editing RAM on LC120 logic card
Power controller sequence memory on LC23 logic card
The types of these memories may change for each and every machine.
Therefore, when a spare logic card is at hand, it is possible to judge the trouble by replacing the ROM ICs and
finding out which ROM IC is defective and the trouble on the circuit board of the logic card.
169
21.3 Trouble-shooting
ERROR lamp comes onI
I
Switch off power
and switch on again.
Defect in CMOS IC area which storescontents of system parameters (LC2)or defect in operation RAM area (LC21
Re-load system parameter tape.
NO
Try pushing in ROM ICs (or RAM ICs) mounted on the eLC2, LC120 and LC23 logic cards by hand.
YReplace logic cards in sequence (including LCl 1.
If something is wrong with LC2, LC120 or LC23 logiccards, find trouble spot by replacing ROM ICs and findout if trouble is ROM IC or the printed circuit board.
170
CHAPTER 22. MAINTENANCE PARTS LIST(from BNP-A2029)
22.1 Spare parts
Name of parts
Tape reader spare parts
Standard
Tape reader lamp unit
Cleaning brush
Quantity Place used
1 set Paper tape reader
Fuse
Fuse
Air filter
Glass-sealed type 10A
Glass-sealed type 3A
2 Power supply
1 Power supply
1 Rear door
Above parts are standard spare parts of MELDAS 5OOOC/51OOC.
22.2 Printed circuit board (Logic card)
_
_
_
Name of partsFunctions Remarks
iroup ofboards Board name
LCl LCIB CPU input & output control, Clock generator, relation
LCIC to CPU, Auto restart function of CPU, Control signal
generation, Sequence instructions control
LC2 LCZA
LC2B
Standard specification memory, The memory for
parameter, Calculation memory, Memory parity
error generator, Battery charging/discharging circuit
LC3 LCSB
LC3C
Operation ready sequence, System clock generator,
Timing generator, Paper tape reader control, Manual
handle control, Spindle revolution detection,
NC standard input signal I/F, Control words decoder
for 110 I/F, Setting and indication board I/F
LC4 LC4B
LC4C
-_-
Pulse distribution circurt, Smoothing circuit,
Drgital Phase Modulation circuit, Resolver exciter,
Resolver output filter, Settings of servo system,
Input I/F relation to axis
Two axes aremounted onone logic card.
__~.
LC120 LC 120A Memory for processing tape, Program for optional Optional card
LC12OB function, Batten/ backed up circuit, Battery charging
LC12OCcircuit, Memory parity error generator
(Cont.)
171
(Cont.)
r Name of parts
;roup ofboards
LC21
Board name
LC2lA
LC2lB
LC22, LC22A
L C 2 2 8
L C 2 3 LC23A
22.3 Board
LC 23A- 1
Functions
Relay I/F, Read-out display, S analog output, D/A
converter
Remarks
Multi data display control, Tape puncher control Optional card
Memory for machine sequence control
Machine sequence I/F
Name of parts I Functions
Board S C 5 1 MELDAS- 10 OC Standard board
Board SC57
Board P Z 5 7
MELDA S- 5 0 0 0 C standard board
Board with multi data display unit (suitable for the standard board
o f MELDAS 5OOOC)
Board D P 5 1
I/ D P 5 2- -
D P box 6 2 A
n 6 4 A
D P box 6 2 B
I, 648
Position read-out display
N-
Position read-out display
N
Position read-out display
I/
for 2 axes
for 1 axis
for 2 axes
for 4 axes
for 2 axes
for 4 axes
h
. .
22.4 Power supply
Name of parts Functions
PD08A DC5V, +lZV, -12V. 24V, Power ON-OFF sequence,
Battery charger circuit
_.._
PDOSA DC5V, +12V, -12V. 24V, Power ON-OFF sequence
Charger PM 1 OA/PM 1 OB ~ Battery charger circuit
172
22.9 Drive amplifier
Suitable motorsName of part4
Low inertia motor Cup motor Direct drive motor
3SlOA/B 18(Iw, 39OW, 75&V 4ocw, 7 5 a v -
3S20A/B 18UV,39(Mr, 75M’, 1.5kW’ 4oav, 75&v, 1.5kw, 2.2kW -
3S40A/B/ 3kW 3.7kW, 5.5kW 75OW, 1.5kW, 2.2kw
S A 2 0 A/ B 1 18OW,39(Iw,75(Iw,l.5M;v 1 4OaV,75Wv’,l.5kW,2.2kW)-
SA40A/B 3kW 3.7&v, 5.5kw 75av, 1.5@hJ, 2.2w
S3S50A,Bl I I
S3S6OA/B I I
ss 6OA/‘B/‘C
22.10 Motor
Name of parts
Low inertia motor
UGMMEM-06AAl
UGMMEM-13AAl
UGivlMEM- 2 5AA 1
UGMMEM- 5 OAA 1
UGMMEM-1 AAA 1
Cup motor
UGCMEM-0 4
UGCMEM-0 8
UGCMEM-- 15
UGCMEM-2 2
UGCMEM-3 7
UGCMEM-5 5
Direct drive motor
HD7 SOW
HD 1.5KW
HD 2.2KW
ClOOO-2.0
c2000-20
c3000-15
Functions
1 8 0 W
3 9 ow
7 5 ow
1.5 KW
3 KW
4 0 ow
8 0 OW
1.5 KW
2.2 KW
3.7 KW
5.5 KW
7 5 ow
1.5 KW
2.2 KW
7 5 ow
1.5KW
2. 2. KW
h
174
22.11 Motor brush
1) Low ineritia motor
UGMMEM-06AAl
UGMMEM-13AAl
UGMMEM-25AAl
UGMMEM-50AAl
UGMMEM-1AAAl
2) Cup motor
Size of brush (mm)
4x12.5x22
4x12.5x22
5x20~25
6x20~25
10x20~25
Type Size of brush (mm)
UGCMEM-04 4x10~12
UGCMEM-06 I
UGCMEM-15 I
UGCMEM-22 6x12.5x22
UGCMEM-37 I,
Type of brush Materials PCS of brush
DP6404699-1 MH-372 2
DP6404699-1 II 2
DP64047 14-1 II 2
DP64047 144 MGQRB-0 2
DP6404714-3 b 2
Type of brush Materials PCS of brush
MG-9RBO 4
I 4
I, - 4
I! - 4
n - 6
3) HD m o t o r
Type Size of brush (mm) Type of brush Materials PCS of brush
HQ750 W 4.7~16~10 _ EG319 8
HDl.5KW I _ I, 8
HD2.2KW * _ I 8
175
22.12 Thermal relay
Table 20-l. Motor - Thermal relay . Drive amplifier
Motor Thermal relay
Drive amplifier
Tvpe I t e m Rated output ItemPrescribedcurrent
Dial
.
. UGMMEM-06AAl 180 W TH-20FS 6.5A 6.2A
8i; UGMMEM-13AAl 3 9 0 w I, I, 7.4AE.;
SA2OA,‘8
& UGMMEM-25AAl 7 5 0 w I, 11 A 1 2 Ac:;
s UGMMEM-50AAl 1.5KW I, I 12.1A
UGMMEM-1AAAl 3.OKW TH-6OFS 28 A 2 4 A SA40A,‘8
UGCMEM-04 4 0 0 w TH-20 8.5A 6.5A
UGCMEM-08 7 5 0 w w I 8A
SAPOA,‘Bbg UGCMEM-15 1.5KW TH-20FS 11 A 1 2 A
E
9u UGCMEM-22 2.2KW TH-60 21 A 1 8 A
UGCMEM-37 3.7KW I, 2 8 A 2 8 A
SA40A/ B
UGCMEM-55 5.5KW I 0 31 A
HD07510 7 5 0 w TH-60 21 A 22 A
bi;E HD150-10 1.5KW * 2 8 A 2 4 A SA40A/ B
?HD220-10 ;.LKW ,, 28 A 2 4 A
176
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