Toshiba TOSNUC 92 Instruction manual

STE 73843–4
CONNECTION MANUAL
TOSNUC 92
!WARNING
• Read this manual before equipment installation and
wiring.
• Save this manual for future reference.
February, 2004
TOSHIBA MACHINE CO., LTD.
Shizuoka, Japan

STE 73843
Preface
This manual describes the connection of the NEW TOSNUC numerical control system
for Lathe machines.
Before installation and wiring of the NEW TOSNUC numerical control system, please
read and completely understand this manual.
[Particulars]
(1) The name of each printed board described in this manual signifies as follows:
Example: N P R 1 A
Assembly group
Function group
Name of function (starting with alphabet N)
In all, three (3) expressions are used for the same printed board.
• Expression of only the name of function irrespective of the design order, such
as the connector name (ex., NRR).
• Expression relating to the design order as in use of a different function (ex.,
NPR1).
• Expression relating to different application by assembly group (ex., NPR1B).
(2) Expression of cable drawing
[1]
[2]
: Signifies twisted pair wire.
: Signifies shielded covering.
(3) A non-insulating type interface is provided for the analog input/output interface.
If noise is heavy, an insulated amplifier may be provided by the user.
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(4) RS232C user interface
To prevent damage of the control circuit at mounting/dismounting a connector, the
AC power switch on the peripheral equipment side should be of a type having
separate common wires. Also mount and dismount the connector with the AC
power turned off on the peripheral equipment side.
CNC system Peripheral
equipment
AC power
supply
Switch with separate common wires
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STE 73843
Cautions on Safety
Before connecting the equipment, be sure to read through this manual and other
attached manuals including the instruction manual to perform proper operation.
The work should be started only after you have fully understood and been familiar with
the knowledge of each device, safety information and cautions.
If any question yet to be clarified arises, do not hesitate to contact us before the work.
In this manual, all items requiring special attention are expressed in the manner shown
below.
!DANGER
Indicates an immediately hazardous situation which, if
not avoided, will result in death or serious injury.
!WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
!CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It also
indicates a hazardous situation which may result in
property damage.
The contents stated in the precautions above are the items which possibly may lead to
a serious accident if not observed. To avoid this, anyone involved should strictly
observe them to assure safety.
As there are also very important descriptions in the general contents though not
stipulated in the DANGER, WARNING and CAUTIONS columns, you should be well
versed in and observe them. It is strongly recommended to keep this manual at hand
so that anyone can get an easy access to it.
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STE 73843
!DANGER
NEVER turn the power on during installation of
equipment and wiring. Otherwise, you will be struck by
electric shock and the equipment will be damaged.
!DANGER
Be sure to connect the grounding line.
If grounding is incomplete, you will be struck by electric
shock and error operation such as uncontrollable axis
will result in.
!WARNING
Be sure to perform electric work pursuant to the
Electrical Installations Technical Requirements, Interior
Wiring Requirements and this manual.
If the power circuit is faulty, power capacity is short or
the work is incomplete, you will be struck by electric
shock and a fire will result in.
!WARNING
Be sure to use the power supply of 200 VAC - 230
VAC, 50/60 Hz. If other line voltage is connected, you
will be struck by electric shock, a fire will be caused by
heat generation to destroy the devices.
!WARNING
NEVER disassemble and repair the equipment by other
than the qualified maintenance engineer. Otherwise, a
fire, electric shock and mis-operation will result in.
!CAUTION
Dispose of waste materials as industrial wastes.
Dispose of batteries in a manner as prescribed by each
autonomy.
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STE 73843
Table of Contents
Page
1. GENERAL DESCRIPTIONS ................................................................................. 11
2. CONFIGURATION ................................................................................................ 12
2.1 System Configuration········································································ 12
2.2 Configurations of Units ····································································· 13
2.2.1 Main Control Unit ..................................................................................... 13
2.2.2 Operation & Display Unit ......................................................................... 14
2.2.3 User Media Drive Unit.............................................................................. 15
2.2.4 Machine Input/Output Module (PLC) ...................................................... 15
2.2.5 Servo Drive / Power Supply Unit.............................................................. 16
2.3 Selective Specifications······································································ 18
2.3.1 Main Control Unit ..................................................................................... 18
2.3.2 Operation & Display Unit ......................................................................... 19
2.3.3 User Media Drive Unit.............................................................................. 20
2.3.4 Machine Input/Output Module (PLC) ...................................................... 20
2.3.5 Servo System ............................................................................................. 21
3. INSTALLATION AND ENVIRONMENTAL CONDITIONS .................................... 22
3.1 Environmental Conditions ································································· 22
3.1.1 Units........................................................................................................... 22
3.1.2 Cabinet....................................................................................................... 23
3.2 Power Supply··················································································· 24
3.3 Cabinet Design Conditions································································· 25
3.4 Unit Installation and Restrictions ······················································· 28
3.4.1 Main Control Unit ..................................................................................... 28
3.4.2 Machine Input/Output Modules (PLC)..................................................... 29
3.4.3 Operation & Display Unit ......................................................................... 30
3.4.4 User Media Drive Unit (FDU2) ................................................................ 31
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Page
3.4.5 Layout of Main Control unit and Servo Drive Units ............................... 32
3.4.6 Encoder Battery Box ................................................................................. 33
3.5 Heat Design of Cabinet······································································ 35
3.5.1 Radiation inside Cabinet........................................................................... 35
3.5.2 Method of Calculating Radiation Volume ................................................ 39
3.5.3 Heating Volume of Each Unit and Printed Board ................................... 40
3.5.4 Radiation from Servo Drive Unit.............................................................. 42
3.6 Measures against Noise and Grounding ··············································· 43
3.6.1 Separation of Signal Cables ...................................................................... 43
3.6.2 Grounding .................................................................................................. 45
3.6.3 Noise Killer ................................................................................................ 47
3.6.4 MPG ........................................................................................................... 48
3.6.5 Measures against Lightning and Radio Hindrance ................................. 48
4. CONNECTION....................................................................................................... 49
4.1 Overall System Diagram···································································· 49
4.2 POWER Module - T9PW2 ·································································· 52
4.2.1 200 VAC Power Supply Input (CNAC): Cable Name W907.................. 52
4.2.2 Unique Line (CNON)................................................................................. 53
4.2.3 High Speed Sensor, Overtravel, Door Interlock (CNIP) .......................... 55
4.2.4 CNC Ready, Power ON, Servo ON, Break Release Output (CNOP)....... 58
4.2.5 DC Power Supply Connector ( CNDC): Cable Name W903 .................. 60
4.3 MAIN Module - T9NC1······································································ 61
4.3.1 PLC Interface (CNPC)............................................................................... 61
4.3.2 Panel Communication and Video Signal Output (CNPN): Cable Name W901 .62
4.3.3 RS232C Port A (CNRS): Cable Name W905.......................................... 64
4.3.4 User Mdia Drive Unit Communication (CNFD): Cable Name W912 ... 65
4.4 SERVO Module - T9SV1 ···································································· 66
4.4.1 Encoder Input (CNFB1, CNFB2, CNFB3, CNFB4): Cable Name W938 .......... 66
4.4.2 Encoder Back-up Battery (CNBT2) .......................................................... 67
4.4.3 Servo Drive Unit Communication Signal (CNSV1/CNSV2/CNSV3/CNSV4) ...... 68
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Page
4.4.4 Spindle Drive Unit Communication Signal (CNSC): Cable Name W913 ......... 69
4.4.5 SPG Input (CNSP)..................................................................................... 70
4.5 Operation & Display Unit (NPN1)······················································· 72
4.5.1 Power Connectors (CNP3, CNP2) ............................................................. 72
4.5.2 Keyboard Input (CN1)............................................................................... 73
4.5.3 Manual Pulse Generator: Connection to MPG (CN9).............................. 74
4.5.4 Panel Communication and Video Signal Input (CN19) ........................... 75
4.5.5 Analog Input (CN15, CN16)...................................................................... 75
4.5.6 Machine Operation Panel I/O ................................................................... 77
4.6 User Media Drive Unit (FDU2)··························································· 85
4.6.1 Power Supply (CN1) .................................................................................. 85
4.6.2 RS422 Communication (CN2): Cable Name W912................................ 86
4.7 Portable MPG Box ············································································ 87
4.8 Machine Input/Output······································································· 89
4.8.1 Connection of CNC to I/O modules ........................................................... 90
4.9 Servo Drive / Power supply Unit ························································· 91
4.9.1 AP28A Servo Drive Unit ........................................................................... 91
4.9.2 SS series Power Supply Unit & AS/AW series Servo Drive Unit............ 92
4.9.3 Servo Motor Brake Circuit ........................................................................ 94
4.10 Others ···························································································· 95
4.10.1 Mounting Protection Breakers.................................................................. 95
4.10.2 Servo Motor Brake Circuit ........................................................................ 96
5. SETTING AND ADJUSTMENT ............................................................................. 97
5.1 MAIN Module - T9NC1······································································ 97
5.1.1 Battery Connector - CNBT1...................................................................... 97
5.1.2 DIP Switch - SW4 ...................................................................................... 97
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Page
5.2 Operation & Display Unit - T9PN** ···················································· 98
5.2.1 DIP Switch - SW1 ...................................................................................... 98
5.2.2 DIP Switch - SW2 ...................................................................................... 98
6. OTHER CAUTIONS............................................................................................... 99
6.1 SPG Selecting Conditions ·································································· 99
6.2 Reference Point Return ··································································· 101
6.2.1 Grid System ............................................................................................. 101
6.2.2 Near-Zero System.................................................................................... 102
6.2.3 ON/OFF Timing of the Deceleration Signal........................................... 104
6.3 Stroke end Limit Switch Signal ························································ 106
6.3.1 Direct Input to CNC ................................................................................ 106
6.3.2 Input from PLC........................................................................................ 108
7. EMERGENCY STOP SIGNAL ............................................................................ 109
8. APPENDICES ..................................................................................................... 112
8.1 Outline drawing and Set Dimensions of Each Unit ······························ 112
8.1.1 Main Control Unit (T9RK**)................................................................... 112
8.1.2 Operation &Display Unit (T9PN**) ....................................................... 114
8.1.3 User Media Drive Unit (FDU2) .............................................................. 118
8.1.4 Portable MPG Box ................................................................................... 119
8.1.5 Manual Pulse Generator (MPG) (OLM–01) ........................................... 120
8.1.6 Spindle Encoder (SPG) (NE–1024) ......................................................... 121
8.1.7 W905 Cable Connection .......................................................................... 122
8.1.8 Encoder Backup Battery Box.................................................................. 123
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Page
8.2 Recommended Cable Drawings ························································· 125
8.2.1 Main Control Unit Power Cable: Cable Name W907 .......................... 125
8.2.2 DC Power Output Cable: Cable Name W903 ...................................... 126
8.2.3 Panel communication and Vide Signal Output: Cable Name W901... 127
8.2.4 RS232C Cable in Cabinet ··· Cable Name W905 ................................... 128
8.2.5 CNC - Servo Communication Cable: Cable Name W906 .................... 129
8.2.6 Position Detector Cable (Serial Absolute Encoder): Cable Name W938 ......... 130
8.2.7 SPG Cable: Cable Name W911/W934 .................................................. 131
8.2.8 User Media Disk Communication Cable: Cable Name W912............. 133
8.2.9 CNC - Spindle Drive Unit Communication Cable: Cable Name W933 ........... 134
8.2.10 NPN1 I/O Cable: Cable Name W914.................................................... 135
8.2.11 Recommended Cable: Twisted Cable (Made by Tachii Electric Wire) ........ 136
8.2.12 Recommended Cable: Twisted Cable (Made by Bando Electric Wire) ........ 137
8.2.13 Recommended Cable: Twisted Cable (Made by Shinko Electric Industries) ..... 138
8.2.14 Recommended Cable: 10C Cable (Made by Tachii Electric Wire)......... 139
8.2.15 Recommended Cable: 10C Cable (Made by Shinko Electric Industries) ..... 140
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STE 73843
1. General Descriptions
This instruction manual describes the electrical and structural specifications for
connecting the TOSNUC 92 system for the machine tools.
Table 1.1.1 Models
Model Abbreviation Relevant machine tool
TOSNUC 92–M T–92M Milling
TOSNUC 92–L T–92L Lathe
This manual describes the main control unit, the operation & display unit, and wiring,
among the system configuration in Section 2.1.
For the Servo drive units, servo motors and the machine I/O modules, only the part
relating to the main control unit is described in this manual.
For details, see respective manuals provided separately.
Table 1.1.2 Instruction Manuals relating this connection manual
Servo Connection Manual
for AS/AW/AP/SS/RE/GP/RU series
ST73953
(STE73953)
Servo Connection Manual
for AM/SU series
ST73899
(STE73899)
Instruction Manual for Distributed I/O Modules
TR64DIRYS-1/TR64DIRYSSRA/TR64DIRYSSRB
ST73880
(STE73880)
Instruction Manual for Distributed I/O Module
TR96DIRY
ST73885
(STE73885)
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STE 73843
2. Configuration
2.1 System Configuration
Generally, a system utilizing the New TOSNUC CNC system is configured as shown
in Fig 2.1.1.
Servo
amplifier
Operation
panel
Pendant
interface
Machine
operation box
Main unit
Power drive
control circuit
PLC
Distributed
I/O Module
Spindle
amplifier
Relay connector
Cabinet
Machine tool
Sensor actuator
Servo
motor
Spindle
drive motor
TOSNUC
MPG
External device
Power
supply
Switchboard
Operation box
Encode
r
Fig. 2.1.1 System configuration
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STE 73843
2.2 Configurations of Units
2.2.1 Main Control Unit
Table 2.2.1
Name Type Printed
board
Function
Main rack
(2 slots)
T9RK2S NBP1 without Option slot
Main rack
(3 slots)
T9RK3S NBP2 with one(1) Option slot
Main power
supply
module
T9PW2 Power supply for Main rack
Inputs (Touch sensor, Stroke limit, Door interlock etc.)
Outputs (Servo on, Brake release etc.)
Power-on/off, EMG-reset/stop push button/LED
Main
module
T9NC1 NNC1 Main CPU, PLC CPU
Communications with Distributed I/O modules
NBM1 Battery backup memory for main CPU and PLC CPU
NPR1 Display control
Communications with Operation & Display unit
Communications with Media drive
RS232C interface
Servo
module
T9SV1 NSI1 Servo control (maximum 4 axes)
Communications with Servo drive units
Communications with Encoders
NNS1 Communications with Mitsubishi Spindle drive
SPG input
CNC
SHAPE
NSH1 Mounted in the Main module
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STE 73843
2.2.2 Operation & Display Unit
Table 2.2.2
Name Type Printed board Function
Horizontal type
Operation & Display
unit
T9PN1H
/ T9PN2H
/ T9PN3H
NPN1 Panel I/O & keyboard control
Display signal interface
MPG interface
NKY1 Function keyboard
NKY2 Key keyboard (Horizontal type)
TFT display & Inverter (NL6448BC-54)
Vertical type
Operation & Display
unit
T9PN1V
/ T9PN2V
/ T9PN3V
NPN1 Panel I/O & keyboard control
Display signal interface
MPG interface
NKY1 Function keyboard
NKY3 Key keyboard (Vertical type)
TFT display & Inverter (NL6448BC-54)
Table 2.2.3 Keyboard Language
T9PN1H / T9PN1V Japanese
T9PN2H / T9PN2V English
T9PN3H / T9PN3V Korean
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STE 73843
2.2.3 User Media Drive Unit
Table 2.2.4
Name Type Printed board Function
User Media drive unit
( Compact Flash card
and Floppy disk )
FDU2B CFC2 Communications with Main rack
Compact Flash card and Floppy
disk interface
User Media drive unit
( Compact Flash card
only )
FDU2C CFC2 Communications with Main rack
Compact Flash card interface
2.2.4 Machine Input/Output Module (PLC)
Table 2.2.5
Type Function
TR64DIRYS-1 Input: 32 points (24VDC inputs)
Output: 32 points (Relay outputs)
TR96DIRY Input: 48 points (24VDC inputs)
Output: 48 points (Relay outputs)
Note: I/O modules shown in Table 2.2.5 are mainly used with this CNC system.
Also other type of I/O modules are available.
See respective manuals for distributed I/O instruction or contact us for details.
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STE 73843
2.2.5 Servo Drive / Power Supply Unit
Table 2.2.6
Name Type Instantaneous maximum output current
[ADC]
Servo Power supply unit SS101 100
SS161 160
Table 2.2.7
Name Type Rated output current [Arms]
Servo Drive unit AS14 14
1 - axis type AS28 18
AS42 42
AS56 56
AS85 85
AS86 86
Table 2.2.8
Name Type Axis Rated output current [Arms]
Servo Drive unit AW28 1st. 14
2 - axes type 2nd. 14
AW42 1st. 14
2nd. 28
AW56 1st. 28
2nd. 28
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STE 73843
Table 2.2.9
Name Type Axis Rated output current [Arms]
Servo Drive unit AP28 1st. 14
with Built-in Power supply 2nd. 14
2 - axes type
Table 2.2.10
Name Type Remark
Regenerative Resistor unit RU09 for AP28A
for Power supply unit RU10 for SS161A
RU12 for SS101A
Note: Units shown in Table 2.2.6 to Table 2.2.10 are mainly used with this CNC system.
Also other type of units available.
See Servo drive instruction manuals or contact us for details.
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STE 73843
2.3 Selective Specifications
This CNC system provides variations for the main control unit, operation & display
unit, machine I/O, and servo system.
Selective specifications and cautions are described in this section.
2.3.1 Main Control Unit
Two (2) types of the main control units as shown in Table 2.3.1 are available.
These units are designed for systems of up to four (4)-axis control.
The set position of each module should be as shown in Fig.2.3.1.
Table 2.3.1
Type Number of slots
(except Power-Module slot)
T9RK2S 2 (No option slot)
T9RK3S 3 (One(1) option slot)
CNDC
CNOP
CNIP
CNP1
CNAC
POWER-ModuleMAIN-Module
CNPC CNCF CNBT
CNPN CNFD PORTA
SERVO-Module
CNSP
CNSC
CNFB4
T9SV1
CNFB3 CNFB2 CNFB1
CNSV4 CNSV3 CNSV2 CNSV1
T9NC1 T9PW1
CNDC
CNOP
CNIP
CNP1
CNAC
POWER-ModuleMAIN-ModuleSERVO-Module
CNPC CNCF CNBT1
CNPN CNFD CNRS
CNSP
CNSC
CNFB4
T9SV1 T9NC1 T9PW2
CNFB3 CNFB2 CNFB1
CNSV4 CNSV3 CNSV2 CNSV1
Option-Module
T9RK2S T9RK3S
Fig. 2.3.1
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STE 73843
2.3.2 Operation & Display Unit
The operation & display units are shown in Table 2.3.2.
Select one of them.
All of them include a Keyboard, a TFT display and control boards.
Table 2.3.2
Type Layout
Keyboard
Language
T9PN1H Japanese
T9PN2H Horizontal English
T9PN3H Korean
T9PN1V Japanese
T9PN2V Vertical English
T9PN3V Korean
F1 F2 F3 F4 F6 F7 F8AUX
$
F9 F10
{ }
[ ]
:( ) ,
;
7 8 9
4 ６５
1 2 3
– 0
<>?
‘ %&
! “ #
*
=
A B C D E F
HI J KL N
OP QRS T U
VW
ON/OFF ON/OFF
@
+
X Y Z
G
M
POS OFSET
PROG DGNOS
RESET
ALL
CLEAR
SHIFT
EDIT
PROG
DATA
EDIT
SHIFT
PAGE
PAGE
MODAL DATA PARAM
DSP TBL
SPACE
FILE SUBDSP
CHG ESC
DEL
PERIOD
CMD
WINDOW
REP
ALT
/
WIND CHG
WIND POS
PREV
ATN
BS
HELP
NEXT YES
NO
F5
DSP TBL MODAL DATA PARAM CMD ALL
PRGM P OSN OFFSET DGNOS ATTN CLEARRESET
F9 F10
SPACESHIFT
WIND POSN
NO
YES
NEXT
BS
PREV
ALT
WINDOW
PERIOD
DEL
ESC
SUBDSPFILE
PAGE
PAGE
SHIFT
EDIT
DATA
EDIT
ON/OFF
ON/OFF CHANG E
REPL
HELP
PRGM
WI ND C HG
Horizontal type Vertical type
Fig. 2.3.2
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STE 73843
2.3.3 User Media Drive Unit
The customers can use User Media drive unit in order to load/dump programs and
some other data.
Table 2.3.3
Type Media
FDU2B Compact Flash card
Floppy disk
FDU2C Compact Flash card
2.3.4 Machine Input/Output Module (PLC)
This CNC system uses a built-in PLC system. The Main module includes PLC
controller. The Main module is connected to distributed I/O modules by the serial
communication cables. TC200 series distributed I/O modules can be used.
The I/O modules mainly used are shown in Table 2.3.4.
Table 2.3.4
Type
(Number of I/O points)
Input type Output type Control power
TR64DIRYS-1
(32 / 32) 24VDC Relay
(24VDC/100VAC) 24VDC
TR96DIRY
(48 / 48) 24VDC Relay
(24VDC/100VAC) 24VDC
Note: See respective instruction manuals for details. PLC functions, TC200 series I/O
modules instruction manuals are provided separately.
– 20 –