Service Manual
L3 Digital Cutter
Keep it in a safe place for future use!
Original operating manual
Software/Firmware version: FW 1.59
Creation date: 09-2014
2
Contents
Contents
1 Introduction.......................................................................................................................................5
1.1 Foreword........................................................................................................................................... 5
1.2 Structure of the service manual....................................................................................................... 5
1.3 Current status of the documentation................................................................................................ 5
1.4 Legal notice...................................................................................................................................... 5
1.5 User level..........................................................................................................................................6
1.6 User level passwords....................................................................................................................... 6
2 Tools, materials and settings......................................................................................................... 7
2.1 Operating resources......................................................................................................................... 7
2.2 List of tools....................................................................................................................................... 9
3 Maintenance list............................................................................................................................. 13
3.1 Identification of maintenance work................................................................................................. 13
3.2 List...................................................................................................................................................14
4 Covers..............................................................................................................................................17
4.1 Foreword......................................................................................................................................... 17
4.2 Overview of covers......................................................................................................................... 17
4.3 Remove the beam covers (A1-A3).................................................................................................20
4.4 Upper covers.................................................................................................................................. 22
4.5 Lower cover plates......................................................................................................................... 26
4.6 Removing the basket (A16)............................................................................................................31
4.7 Removing the control panel........................................................................................................... 33
4.8 Remove front side support (A17)................................................................................................... 37
5 Lubrication diagram....................................................................................................................... 41
5.1 Cleaning the X axis guide rails...................................................................................................... 41
5.2 Oiling the X-axis guide rails........................................................................................................... 43
5.3 Cleaning/oiling Y axis guide rails................................................................................................... 48
6 Side support................................................................................................................................... 49
6.1 Loosen synchronous shaft..............................................................................................................49
6.2 Insert/remove synchronous shaft....................................................................................................49
6.3 Fitting/removing the X axis guide carriage..................................................................................... 55
6.4 Replacing the drive belt..................................................................................................................63
6.5 Replace the X encoder sensor.......................................................................................................69
6.6 Replacing the X motor....................................................................................................................73
6.7 Replacing the X-axis fork light barrier............................................................................................ 84
6.8 Align the beam to be parallel......................................................................................................... 86
6.9 Recalibrating "cogging"...................................................................................................................98
7 Beam.............................................................................................................................................. 101
7.1 Fitting/removing Y toothed belt.....................................................................................................101
7.2 Fitting/removing the Y axis drive.................................................................................................. 112
7.3 Replacing the Y axis motor.......................................................................................................... 121
7.4 Replacing the module carriage wipers......................................................................................... 131
3
Contents
7.5 Replacing the module carriage linear ball bearing unit................................................................ 134
7.6 Replacing the Y-axis fork light barrier.......................................................................................... 142
8 General mechanics.......................................................................................................................145
8.1 Subsequent change of location.................................................................................................... 146
8.2 Leveling the cutter........................................................................................................................ 150
9 Table plate.....................................................................................................................................155
9.1 Leveling the table plate................................................................................................................ 155
10 ITI..................................................................................................................................................161
10.1 Set ITI......................................................................................................................................... 161
10.2 Initialize ITI..................................................................................................................................162
11 Vacuum system.......................................................................................................................... 167
11.1 Vacuum zones............................................................................................................................ 167
11.2 Vacuum valves and boards........................................................................................................ 169
11.3 Possible tests..............................................................................................................................173
11.4 Performing the running-in procedure..........................................................................................173
12 Safety device.............................................................................................................................. 175
12.1 Note for the presentation conventions....................................................................................... 175
12.2 Overview of the light barriers..................................................................................................... 176
12.3 Replacing the left light barriers.................................................................................................. 178
12.4 Replacing the right light barriers................................................................................................ 179
12.5 Setting the light barriers............................................................................................................. 180
13 Electrical system/electronics.................................................................................................... 183
13.1 Electrostatic discharge (ESD).....................................................................................................183
13.2 Description.................................................................................................................................. 184
13.3 Start-up....................................................................................................................................... 194
13.4 Boards.........................................................................................................................................197
13.5 Connecting options to the P-box................................................................................................ 308
13.6 Vacuum generator...................................................................................................................... 310
14 Firmware update.........................................................................................................................311
14.1 Firmware update with ServiceTool............................................................................................. 311
14.2 Firmware update using interface................................................................................................ 312
15 Pneumatics..................................................................................................................................325
15.1 Requirements..............................................................................................................................325
15.2 Basic service unit........................................................................................................................325
16 Layouts........................................................................................................................................ 327
16.1 Contents......................................................................................................................................327
16.2 Pneumatics................................................................................................................................. 328
16.3 Electrical system/electronics.......................................................................................................330
4
Introduction
1 Introduction
1.1 Foreword
Dear customer,
Provide maintenance and service personnel with Volume 2 "Service manual" if required.
Work which is described in this manual must only be carried out by authorised service personnel.
Contact
Zünd Systemtechnik AG
Industriestrasse 8
CH - 9450 Altstätten
Tel: +41 71 757 8181
Fax: +41 71 757 8191
info@zund.com
www.zund.com
1.2 Structure of the service manual
The service manual consists of separate chapters that are numbered consecutively.
The table of contents provides information on the structure of the individual chapters.
1.3 Current status of the documentation
To ensure that the documentation is complete and up-to-date at all times:
• do not remove parts of the documentation
• request copies of missing or illegible pages from the manufacturer, or download them from the
Zünd homepage and print them out
• if any new documentation is provided as a result of conversions taking place, file it immediately
• if the documentation is modified, file the new versions and destroy the old copies
• if the documentation exists in more than one language, ensure that all languages are kept up to
date
1.4 Legal notice
The information in this publication is intended for informational purposes only and is subject to change
without notice. This does not however constitute an obligation on the part of Zünd Systemtechnik AG.
No part of this document may be copied, distributed, used or disclosed to third parties without express
permission. Offenders will be liable for damages.
5
Introduction
1.5 User level
Access to menus and functions is blocked depending on the user level. The user levels have a
hierarchical structure. This means that the next highest user also has access rights to the menu
functions of the subordinate user.
Tip:
Preferably, for service and installation work on the cutter swap to user level"Service".
User level
Description
Users 1 - 3
All menus and functions needed for the operation of the machine are
accessible
Operator
Simple, uncomplicated adjustments can be made
Service
Cutter settings that may only be adjusted by authorized service
personnel
Factory
-
A Switch to4-2 Passwordmenu
B Enter your user code
Results
The user level is approved and is displayed under4-1 User level.
1.6 User level passwords
User level
Password
User 1
6
User 2
12
User 3
123
Operator
9450
Service
240360
Tools, materials and settings
2 Tools, materials and settings
2.1 Operating resources
2.1.1 Using operating resources
Diligent observance of the instructions for handling of operating resources will increase the machine's
reliability and extend its service life.
Follow the regulations for using chemicals, particularly cleaning fluid, lubricants and adhesives. (See
chapter "Safety")
Environmental protection
• Always take care to protect the environment
• Observe the disposal regulations applicable in your country
• Dispose of spent operating resources correctly
Disposal
This concerns spent materials such as lubricants, adhesives, water/oil mixtures (maintenance
unit) and all devices that came into contact with these materials.
• Observe the rules on environmental protection when disposing of spent materials.
• Collect and store all spent materials separately in suitable containers and dispose of them in
an environment-friendly manner and only at official sites.
• Observe national regulations!
2.1.2 Cleaning agents
Caution:
The use of incorrect cleaning agents not approved by Zünd will damage the machine.
Only use cleaning fluids recommended by Zünd Systemtechnik.
Do not use abrasive cleaning agents. Caustic substances and scouring agents can damage
surfaces of the cutter (e.g. operating unit).
Cleaning agents
Place of use
Plastic cleaning agent
Covers, metal parts
7
Tools, materials and settings
2.1.3 Lubricants
X/Y axis guide rails, bearings
This machine uses a specially adapted synthetic lubricating oil that is also used in the food and
pharmaceutical industries. This features impressive resistance to water and protection against
corrosion and can be used at a temperature range of between -25 °C and +120 °C.
Name
Specification
®
Klüberoil
4UH1
Gears
To lubricate the gears, a Teflon special grease is used for precision gears in order to reduce friction.
Name
Specification
Fin Grease MP 2/3
-
2.1.4 Adhesives
Screw locking
Only use adhesives for screw locking if this is specifically stipulated in the service manual.
8
Name
Specification
Loctite
243
Tools, materials and settings
2.2 List of tools
Image
Description
Use
Various Allen keys (SW 1.5 to 6)
Various open-ended spanners (SW
5.5-19.2x10)
various Phillips and slotted screwdrivers
Torx keys T10, T25, T30
Ratchet set with bolt nuts and Allen inserts
Gaffer tape
9
Tools, materials and settings
Image
Description
Use
Mounting bridges and screws for fastening
rotor
For working on the X motor
External gear clamp (at least 2 arms)
For pulling off bearings at X
drive
Hook wrench
For working on the X drive
Feeler gauge
Lever gauge with dial gauge holder
(resolution of 0.1 mm)
10
For adjustment work on Y
drive
Tools, materials and settings
Image
Description
Use
Dial gauge (resolution of 0.1 mm)
For aligning table plate
Dial gauge support
For aligning table plate
Bar adjusting gauge
For adjusting bar parallelism
Precision spirit level (recommended 0.05
mm/m)
To level the machine
Adjusting gauge
To level the machine
To align the ITI
11
Tools, materials and settings
Image
12
Description
Use
Tension meter, Sonic 507-CUIKER
RUD.AGhttp://www.uiker.ch
For measuring belt tension on
X- and Y-drives
Lubricating set (order no. 5105269)
To lubricate the X-guide
bearings
Maintenance list
3 Maintenance list
3.1 Identification of maintenance work
Different types of symbols (circle, box, star - solid; circle, box, star - outline) divide the service and
maintenance tasks into two groups.
Outline symbols: , ,
• Authorized service personnel of Zünd Systemtechnikcarry out these service and maintenance
tasks.
Solid colored symbols: , ,
• Service and maintenance tasks are the individual responsibility of the company operating the
machine or its operatingpersonnel.
13
Maintenance list
3.2 List
Note:
If necessary, carry out work before the stated intervals.
Change worn parts before the specified intervals as well.
Work/inspections to be carried out daily
General
Visually check the machine for damage
Free the machine of dust and processing residue
Check electrical equipment (options) to ensure they function
Check correct functioning of the emergency stop switch
Check all safety devices (correct functioning of light barriers, protective trip switch)
Check function of lighting strip
Work/inspections to be carried out monthly
X axis drive, direct drive
Clean and oil guide rails / guide carriage
Y axis drive
Clean and oil the guide rails Further information can be found in chapterClean/oil Y-axis guide
rails.
Vacuum generator 1-9 kW / 1-15 kW
Clean the filter. Further information can be found in chapterReplacing the vacuum turbine filter.
Maintenance unit
Draining condensation water
Work/inspections to be carried out yearly
General
Check correct functioning of the emergency stop switch
Check all safety devices (correct functioning of light barriers, protective trip switch)
Check function of lighting strip
Table complete
Check all screw connections and tighten according to requirements, if necessary
Check leveling
14
Maintenance list
Check cabling/wiring and cable routing for signs of wear
Check air connections/pneumatics for leaks
Vacuum plate
Check leveling and adjust if required
Check the correct functioning of the vacuum zone control
Beam
Check perpendicularity and align if required
Check length compensation
X axis drive, direct drive
Clean and oil guide rails / guide carriage
Check tension of toothed belt is correct and readjust if necessary
Check alignment of toothed belt is correct and readjust if necessary
Clean the drive belts
Clean the drive and guide rollers
Y axis drive
Clean and oil the guide rails Further information can be found in chapterClean/oil Y-axis guide
rails.
Check alignment of toothed belt and readjust if necessary
Check tension of toothed belt and readjust if necessary
Check if tension of motor belt is correct and readjust if necessary
Module carriage
Check play, replace bearing if necessary
Replace wiper
Vacuum generator 1-9 kW / 1-15 kW
Check functionality
Clean the filter. Further information can be found in chapterReplacing the vacuum turbine filter.
Check piping for damage and tightness
General inspection
Maintenance unit
Draining condensation water
Tasks/inspections at special intervals
Beam
Clean and oil guide rails / guide carriage
X axis drive, direct drive
Clean and oil guide rails / guide carriage
15
Maintenance list
Vacuum generator 1-9 kW / 1-15 kW
Clean the grid. Further information can be found in chapterReplacing the vacuum turbine
filter.
6000
General inspection
operating
hrs.
16
Covers
4 Covers
4.1 Foreword
This section describes the removal of the covers. In the overview there is a list of which covers are
removed during specific tasks.
Danger:
Danger of cutting injuries
The covers may have sharp edges.
Extreme caution is required when handling the covers.
Caution:
Beware of large and heavy covers
The covers can be heavy and not ergonomic, which can lead to back injuries if handled by one
person only.
Extra help is needed when handling the covers.
Note:
Assembling the covers incorrectly can damage the machine.
Always attach the covers correctly!
If possible, screw on the covers!
Before initial operation of the machine, manually move the beam and the carriage back and forth.
4.2 Overview of covers
Tip:
The covers are labeled with the letter "A" and a number in the following diagrams.
This labeling is the same throughout the entire manual.
4.2.1 Covers tasks
The following table is an excerpt of the tasks carried out with the covers removed
Item
Use
Fit/remove X-drive unit
A4 - A8
Fork light barrier for the X-axis
17
Covers
Item
Use
Fit/remove X toothed belt
Fit/remove X-guide carriage
A6, A7
Align the beam to be parallel
Fit/remove Y toothed belt
A1 - A3
Fit/remove Y drive
Fork light barrier for the Y axis
A9
Power box
A11
Electronics unit
A15
Maintenance unit
A9 - A14
Vacuum system
4.2.2 L3 C-40
18
Covers
Figure 1: Overview of L3 C-40 covers
Figure 2: Overview of L3 C-40 covers
19
Covers
4.3 Remove the beam covers (A1-A3)
Tip:
Covers A1/A2/A3 also have Velcro® fasteners.
Remove cover A1
A Remove the screws (item 3) (x2)
B Pull the cover (A1) upwards and remove
20
Covers
Remove cover A2
Tip:
Manually push the carriage back and forth to enable you to pull the cover out.
A Remove the screws (item 2) (x2)
B Pull the cover (A2) upwards and remove
Remove cover A3
Tip:
Manually push the carriage back and forth to enable you to pull the cover out.
A Remove the screws (item 1) (x2)
B Pull the cover (A3) upwards and remove
21
Covers
4.4 Upper covers
4.4.1 Disassemble the front cover plates (A4, A5)
Position the operating unit so that disassembly of the cover is possible.
Note:
Disassemble both front cover plates simultaneously. The example shows the left side only.
The sequence of the screws to be loosened must be followed.
A Loosen the inner screw (item 1).
A magnet holds the cover plate (item 3) in position.
B Unscrew both outer screws (2).
C Remove the cover plate (item 3)
4.4.2 Dismantle left cover (A6)
Note:
The synchronous shaft is depicted with partial transparency in the diagram to make it easier to
see the whole diagram.
22
Covers
This does not need to be removed for disassembly of the cover.
A Unlock the emergency stop switch from below and unplug.
B Remove the screws (item 3) and washers (item 2) from the fixing brackets (item 1) (4x).
C Remove the cover.
23
Covers
4.4.3 Dismantling the rear cover (A7)
A Unscrew the screws (item 1) (L3 C-40 10x)
B Remove the screws and washers (item 1+2) (L3 C-40 10x).
C Lift the cover plate, pull it out to the rear and remove it.
24
Covers
4.4.4 Dismantle right cover (A8)
A Unlock the emergency stop switch from below and unplug.
B Remove the screws (item 3) and washers (item 2) from the fixing brackets (item 1) (4x).
C Remove the cover.
25
Covers
4.5 Lower cover plates
4.5.1 Disassemble the front cover plate (A10)
Note:
Disassembly is the same for all three front cover plates.
A Fold the cover plate downward and outward.
B Lift the folded cover plate up at an angle.
C Pull out the cover plate and remove it.
26
Covers
4.5.2 Open the power unit (A9)
Danger:
Risk of death due to electrical voltage
Work on the electrical system may be carried out with the power disconnected only.
• Disconnect from mains
• Secure against reconnection
• Verify that no voltage is present
• Cover or shield any live adjacent parts
1
Cover
2
Screws
A Remove cover A9.
B Remove the screws.
C Lift and remove the cover.
27
Covers
4.5.3 Open the electronics unit (A11)
1
Cover
2
Screws
A Remove cover A11.
B Remove the screws.
C Lift and remove the cover.
28
Covers
4.5.4 Dismantling the lateral cover plates (A12, A14)
Note:
Disassembly is the same for all side covers.
A Loosen the screws (item 1) (4x)
B Fold the cover plate outward.
C Pull the cover plate upward at an angle, pull out and remove it.
29
Covers
4.5.5 Disassemble the rear cover plate (A13)
Caution:
For large and heavy covers
The covers are heavy and not ergonomic, which can lead to back injuries if handled by one
person only.
Extra help is needed when handling the covers.
A
B
C
D
30
Loosen the screws (item1) (4x).
Hold the covers on the openings (item 2) and lift them up.
Fold the cover plate outward.
Pull the cover plate upward at an angle, pull out and remove it.
Covers
4.6 Removing the basket (A16)
Caution:
For large and heavy covers
The covers are heavy and not ergonomic, which can lead to back injuries if handled by one
person only.
Extra help is needed when handling the covers.
4.6.1 Preparatory tasks
A Remove A6 (Dismantle left cover (A6) on page 22)
B Remove A7 (Dismantling the rear cover (A7) on page 24)
C Remove A8 (Dismantle right cover (A8) on page 25)
4.6.2 Unplugging the light strip
The light strip is installed in the rear part of the basket. Before dismantling the basket, the cabling must
be removed from both sides of the light strips.
1
Shielding bracket
3
right plug
2
left plug
4
Shielding bracket
A Remove the shielding bracket
B Unplug the plug side.
C Repeat the procedure on the other side.
31
Covers
4.6.3 Loosening and removing the basket
1
Screw
2
Washer
3
Basket
A Remove the screws and washers.
B Remove the basket.
32
Covers
4.7 Removing the control panel
For some tasks in the area of the front drive it is necessary to remove the control panel.
4.7.1 Removing the operating unit
Note:
Risk of damage to the operating unit
• The operating unit can be damaged or scratched during removal.
Do not use any objects with sharp edges or points to remove the operating unit.
The operating unit can be pushed out of the bracket from below with your fingers.
1
Control panel
2
Operating unit
A
B
C
D
Push the operating unit out of the bracket from its front side.
Remove the plug from the operating unit.
Loosen the locking mechanism on the emergency stop switch and remove the cable.
Put the operating unit aside.
33
Covers
4.7.2 Removing the cable covers
1
Control panel
2
Screw
3
Cable covers
A Remove the screws.
B Remove both cable covers.
34
Covers
4.7.3 Loosen the cable attachments
Note:
Risk of damage to the cables
• The cables can become damaged when removing the cable ties.
When separating the cable tie, make sure that no cables are damaged.
1
Cable clamp
2
Cable attachment with cable tie
3
Control panel
A
B
C
D
Remove the screw on the cable clamp.
Remove the cable clamp.
Sever and remove the cable ties.
Pull back the cable to the energy chain, roll it up and secure it with cable ties.
35
Covers
4.7.4 Unhook the control panel
1
Screw and washer
2
Control panel
3
Screw and washer
A Remove the screws and washers (item 3) on both sides.
B Unscrew the screws on both sides (item 1).
C Lift the control unit parallel and pull it out.
36
Covers
4.8 Remove front side support (A17)
4.8.1 Preparatory tasks
Remove the control panel (Removing the control panel)
4.8.2 Loosen the cable attachments
Note:
Risk of damage to the cables
• The cables can become damaged when removing the cable ties.
When separating the cable ties, make sure that no cables are damaged.
1
Cable attachment with cable tie
2
Screws and washers
3
Angle bracket
A
B
C
D
Sever and remove the cable ties.
Remove the screws and washers.
Swing the loose angle bracket downward.
Pull back the cable to the energy chain, roll it up and secure it with cable ties.
37
Covers
4.8.3 Removing the mounting plate
1
Screw and washer
2
Mounting plate
3
Angle bracket
A Remove the screws and washers (8x).
B Remove the mounting plate.
38
Covers
4.8.4 Remove the side support
1
Screws and washers
2
Side support
A Remove the screws and washers (6x).
B Remove the side support.
39
Covers
40
Lubrication diagram
5 Lubrication diagram
Lubricate all lubricating points indicated in the lubrication diagram in accordance with the specified
maintenance intervals.
®
The machine is lubricated usingKlüberoil 4UH1 .
5.1 Cleaning the X axis guide rails
The beam is mounted on each side on a guide rail. Clean these guide rails at intervals according to
the maintenance list!
5.1.1 Tools and materials
•
•
Lubricant for guide rails, bearings
clean, lint-free cloth
5.1.2 Preparatory tasks
A Switch off the cutter at the main switch.
B Remove the following covers:
• A4 and A5
• A7 and A8
41
Lubrication diagram
5.1.3 Cleaning the guide rails
A
B
C
D
42
Thoroughly clean the entire length of the guide rails using a lint-free cloth.
Soak a lint-free cloth with lubricant for guide rails / bearings and oil the guide rails.
Carry out this process on both sides.
Install all covers.
Lubrication diagram
5.2 Oiling the X-axis guide rails
The beam is mounted with 2 guide bearings on each side of a guide rail. Oil these bearings at
intervals according to the maintenance schedule!
5.2.1 Tools and materials
•
•
Lubricant for guide rails, bearings
Lubricating set for guide rails, guide bearing, X-axis (item no.: 5105269)
5.2.2 Preparatory tasks
A Switch off the cutter at the main switch.
B Remove the following covers:
• A4 and A5
• A7 and A8
43
Lubrication diagram
5.2.3 Mounting the rear lubricating set
1
Guide rail
2
Hollow screw
3
Steel belt
4
Lubricating set
A Position the lubricating connection of the lubrication set under the steel belt and position so that
both guide carriages can be lubricated.
B Mount the lubrication set as shown.
C Tighten the hollow screw with an Allen key.
44
Lubrication diagram
5.2.4 Lubricate the rear lubrication points
1
Feed line
2
right guide carriage
3
left guide carriage
A
B
C
D
E
F
G
H
I
Press the syringe until the feed line is ventilated.
Position the right guide bearing above the lubrication connection.
Use the syringe to insert approx. 1 ml of oil into the guide bearing.
Move the beam forward and backward 10 times over the length of the guide carriage above the
lubrication connection.
Use the syringe to extract excess oil.
Press the syringe until the feed line is ventilated.
Position the guide bearing above the lubrication connection.
Repeat steps C to E.
Dismantle the lubricating set.
45
Lubrication diagram
5.2.5 Mount front lubricating set
1
Guide rail
2
Hollow screw
3
Steel belt
4
Lubricating set
A Push the beam all the way to the right.
B Position the lubricating connection of the lubrication set so that both guide carriages can be
lubricated.
Note:
Feed the lubricating connection under the steel belt.
C Mount the lubrication set as shown.
D Tighten the hollow screw with an Allen key.
46
Lubrication diagram
5.2.6 Lubricate the front lubrication points
1
right guide carriage
2
Feed line
3
left guide carriage
A
B
C
D
E
F
G
H
I
Press the syringe until the feed line is ventilated.
Position the right guide bearing above the lubrication connection.
Use the syringe to insert approx. 1 ml of oil into the guide bearing.
Move the beam forward and backward 10 times over the length of the guide carriage above the
lubrication connection.
Use the syringe to extract excess oil.
Press the syringe until the feed line is ventilated.
Position the guide bearing above the lubrication connection.
Repeat steps C to E.
Dismantle the lubricating set.
5.2.7 Final task
Refit and secure all covers.
47
Lubrication diagram
5.3 Cleaning/oiling Y axis guide rails
A
B
C
D
E
48
Switch off the cutter at the main switch.
Remove covers A2 and A3.
Clean the entire length of the guide rails using a lint-free cloth.
Soak a lint-free cloth with lubricant for guide rails / bearings and oil the guide rails.
Reinstall all covers.
Side support
6 Side support
6.1 Loosen synchronous shaft
For certain work it is sufficient if the synchronous shaft coupling is loose on one side.
Thus complete disassembly of the synchronous shaft is not necessary.
6.1.1 Preparatory tasks
Remove cover A6.
6.1.2 Loosen coupling on one side
Tip:
Which of the two couplings is open is not relevant.
Unscrew both screws (1).
6.2 Insert/remove synchronous shaft
6.2.1 Preparatory tasks
Remove cover A6.
49
Side support
6.2.2 Dismantling
6.2.2.1 Coupling open
Caution:
Risk of damage to the coupling
After removal of the coupling half shell, the synchronous shaft can swing down and thus damage
the coupling on the other side.
Hold the coupling horizontal after loosening the coupling half shell.
1
Screws
2
Coupling half-shell
A Unscrew both screws (3).
B Unscrew and remove both screws (1).
C Remove the coupling half shell.
50
3
Screws
Side support
6.2.2.2 Extending the synchronous shaft
Caution:
Risk of damaging the coupling by swiveling too far.
Extend the synchronous shaft as flat as possible.
1
left X-axis bearing
3
Synchronous shaft
2
Shaft
4
right X-axis bearing
A Push the synchronous shaft to the right.
B Slightly swing out the synchronous shaft and extend it carefully.
51
Side support
6.2.3 Assembly
6.2.3.1 Retracting the synchronous shaft
Caution:
Risk of damaging the coupling by swiveling too far.
Retract the synchronous shaft as flat as possible.
1
left X-axis bearing
3
Synchronous shaft
2
Shaft
4
right X-axis bearing
A Push the synchronous shaft as flat as possible onto the right drive shaft.
B Align the synchronous shaft horizontally and against the left shaft.
C Push the synchronous shaft slightly to the left.
52
Side support
6.2.3.2 Mounting the coupling half shell
1
Screws
2
Coupling half-shell
3
Screws
A Mount the coupling half shell.
B Insert both screws (3) and loosely tighten them.
C Loosely tighten both screws (1).
53
Side support
6.2.3.3 Centering the synchronous shaft
Note:
Risk of damaging the coupling through tightened screws.
It must be possible to easily move the synchronous shaft.
x
Distance = 22 mm
A Center the synchronising shaft.
B Distancexmust be checked on both sides.
54
Side support
6.2.3.4 Tightening the synchronizing shaft
Note:
Risk of damaging the coupling and the shaft through uneven tightening.
• Tighten the screws evenly.
• DistanceYis to be maintained.
• Tighten the screws with a maximum of15 Nmtorque.
Tip:
Align the synchronous shaft in such a way that there is sufficient space to tighten the screws.
1
Coupling half-shell
3
Coupling
2
Screws
Y
approx. 1.1 mm
A
B
C
D
E
Tighten both screws alternately.
Check distanceYon both sides.
Tighten the screws with a torque of15 Nm.
Before tightening the second coupling, check if the beam is parallel.
Repeat procedures A to C on the other side.
6.3 Fitting/removing the X axis guide carriage
6.3.1 Preparatory tasks
Remove the following covers.
• A7, A8
• Also A16 to simplify work
55
Side support
6.3.2 Replacing the rear guide carriage
6.3.2.1 Removing the rubber buffer
1
Rubber buffer on bracket
2
Screws (2 pcs)
A Remove the screws.
B Remove the rubber buffer with the bracket.
56
Side support
6.3.2.2 Removing the limit stop plates
1
Screws (2 pcs)
2
Limit stop plates
3
Base plate
A Remove both screws.
B Remove the limit stop plates.
57
Side support
6.3.2.3 Removing the guide carriage
1
Screws (2 x 4 pcs)
2
Guide carriage (2 pcs)
A
B
C
D
58
Loosen and remove the screws.
Slightly lift the beam
Move both guide carriages to the right.
Lower the beam and place it on the anchor.
Side support
6.3.2.4 Removing the dirt deflector
Tip:
Reuse the dirt deflector and the screws.
Clean the dirt deflector before remounting.
1
Screws
2
Dirt deflector
3
Guide carriage
A Remove both screws.
B Pull the dirt deflector upward from the guide carriage.
C Clean the dirt deflector.
6.3.2.5 Installation/assembly
Note:
Risk of damage to the new guide carriages.
When retracting the guide carriages along the rails, balls can fall out of the bearings.
Used the plastic piece provided for retraction.
Tip:
The rear guide carriages are floating.
When fastening, make sure that the guide carriage is tightened in the center of the support plate
to continue to ensure longitudinal compensation.
Assembly takes place in the reverse order of disassembly.
59
Side support
6.3.3 Replacing the front guide carriage
6.3.3.1 Removing the rubber buffer
1
Rubber buffer on bracket
2
Screws (4x)
3
Screw
4
Bracket
A
B
C
D
60
Remove the screws (item 2).
Remove the rubber buffer with the bracket.
Remove the screw (item 3).
Remove the bracket.
Side support
6.3.3.2 Removing the guide carriage
1
Screws (2 x 4 pcs)
2
Guide carriage
A
B
C
D
Loosen and remove the screws.
Slightly lift the beam
Move both guide carriages to the right.
Lower the beam and place it on the anchor.
6.3.3.3 Removing the dirt deflector
Tip:
Reuse the dirt deflector and the screws.
Clean the dirt deflector before remounting.
61
Side support
1
Screws
2
Dirt deflector
3
Guide carriage
A Remove both screws.
B Pull the dirt deflector upward from the guide carriage.
C Clean the dirt deflector.
6.3.3.4 Installation/assembly
Note:
Risk of damage to the new guide carriages.
When retracting the guide carriages along the rails, balls can fall out of the bearings.
Used the plastic piece provided for retraction.
Assembly takes place in the reverse order of disassembly.
6.3.4 Final tasks
A Oiling the X-axis guide rails on page 43
B Fitting the covers
C Recalibrating "cogging" on page 98
62
Side support
6.4 Replacing the drive belt
6.4.1 Foreword
Caution:
Danger of cutting injuries
The metal belt can cause cutting injuries.
Extreme caution must be exercised when handling the metal belt.
Note:
Always replace the toothed belts in pairs.
Replacing only one toothed belt can result in damage to the X axis guide carriages and a loss of
quality when working.
6.4.2 Settings
Belt tension
Toothed belt
Frequency in Hz
new
54
run-in (after 60 h)
51 ± 1
Toothed belt movement
Note:
• On new systems, the objective is to not use the full tolerance.
• The minimum distance between the toothed belt and the outer edge of the roller may not be
greater than1.0 mm.
Belt movement across a distance
Deviation in mm
across 500 mm travel path
< 2.0
across entire length
6.0
Movement of the metal belt
Note:
• On new systems, the objective is to not use the full tolerance.
63
Side support
•
The minimum distance between the metal belt and the outer edge of the roller may not be
greater than1.0 mm.
Belt movement across a distance
Deviation in mm
across 500 mm travel path (X=0 and above)
< 2.0
across entire length
6.0
6.4.3 Preparatory tasks
A Remove covers A4 to A8.
B Loosen or remove the synchronous shaft.
6.4.4 Activities
6.4.4.1 Dismantling the belt
Tip:
The belt is dismantled the same way on both sides. However, the procedure is only illustrated
once.
Tip:
Pulling in the string makes the subsequent retraction of the drive belt easier.
64
Side support
1
Belt locking bolt
2
Tensioning screw
A Reduce the belt tension by unscrewing the tensioning screw.
Belt tension is reduced far enough to unscrew the belt locking bolt.
B
C
D
E
Use a screwdriver to pull the belt locking bolt upward.
Rotate the belt tensioning screw fully and remove it.
Attach a string to the metal belt.
Pull he belt out and pull in the string in the same step.
6.4.4.2 Assembling the drive belt
Tip:
Depending on the scope of delivery of the spare parts ordered, a conversion or a completion with
existing parts may be necessary.
1
Toothed belt
5
Drive steel belt
2
Hexagonal screws (4 pcs)
6
Upper section of strap lock
65
Side support
3
Upper section of belt lock
7
Lower section of strap lock
4
Lower section of belt lock
8
Allen screws (4 pcs)
A
B
C
D
E
Loosen and remove the screws.
Dismantle the belt and strap locks.
Replace the toothed belt or steel belt, if required.
Place the toothed belt in the center of the strap and belt locks when assembling.
Tighten the screws.
6.4.4.3 Dismantling the belt
Tip:
Pull in the drive belt by using the string.
1
Bolts
2
Tensioning screw
A
B
C
D
E
F
66
Push the belt through the side support and push it below the work roller.
Fix the steel belt to the belt anchor with the bolts.
Pull the bolts downward until the locking washer is flush to the belt anchor.
Place toothed belt around the drive roller.
Attach the belt locking unit to the belt anchor, fix with the tensioning screw.
Tension belt using tensioning screw.
Side support
6.4.4.4 Moving the bar into position
The beam needs to be placed at an exact distance in order to measure belt tension.
1
Roller axis
2
Pick position
3
Bolts on belt anchor
A Manually push the beam 2-3 times along the entire length.
B Position the beam as shown.
C Set the distance between the bolts on the belt anchor and the middle of the roller as shown in the
diagram.
67
Side support
6.4.4.5 Measuring belt (toothed belt) tension
Tip:
Adjust the tension of the X and Y toothed belts with the tensioning screws.
For belt drives (e.g. Y drive motor), the belt tension is adjusted by altering the distance between
the belt pulleys.
Figure 3: Belt tension meter
Measure the belt frequency (toothed belt) using the belt tension meter (frequency meter).
A Pluck the belt
B Carry out the first measurement
C Perform two additional reference measurements
D Compare the frequency with the value from the table
E If necessary, set to the required tension.
a) Increase belt tension to increase the frequency.
b) Decrease belt tension to decrease the frequency.
F Carry out steps A-D again after adjusting belt tension.
6.4.5 Final tasks
A Align the beam to be parallel on page 86
B Reattach and secure all covers
C Recalibrating "cogging" on page 98
68
Side support
6.5 Replace the X encoder sensor
6.5.1 Preparatory tasks
A Remove covers A5 and A6.
B Removing the synchronous shaft
6.5.2 Dismantling
6.5.2.1 Remove cover
Note:
The measuring ring under the cover is very sensitive.
There must be no magnetic parts in the vicinity of the measuring ring.
Proceed with extreme caution when working on and around the measuring ring.
1
Screws with washers
2
Cover
A Loosen and remove the screws.
B Remove the cover.
69
Side support
6.5.2.2 Removing the X axis encoder
1
Screws
2
X-axis sensor
3
ACS-ENC board
A Remove the screws.
B Remove the X-axis sensor.
C Unplug the encoder plug on the ACS-ENC board (S2).
70
Side support
6.5.3 Assembly
6.5.3.1 Inserting the X axis encoder
1
Screws
2
X-axis sensor
3
Cutting edge
4
ACS-ENC board
A
B
C
D
E
Plug in the encoder plug on the ACS-ENC board (S2).
Position the X-axis sensor with screws.
Push the X-axis sensor upward until it rests against the cutting edge.
Tighten the screws.
Lay the cables and secure them with cable ties, if required.
71
Side support
6.5.3.2 Attach the cover
1
Screws with washers
2
Cover
A Attach the cover.
B Tighten the screws.
6.5.4 Final tasks
A Install the synchronous shaft.
B Align the beam to be parallel on page 86
C Fit and secure all the covers.
72
Side support
6.6 Replacing the X motor
6.6.1 Foreword
Caution:
Risk of crushing when handling the X-motor.
Mount the mounting bridges on the X-motor before starting work
Caution:
Risk of damage to the X motor.
Mount the mounting bridges on the X-motor before starting work
The X motor is equipped with strong permanent magnets that may cause personal injury and damage
the motor if used improperly.
Note:
General notice for exchanging components in the X drive train.
The following components must always be replaced in pairs (both sides) in order to ensure
accuracy of the cutter and a long service life.
• Toothed belt
• Drive roller
6.6.2 Preparatory tasks
A Remove covers A4, A5, A6, A11 and A17.
B Open the electronics unit (A11) on page 28
6.6.3 Dismantling
6.6.3.1 Removing the X motor
Unplug plugs S17 and S18 on the ACS_AMPLIFIER_XBL_BOARD.
73
Side support
6.6.3.2 Disassembling the fan housing
1
Screws with washers
2
Fan housing
A Unplug the plug on the ACS_Amplifier_Board S12.
B Remove the screws (4x).
C Pull out the fan housing upwards.
74
Side support
6.6.3.3 Dismantling the angled plate
1
Angled plate
2
Screws with washers
A Loosen and remove the screws.
B Remove the angled plate.
75
Side support
6.6.3.4 Mounting the mounting bridges
Note:
The mounting bridges hold the motor anchor and rotor at a precise distance from one another
after mounting.
The mounting bridges are included as standard with every machine.
1
Mounting bridge
2
Short screws (M4 x 25)
3
Long screws (M5 x 35)
A
B
C
D
E
76
Position the mounting bridges.
Tighten 2 short screws (item 2) on the stator.
If necessary, turn the rotor until the hole patterns between the mounting bridge and rotor match.
Insert two long screws (item 3) on the rotor and loosely tighten them.
Repeat procedure A-D on the other side.
Side support
6.6.3.5 Loosening the rotor
A Remove the screws (item 1) (6x).
B Tighten the screws (item 2).
77
Side support
6.6.3.6 Removing the motor
1
Motor
2
Screws (8 pcs)
A Remove the screws (8x).
B Remove the motor.
78
Side support
6.6.4 Assembling the X motor
6.6.4.1 Installing the motor
1
Motor
2
Screws (8 pcs)
A Position the motor so that the cables are below it.
B Loosely tighten all screws (8x).
C Tighten the screws crosswise.
6.6.4.2 Securing the rotor
79
Side support
1
Screws (12.9 M5 x 20)
2
Short screws (M4 x 25)
A
B
C
D
80
Match the hole pattern of the rotor to the pattern on the drive shaft.
Loosely tighten all screws (item 1) (6x)
Loosen the screws (item 2)(4x).
Tighten the screws (item 1) crosswise (6x).
Side support
6.6.4.3 Removing the mounting bridges
Tip:
The mounting bridges and corresponding screws should be stored with the machine's
service materials after disassembly.
The mounting bridges are included as standard with every machine.
1
Mounting bridge
2
Short screws (M4 x 25)
3
Long screws (M5 x 35)
A Loosen and remove the screws (8x).
B Remove the mounting bridges (2x).
6.6.4.4 Mount angled plate
81
Side support
1
Angled plate
2
Screws with washers
A Position the angled plate parallel to the side support with the screws.
B Tighten the screws.
82
Side support
6.6.4.5 Mounting the fan housing
1
Screws with washers
2
Fan housing
A Position the fan housing and fix it with the screws.
B Tighten the screws.
C Plug in the fan plug on the ACS_Amplifier_Board S12.
6.6.4.6 Connect X-motor
Plug in plugs S17 and S18 on the ACS_AMPLIFIER_XBL_BOARD.
6.6.5 Final tasks
A Close the electronics unit.
B Reattach and secure all covers
C Recalibrating "cogging" on page 98
83
Side support
6.7 Replacing the X-axis fork light barrier
6.7.1 Foreword
The axis zero mark is recognized by a fork light barrier.
The fork light barrier is located in the area around the zero point. A small plate with a 1 mm wide slot
interrupts the fork light barrier.
Function in normal mode
If the fork light barrier is free, the axis moves toward the zero point at "high" speed. As soon as the
small plate interrupts the beam of light, the speed decreases and the axis moves up to the slot and
detects the beginning/end of it. The center of the two values is the zero point. If the small plate is
already in the light barrier when switched on, the axis starts to move "slowly".
Function in interrupted mode
If the beam of light is interrupted by a foreign object, the control unit moves slowly into the buffer,
changes direction and then moves in reverse to the buffer and remains still without an error message.
Tip:
The fork light barrier is only replaced if defective.
It is not necessary to set the fork light barrier mechanically.
6.7.2 Preparatory tasks
A Remove cover A5.
B Remove the front left wiper brush.
84
Side support
6.7.3 Activities
6.7.3.1 Replacing the fork light barrier
1
Screw
3
Slot
2
Fork light barrier
4
ACS_ENC_BOARD
A
B
C
D
Unplug the fork light barrier plug on the ACS_ENC_BOARD (S1)
Remove the screw.
Remove the fork light barrier.
Mount and connect a new fork light barrier in the slot.
6.7.4 Final task
A Reattach and secure all covers
B Recalibrating "cogging" on page 98
85
Side support
6.8 Align the beam to be parallel
6.8.1 Foreword
Parallel alignment of the beam is necessary after the following work:
• Replace the toothed belt
• Loosen synchronising shaft
• Insert/remove synchronous shaft
• Fitting/removing the X-axis drive unit
6.8.2 Preparatory tasks
•
•
Remove covers A2, A3, A5 and A6.
Remove the left wiper brushes from front and rear.
6.8.3 Activities
6.8.3.1 Unscrewing the beam screw connections
Tip:
To prevent tension in the beam and to be able to better align the beam, loosen the 12 screws
somewhat.
1
86
Beam
Side support
2
Screws (6x)
3
X-guide carriage
A Loosen the screws slightly.
B Repeat the procedure on the other side.
6.8.3.2 Installing the adjusting gauge for the beam
1
Adjusting gauge
2
Screw
3
Interior thread in the beam
A Position the adjusting gauge on the beam.
B Tighten the screw.
C Repeat the procedure on the other side.
87
Side support
6.8.3.3 Measuring points
Tip:
The following sequence of measuring points (MP1 to MP3) should be heeded if possible.
88
MP1
Measuring point 1, middle of the X-guide rail
MP2
Measuring point 2, beam stop right
MP3
Measuring point 3, beam stop left
Side support
6.8.3.4 Position the adjustment gauge
1
Knurled screw
2
Metal rod
3
Stop and bracket of the rubber buffer
A
B
C
D
E
Push the beam to approx. 50 mm in front of the left limit stop.
Loosen the knurled screw.
Push the metal rod down until it reaches the lower edge of the rubber buffer.
Tighten the knurled screw.
Repeat the procedure on the other side.
89
Side support
6.8.3.5 Disassembling the fan housing
1
Screws with washers
2
Fan housing
A Unplug the plug on the ACS_Amplifier_Board S12.
B Remove the screws (4x).
C Pull out the fan housing upwards.
90
Side support
6.8.3.6 Installing the adjustment device
The rotor may move slightly due to the magnetic field, which makes it harder to set the bars in parallel.
Install an adjustment device to make this easier.
1 Stator
4 Screws (2x)
2 Rotor
5 Screw and washer
3 Adjustment device
A
B
C
D
Position the adjustment device on the rotor and tighten with the screws.
Turn the rotor to the required position.
Attach the screw and washer to the stator.
Fix the stator in the desired position by tightening the screw (item 5).
91
Side support
6.8.3.7 Fixing the rotor
1
Stator
2
Adjusting gauge with slot
3
Screw and washer
Fix the stator in the desired position by tightening the screw (item 3).
92
Side support
6.8.3.8 Align the beam to be parallel
Note:
The two metal rods may not be bent or rest on the stop.
1
Screws
3
Metal rod
2
Axis
4
Stop
A
B
C
D
Carefully move the beam to the left until the metal rod is almost flush to the stop.
With the feeler gauge, set the distance between the metal rod and the stop to exactly 0.05 mm.
Fasten the rotor.
Center the synchronous shaft.
93
Side support
Tip:
Centering can be omitted if the synchronous shaft has been loosened only just one side.
Note:
Risk of damaging the coupling through tightened screws.
It must be possible to easily move the synchronous shaft.
x
Distance = 22 mm
E Set up the synchronous shaft coupling in such a way that the screws can be tightened from above.
F Tighten the screws of the coupling.
Note:
Risk of damaging the coupling and the shaft through uneven tightening.
• Tighten the screws evenly.
• The Y-distance is to be kept.
94
Side support
•
Tighten the screws with a maximum of15 Nmtorque.
Tip:
Align the synchronous shaft in such a way that there is sufficient space to tighten the screws.
1
Coupling half-shell
3
Coupling
2
Screws
Y
approx. 1.1 mm
a)
b)
c)
d)
Tighten both screws alternately.
Check distanceYon both sides.
Tighten the screws with a torque of15 Nm.
Repeat the procedure with the second coupling, if needed.
95
Side support
6.8.3.9 Checking that the beam is parallel
A Loosen and remove the rotor fastener.
B Unscrew the knurled screw on the adjusting gauge.
C Push the metal rod upwards and fix in place.
D Repeat the procedure on the other side.
E Move the beam over the entire table length three or four times.
F Repeat the measurement for parallel positioning (Align the beam to be parallel)
Results
If there are any deviations in parallel positioning, repeat the alignment process (Align the beam to be
parallel).
6.8.3.10 Tighten the beam's screw connection
1
Beam
2
Screws (6x)
3
X-guide carriage
A Tighten the screws.
B Repeat the procedure on the other side.
6.8.4 Final tasks
A Remove the adjusting gauge for the beam.
B Remove the adjustment device for rotor fastening.
C Mount the fan housing.
96
Side support
D Fit and secure all the covers.
97
Side support
6.9 Recalibrating "cogging"
This measurement must be made if one of the following events occurs:
• The MC board was replaced.
• The motor was removed and reinstalled.
• The motor was replaced.
• The zero mark encoder was removed and reinstalled.
• The zero mark encoder was replaced.
• The drive belt was removed from the engine side and reinstalled.
• The drive band was replaced on the motor side.
Foreword
The direct drive (X-drive) motors have so-called cogging. This is a permanently magnetic cogging
torque between the rotor magnets and the stator pole pieces. This characteristic influences the control
of the motor.
Preparatory tasks
Note:
Cables laid across the boom on the module will impair the measurement procedure and result in
false readings.
A Remove any suction pipes attached to the module.
B Remove objects from the table
Measuring
A
B
C
D
Switch to the menuUser level 4-1tab.
Enter and confirm the service password.
Switch to the menuCalibrate X-axis 10-1-8tab.
Use the keyOKto confirm.
Results
Tip:
The test takes approx. 3.5 minutes.
The measurement starts:
• The beam travels across the entire working area.
• The beam subsequently moves to the zero mark.
• The measurement is complete.
98
Side support
Error during measurement
Error 31303
Possible reasons for the error:
• Measurement was interrupted, hindered or falsified due to manual intervention.
• Measurement procedure generated false readings due to objects on the table plate.
• The beam bearing is moving sluggishly, is dirty or damaged.
A Localise and/or rectify the source of the error.
B Repeat measurement.
Error 31102
Tip:
This error is only displayed after the device is switched on
Possible reasons for the error:
• Measurement was interrupted or not yet carried out.
A Acknowledge the error.
B Repeat measurement.
99
Side support
100
Beam
7 Beam
7.1 Fitting/removing Y toothed belt
7.1.1 Settings
Belt tension settings
Y toothed belt
Frequency in Hz
new
54
run-in (after 60 h)
51 ± 1
Y-motor belt
Frequency in Hz
new
270 - 295
run-in (after 60 h)
245 - 270
Toothed belt movement
Note:
• On new systems, the objective is to not use the full tolerance.
• The minimum distance between the toothed belt and the outer edge of the roller may not be
greater than1.0 mm.
Belt movement across a distance
Deviation in mm
across 500 mm travel path
< 2.0
across entire width
6.0
7.1.2 Preparatory tasks
A Remove the modules and set them aside
B Remove covers A1, A2, A3.
7.1.3 Dismantling
7.1.3.1 Dismantling the interface unit
A Unscrew the screws (item 1) (9x)
101
Beam
B Remove the cover (item 2) from the module carriage.
C Unplug electrical plug of the SEM-LP on the MTS_YS_BOARD on page 282
D Unscrew the screws on both sides (item 4) (4x)
E Remove the interface unit entirely (item 3)
102
Beam
7.1.3.2 Dismantling the belt
A Unscrew the belt tensioning screw (item 2).
B Pull the belt locking bolt (item 1) up and out using a screwdriver.
C Remove the belt.
103
Beam
7.1.3.3 Belt replacement
1
Screws
2
Belt locking unit
3
Belt
A
B
C
D
E
104
Loosen and remove the screws. (8x)
Remove the belt locking unit.
Remove the belt and replace with a new one.
Place the belt locking unit on the belt and secure with the screws.
Tighten the screws.
Beam
7.1.4 Assembly
7.1.4.1 Assembling the belt
A Retract the belt.
B Insert the belt locking bolt (item 1).
C Tighten the belt tensioning screw (item 2) to tighten the belt.
105
Beam
7.1.4.2 Check belt movement
1
Roller outside edge
2
Toothed belt
A Push the module carriage back and forth over the full width three or four times.
B Observe the belt and compare it with the specified tolerance values from the table. (see Settings on
page 101)
C Adjust the belt movement if there is any deviation from the specified value.
106
Beam
7.1.4.3 Adjusting the belt tracking
The rear counter bearing (item 1) is easily accessible from the right side.
A Turn the screw (item 3) in the required direction with an Allen key (item 2).
B Move the module carriage and check belt tracking.
C Repeat the process until the belt tracking matches the specification.
107
Beam
7.1.4.4 Moving the module carriage into position
The module carriage needs to be placed in an exact position in order to measure the belt tension.
A Manually push the module carriage 2-3 times along the entire width
B Position the module carriage.
C Set the distance between the belt lock (item 1) and the middle of the roller (item 3) as shown in the
diagram.
108
Beam
7.1.4.5 Measuring belt (toothed belt) tension
Tip:
Adjust the tension of the X and Y toothed belts with the tensioning screws.
For belt drives (e.g. Y drive motor), the belt tension is adjusted by altering the distance between
the belt pulleys.
Figure 4: Belt tension meter
Measure the belt frequency (toothed belt) using the belt tension meter (frequency meter).
A Pluck the belt
B Carry out the first measurement
C Perform two additional reference measurements
D Compare the frequency with the value from the table
E If necessary, set to the required tension.
a) Increase belt tension to increase the frequency.
b) Decrease belt tension to decrease the frequency.
F Carry out steps A-D again after adjusting belt tension.
109
Beam
7.1.4.6 Installing the interface unit
A Insert the interface unit (item 1)
B Tighten the screws on both sides (Pos. 2) (4x)
C Plug in the electrical plug on the Y board
D Install the cover (Pos. 2) on the module carriage
E Tighten the screws (Pos. 1) (9x)
110
Beam
7.1.5 Final task
A Reattach and secure all covers.
B Fit and secure the modules on the module carriage.
C Connect the electrical and air lines of the modules.
111
Beam
7.2 Fitting/removing the Y axis drive
7.2.1 Settings
Y-motor belt
Frequency in Hz
new
270 - 295
run-in (after 60 h)
245 - 270
7.2.2 Preparatory tasks
A
B
C
D
Remove the modules and set them aside
Remove covers A1, A2, A3.
Dismantling the interface unit on page 101
Assembling the belt on page 105
7.2.3 Dismantling
7.2.3.1 Removing the covers
A Remove the screws (item 2)
B Remove the cover (item 1)
112
Beam
7.2.3.2 Loosening the motor toothed belt
Unscrew the screws (item 2) (3x)
Results
The motor toothed belt (item 1) is loose.
7.2.3.3 Removing the gearbox plate
A
B
C
D
Unscrew the lock nut and tensioning screw (item 1).
Unscrew the tensioning screw (item 1).
Remove the screws (item 4) (3x).
Remove the gearbox plate (item 3).
113
Beam
7.2.3.4 Removing the Y-drive unit
A Unscrew the setscrew with the hexagon socket-head (item 1).
B Remove the screws (item 3) (4x).
C Remove the Y-drive unit (item 2).
7.2.3.5 Pulling out the drive wheel
A Remove the screws (item 2) (2x).
B Remove the cover plate (item 1).
C Pull out the drive wheel (item 3).
114
Beam
7.2.4 Assembly
7.2.4.1 Inserting the drive wheel
A Retract the drive wheel (item 3).
B Attach the cover plate (item 1).
C Tighten the screws (item 2) (2x)
115
Beam
7.2.4.2 Fitting the Y-drive unit
A
B
C
D
Position the drive wheel so that the flat area of the axis (item 1) is pointing upward.
Insert the Y-drive unit (item 3). Alignment pins ensure proper alignment.
Tighten the screws (item 4) (4x)
Tighten setscrew with hexagon socket head screw (item 2).
7.2.4.3 Mounting the gearbox plate
A Position the gearbox plate (item 1) using the alignment pins.
B Tighten the screws (item 2) (3x).
116
Beam
7.2.4.4 Synthetic fiber (Canevesit) gear wheel setting
A
B
C
D
E
F
Unscrew the clamping screw (item 2).
Remove the set screw with the hexagon socket-head (item 3) by turning it several times.
Unscrew the lock nut (item 6).
Tighten the screw (item 7) until the spring (item 5) is completely compressed.
Turn the screw (item 7) 90° (a quarter turn).
Tighten the lock nut (item 6).
117
Beam
7.2.4.5 Tightening the motor timing belt
A
B
C
D
E
118
Loosely tighten the screws (item 2) (x3).
Use a screwdriver to move the motor unit downwards and tighten the belt (item 1) while doing so.
Tighten the screws (item 2) (3x).
Measure the frequency using a belt tension meter (frequency meter). (See the following page)
Repeat the tensioning process until the default value of the belt tension is reached.
Beam
7.2.4.6 Measuring belt (toothed belt) tension
Tip:
Adjust the tension of the X and Y toothed belts with the tensioning screws.
For belt drives (e.g. Y drive motor), the belt tension is adjusted by altering the distance between
the belt pulleys.
Figure 5: Belt tension meter
Measure the belt frequency (toothed belt) using the belt tension meter (frequency meter).
A Pluck the belt
B Carry out the first measurement
C Perform two additional reference measurements
D Compare the frequency with the value from the table
E If necessary, set to the required tension.
a) Increase belt tension to increase the frequency.
b) Decrease belt tension to decrease the frequency.
F Carry out steps A-D again after adjusting belt tension.
119
Beam
7.2.4.7 Installing the covers
A Attach the cover (item 1).
B Tighten the screws (item 2).
7.2.5 Final task
A
B
C
D
E
120
Assembling the belt on page 105
Installing the interface unit on page 110
Reattach and secure all covers
Mount the modules on the module carriage
Connect the electrical and air ducts of the modules
Beam
7.3 Replacing the Y axis motor
7.3.1 Preparatory tasks
A Remove the modules and set them aside
B Remove covers A1, A2, A3.
C Dismantling the interface unit
7.3.2 Dismantling
7.3.2.1 Removing the covers
A Remove the screws (item 2)
B Remove the cover (item 1)
121
Beam
7.3.2.2 Unplugging the cable
Unplug the supply cable (item 1) and the encoder cable (item 2).
7.3.2.3 Loosening the motor toothed belt
Unscrew the screws (item 2) (3x)
Results
The motor toothed belt (item 1) is loose.
122
Beam
7.3.2.4 Pulling out the motor toothed belt
A Remove the counter-bearing screws (item 3).
B Swing the counter bearing (item 2) to one side.
C Pull out the motor belt (item 1).
123
Beam
7.3.2.5 Removing the motor
A Remove the motor screws (item 2) (x3).
B Pull the motor (item 1) out of the bracket of the beam.
124
Beam
7.3.3 Assembly
7.3.3.1 Pulling in the motor
A Insert the motor (item 1) into the bracket in the beam.
B Loosely tighten the motor screws (item 2) (x3)
125
Beam
7.3.3.2 Threading in the motor toothed belt
A Thread in the motor belt (item 1) and push onto the motor pinion.
B Swing the counter bearing (item 2) into position.
C Tighten the counter bearing screws (item 3).
126
Beam
7.3.3.3 Tightening the motor timing belt
A
B
C
D
E
Loosely tighten the screws (item 2) (x3).
Use a screwdriver to move the motor unit downwards and tighten the belt (item 1) while doing so.
Tighten the screws (item 2) (3x).
Measure the frequency using a belt tension meter (frequency meter). (See the following page)
Repeat the tensioning process until the default value of the belt tension is reached.
127
Beam
7.3.3.4 Measuring belt (toothed belt) tension
Tip:
Adjust the tension of the X and Y toothed belts with the tensioning screws.
For belt drives (e.g. Y drive motor), the belt tension is adjusted by altering the distance between
the belt pulleys.
Figure 6: Belt tension meter
Measure the belt frequency (toothed belt) using the belt tension meter (frequency meter).
A Pluck the belt
B Carry out the first measurement
C Perform two additional reference measurements
D Compare the frequency with the value from the table
E If necessary, set to the required tension.
a) Increase belt tension to increase the frequency.
b) Decrease belt tension to decrease the frequency.
F Carry out steps A-D again after adjusting belt tension.
128
Beam
7.3.3.5 Inserting the cable
Plug in the supply cable (item 1) and the encoder cable (item 2).
7.3.3.6 Installing the covers
A Attach the cover (item 1).
B Tighten the screws (item 2).
129
Beam
7.3.4 Final task
A Installing the interface unit on page 110
B Reattach and secure all covers
C Mount the modules on the module carriage
D Connect the electrical and air ducts of the modules
130
Beam
7.4 Replacing the module carriage wipers
7.4.1 Preparatory tasks
A Remove the modules and set them aside
B Remove covers A1, A2, A3.
C Dismantling the interface unit on page 101
7.4.2 Dismantling
7.4.2.1 Disassembling the cover plate
A Loosen and remove the screws (item 1)
B Push the cover plate (item 2) downward and remove it
131
Beam
7.4.2.2 Disassembling the wipers
A Remove the screws (item 2) (4x).
B Extend the wipers (item 1) outwards from the sides (4x).
132
Beam
7.4.3 Assembly
7.4.3.1 Mounting the wipers
Tip:
The short screws are to be inserted above, the longer ones below.
A Insert the wipers (item 1) (4x) on the sides.
B Tighten the screws (item 2) (4x).
7.4.3.2 Mounting the cover plate
7.4.4 Final task
Reattach and secure all covers.
133
Beam
7.5 Replacing the module carriage linear ball bearing unit
7.5.1 Tools and materials
•
•
Loctite 243
®"
Lubricant "Klüberoil
7.5.2 Preparatory tasks
A Remove the modules and set them aside
B Remove covers A1, A2, A3.
C Dismantling the interface unit
7.5.3 Dismantling
7.5.3.1 Disassembling the cover plate
A Loosen and remove the screws (item 1)
B Push the cover plate (item 2) downward and remove it
134
Beam
7.5.3.2 Loosening the belt anchor on the module carriage
A Remove both screws (item 2).
B Slide the loose belt anchor (item 1) to the top or the end of the beam.
7.5.3.3 Dismantling the module carriage
A
B
C
D
E
Unscrew and remove the Phillips screws (item 4) on the wipers (item 3) (4x).
Remove the wipers (item 3) (4x).
Unscrew and remove the screws (item 2 (8x)) on the ball bearings (item 1 (4x)).
Remove the ball bearings (item 1 (4x)).
Remove the module carriage.
135
Beam
7.5.4 Assembly
7.5.4.1 Assembling the linear ball bearing unit on the top of the module carriage
•
®
•
Oil the linear ball bearing unit with "Klüberoil lubricant.
Secure all screws (linear ball bearing unit) with Loctite 243!
A
B
C
D
E
Loosely screw the linear ball bearing units (item 1) into place.
Push the linear ball bearing unit (item 1) against the top cutting edge of the module carriage.
Tighten the screw (item 3).
Tighten the screw (item 2).
Repeat steps A to D on the other side.
7.5.4.2 Assembling the module carriage
•
•
•
136
Oil the linear ball bearing units
Clean and oil the slide rails
Secure all screws (linear ball bearing unit) with Loctite 243!
Beam
Tip:
The module carriage plate is depicted with partial transparency in the diagram to make it easier to
see the whole diagram.
A
B
C
D
Place the module carrier on the top guide rail of the beam.
Slightly unscrew the adjusting screw (item 3) with an Allen key.
Push the linear ball bearing unit upward (item 4) and gently tighten the screws (items 1 and 2).
Tighten the adjusting screw (item 3) with an Allen key.
The linear ball bearing unit (item 4) is pushed upward.
E
F
G
H
Tighten the screw (item 2).
Tighten the screws (item 1).
Repeat the procedure on the other side.
Push the module carriage up and move it back and forth.
The balls in the upper linear ball bearing units must move.
137
Beam
7.5.4.3 Checking bearing clearance
Before adjusting the bearing clearance, check the play across the entire length.
Aim of the setting: the module carriage should be able to move smoothly and without play along the
entire length of the bar!
The balls in the upper linear ball bearing units (item 1) must run with the carriage!
A Slightly raise the module carriage and push along the entire beam width.
B Shake along the entire beam length of the module carriage. There must not be any noticeable play
C Adjust the lower bearing with the adjustment strap, until no more play is noticeable.
Results
The balls in the upper linear ball bearing unit (item 1) move with the carriage and there is noticeable
play: bearing play is too great.
The balls in the upper linear ball bearing unit do not move with the carriage and there is no noticeable
play: too little bearing play.
Adjusting the bearing clearance
138
Beam
7.5.4.4 Adjusting the bearing clearance
A With the allen key (item 5) tighten the screws (item 4) of the lower counter-bearing until the balls
(item 1) run along the upper counter-bearing.
B Tighten the screws (item 3) on the right.
C Tighten the screws (item 6) on the left.
D Check bearing play (item 1). See: Checking bearing clearance
139
Beam
7.5.4.5 Mounting the wipers
A Insert the wipers (Pos. 1) (4x)
B Tighten the screws (item 2) (4x)
7.5.4.6 Connecting the belt anchor to the module carriage
A
B
C
D
140
Moving the belt anchor or the module carriage into position.
Attach both screws (item 2) between the module carriage and the belt anchor (item 1).
Press the belt anchor downward into the slot on the module carriage.
Tighten both screws (item 2).
Beam
7.5.4.7 Mounting the cover plate
A Push the cover plate (item 2) from underneath over the external flanks of the module carriage.
B Tighten the screws (item 2) (4x).
7.5.5 Final task
Reattach and secure all covers.
141
Beam
7.6 Replacing the Y-axis fork light barrier
7.6.1 Foreword
The axis zero mark is recognized by a fork light barrier.
The fork light barrier is located in the area around the zero point. A small plate with a 1 mm wide slot
interrupts the fork light barrier.
Function in normal mode
If the fork light barrier is free, the axis moves toward the zero point at "high" speed. As soon as the
small plate interrupts the beam of light, the speed decreases and the axis moves up to the slot and
detects the beginning/end of it. The center of the two values is the zero point. If the small plate is
already in the light barrier when switched on, the axis starts to move "slowly".
Function in interrupted mode
If the beam of light is interrupted by a foreign object, the control unit moves slowly into the buffer,
changes direction and then moves in reverse to the buffer and remains still without an error message.
Tip:
The fork light barrier is only replaced if defective.
It is not necessary to set the fork light barrier mechanically.
7.6.2 Preparatory tasks
Remove cover A1
142
Beam
7.6.3 Activities
7.6.3.1 Replacing the fork light barrier
A
B
C
D
E
Unplug the cable on the ACS_X_BOARD (item 1).
Attach string to the cable so it is easier to reinsert.
Remove the screw (item 3).
Remove the fork light barrier (item 2).
Mount and connect a new fork light barrier and plug it into the ACS_X_BOARD.
7.6.4 Final task
Reattach and secure all covers
143
Beam
144
General mechanics
8 General mechanics
145
General mechanics
8.1 Subsequent change of location
Note:
Risk of damage to the cutter
The cross braces must be mounted if the cutter is subsequently moved via a forklift or with two
palette trucks.
8.1.1 Preparatory tasks
A
B
C
D
Remove the air connector.
Disconnect the power supply.
Remove covers A10, A12, A13 and A14.
Remove the vacuum generator.
8.1.2 Taking the cross braces out of the intermediate storage position
After installation of the cutter the cross braces were hooked in on both rear feet and screwed tight.
1
Cross braces (2x)
2
Screws (8x)
A Unscrew the screws on both feet.
B Lift up the cross braces and pull them out to the front.
146
General mechanics
8.1.3 Mounting the cross braces
1
Longitudinal brace
2
Screws (8x)
3
Cross braces (2x)
A Pull in the cross brace from below on the screws.
B Tighten the screws.
C Repeat the process with the second cross brace.
8.1.4 Moving the cutter
Caution:
Risk of damage to the cutter with long transport routes.
If the cutter is transported over long distances, the following points are to be met:
• Transport the cutter on a transport pallet
• Install the module carriage transport locking device
• Fix the beam
Move the cutter to the desired location with two pallet trucks or a forklift truck.
147
General mechanics
8.1.5 Dismantling the cross braces
The cross braces are only mounted for the installation and subsequent placement of the cutter and will
be subsequently dismantled and attached to the cutter.
1
Longitudinal brace
2
Screws (8x)
3
Cross braces (2x)
A Loosen the screws.
B Extend the cross brace at the bottom.
C Repeat the process with the second cross brace.
148
General mechanics
8.1.6 Storing the cross braces
After installation of the cutter or after relocation, the cross braces will be attached to both rear feet.
1
Cross braces (2x)
2
Screws (8x)
A Retract the cross brace from above.
B Repeat the process with the second cross brace.
C Tighten the screws.
8.1.7 Final tasks
A
B
C
D
E
Positioning and connecting the vacuum generator.
Attach the air connector.
Connect the power supply.
Leveling the cutter
Mount and secure all covers.
149
General mechanics
8.2 Leveling the cutter
8.2.1 Leveling uneven surfaces
1
Foot
2
String
3
Floor, unevenness
A Connect the support ends with a string (4x) and tighten.
B Place the green supports under the setscrews
C Align the height of the feet (max. 20 mm). The distance between the highest point on the uneven
floor and the string must be at least 5 mm.
150
General mechanics
8.2.2 Initial leveling of the table
Caution:
Beware of mechanical stresses
• Build up the tension by lifting the corners.
• Re-tighten the screw connections of the side supports.
Settings accuracy: ±0.5 mm/m
1
Setscrew
2
Lock nut
3
Spirit level
A
B
C
D
E
F
Lift each cutter corner to build up the tension.
Raise the table approx. 1 cm using the setscrews.
Lay the spirit level on the base frame.
Determine the lowest position of the foot and use the setscrews to adjust it upwards.
Use the setscrew to raise the position of the lowest foot.
Repeat the procedure on all four feet
The table is already leveled
151
General mechanics
8.2.3 Mount the adjusting gauge
1
Interior thread in the beam
2
Adjusting gauge
3
Screw
A Remove cover A3.
B Position the adjusting gauge on the beam.
C Tighten the screw.
152
General mechanics
8.2.4 Leveling the table
Settings accuracy: ±0.2 mm/m
1
Spirit level
4
Setscrew
2
Guide rail
5
Lock nut
3
Adjustment gauge on beam
A Remove covers A6, A12 and A14.
B Place the spirit level on a guide rail or lay the adjustment gauge on the beam.
C Determine the lowest positioned foot. For example:
a) Guide rail rear right
b) Adjustment gauge on beam, left position
c) Guide rail, rear left
d) Adjustment gauge on beam, right position
153
General mechanics
D Use the setscrew to raise the position of the lowest foot.
E Repeat the procedure on all four feet.
F Screw in the lock nuts.
8.2.5 Final tasks
A Remove the adjustment gauge.
B Fit and secure all the covers.
154
Table plate
9 Table plate
9.1 Leveling the table plate
9.1.1 Foreword
The table plate must be adjusted under the following conditions:
• during initial setup or reconstruction
• following adjustment of the support feet
9.1.2 Preparatory tasks
A
B
C
D
Removing covers A6, A7, A8, A10, A12, A13 and A14.
Mount 2 modules on the module carriage
Leave one slot free on the module carriage.
Remove the cutting surface.
9.1.3 Preconditions
•
•
•
•
The cutter is leveled using a precision spirit level.
There is no cutting surface on the table.
Two modules are mounted on the module carriage.
An assistant is available.
9.1.4 List of tools
•
•
•
Adapter and dial gauge support
Dial gauge with 1/100 mm resolution
Torque wrench
155
Table plate
9.1.5 Activities
9.1.5.1 Mounting the dial gauge
1
Module carriage
3
Dial gauge
2
Adapter
4
Dial gauge support
A
B
C
D
Position the adapter on the module carriage and tighten.
Position the dial gauge support at the correct height, level and screw tight.
Push the dial gauge into the dial gauge support and push it down until it is resting on the table.
Subsequently push the dial gauge down further until the pointer has made two complete turns and
is back at the zero position.
The two turns are necessary for the measurement of positive as well as negative paths.
E Use the knurled screw to fix the dial gauge.
156
Table plate
9.1.5.2 Setting the dial gauge
1
Dial gauge, insertion position
4
Measuring plane
2
Turns
5
Dial gauge support
3
Dial gauge in measuring position
Important:
Dial gauges are sensitive precision instruments and must therefore be handled with care. When
pushing to the next measuring point, ensure that the dial gauge does not snag anywhere. This can be
prevented by lifting the sensor.
A Push the dial gauge down until the pointer has made 2 turns and is at "0".
B Fix the dial gauge in the dial gauge support with the knurled screw.
Results
The dial gauge pointer can move in positive or negative directions.
157
Table plate
9.1.5.3 Setting points
158
1
Measuring range
2
Vacuum plate
3
Setting points
Table plate
9.1.6 Final task
A Remove the dial gauge and dial gauge holder
B Reattach and secure all covers
159
Table plate
160
ITI
10 ITI
10.1 Set ITI.
10.1.1 Preparatory tasks
A Remove cover A8.
B Remove the cutting surface.
10.1.2 Adjustment procedure
Tip:
The adjustment with the adjusting gauge it described in the following.
If adjusting without this gauge, make sure that the upper edge of the ITI is 5 mm above the table
plate.
Adjustment can also be carried out with 5 mm thick sheet, for example.
1
Adjusting gauge
4
ITI
2
Table plate
5
Screws 2x
3
Cut-out on the adjusting gauge
161
ITI
A
B
C
D
E
Unscrew both screws slightly.
Place the adjusting gauge on the table plate so that the slot is flush to the ITI.
Press the adjusting gauge flat onto the table plate.
Push the ITI upwards until it is flush to the adjusting gauge.
Tighten both screws.
Results
The ITI is aligned with a height difference of 5 mm, parallel to the table plate.
10.1.3 Final tasks
A Remove the adjustment gauge.
B Mount the cutting surface.
C Fit and secure all the covers.
10.2 Initialize ITI
10.2.1 Software settings for ITI
Menu no. / description
Adjusting value
Description
off
on
The ITI is automatically set to active during
installation.
1-9-2 ITI
1-9-2-1 ITI
1-1-1-2-5 Test cut
A test cut is carried out.
1-9-2-4-1-1 Define position
Define X and Y position to determine the light beam.
The markings are visible in ITI.
1-9-2-4-1-2 X-Position
Direct entry of the position possible (not
recommended).
1-9-2-4-1-3 Y-Position
Direct entry of the position possible (not
recommended).
1-9-2-4-2 Sensor height
1-9-2-4-2-1 Check
Measures whether the installation height of the ITI
is correct. The setting tolerance is ± 0.2 mm. Use
is not mandatory if the ITI was installed with the
adjusting gauge. The function must be carried out if
the ITI was installed without adjusting gauge.
1-9-2-4-3 Probing offset
Value on the ITI must be entered here. (Determines
the difference between surface ITI and light beam. Is
needed for initialization of CTT1-3, PPT and RM-A
suction bell).
The value to be entered is found on the outside of
the ITI and is also visible without dismantling the
cover.
162
ITI
Menu no. / description
Adjusting value
1-9-4-1 Underlay
1-9-4-1-1 Thickness
Description
This defines whether it is regarding a conveyor belt
(table with material transport) or a cutting underlay
(static table).
0.7 mm to 10 mm
1-9-4-1-2 Calibration
Direct entry and display of the thickness of the
cutting underlay.
Function to determine the thickness of the underlay.
Tip: Should be performed for better accuracy.
1-9-4-1-3 Cutting depth
0.0 mm to thickness
of underlay -0.7 mm
Prevents cutting too deeply into the underlay and its
destruction
Default: 1.5 mm
1-6-3 additional underlay
off
on
Must be activated if an additional underlay is placed
on the normal cutting underlay (e.g., grip). The Init
positions of all tools are automatically raised (ON) or
lowered (OFF). The online dialog of the cutter shows
if the additional underlay is activated.
1-9-4-3-1 Thickness
0.7 mm to 60 mm
Direct entry and display of the thickness of the
additional underlay (e.g., sealgrid)
1-9-4-3-2 Calibration
Function to determine the thickness of the additional
underlay. Tip: should be carried out for better
accuracy.
10.2.2 Determine X and Y position for the ITI
The position of the ITI is determined with the laser beam.
The laser beam is aligned to the grooves milled into the ITI.
A 1-9-2-4-1-1 Define positionselect in cutter menu.
B Follow the instructions on the display.
163
ITI
10.2.2.1 Determining the X-position for the ITI
1
Laser pointer
2
Laser beam in X-position mark
3
ITI
A Position the laser beam in the X-position mark using the travel keys.
B Confirm the X-axis position.
C Follow the instructions on the display.
164
ITI
10.2.2.2 Determine Y position for ITI
1
Laser pointer
2
Laser beam in Y position mark
3
ITI
A Position the laser beam in the Y position mark using the travel keys.
B Confirm the Y-axis position.
C Confirm the change.
165
ITI
10.2.3 Enter probing offset
Tip:
Individual values are provided for each ITI on a sticker.
The sticker is visible when lifting the wiper brushes.
1
ITI
3
Wiper brush (cross-sectional view)
2
Difference value
4
ITI mounting plate
A Read the negative value on the sticker and make note of it.
B 1-9-2-4-3 Probing offsetselect in cutter menu.
C Enter and confirm the value.
166
Vacuum system
11 Vacuum system
11.1 Vacuum zones
Division of the vacuum zones in L3 C-40
167
Vacuum system
Division of the vacuum zones in L3 C-56
168
Vacuum system
11.2 Vacuum valves and boards
11.2.1 Push the valve island forward
To facilitate access to the individual vacuum valves, air connections and boards, the support sheet of
the vacuum island can be pushed forward.
Note:
Risk of damage to the valve island from the control panel.
The control panel may not be pushed to the left if the valve island is in the foremost position.
1
Screws and washers (2x)
2
Support plate
A
B
C
D
Remove cover A5.
Release the screws on both sides.
Pull the support plate forward.
Tighten the screws on both sides.
169
Vacuum system
11.2.2 Description of the valve island and boards (L3-C40)
1
Valves 1 to 24
2
ACS_VALVE_SWITCH_BOARD Master
3
Valves 25 to 40
4
ACS_VALVE_SWITCH_BOARD Slave1
Individual valves are fitted with LEDs, which represent activation of the valve.
Tip:
The valves behave inversely to the switched vacuum zones.
A switched-on valve means that this vacuum zone is inactive.
11.2.3 Description of the valve island and boards (L3-C56)
170
1
Valves 1 to 24
2
ACS_VALVE_SWITCH_BOARD Master
3
Valves 25 to 40
4
ACS_VALVE_SWITCH_BOARD Slave1
5
Valves 41 to 56
Vacuum system
6
ACS_VALVE_SWITCH_BOARD Slave2
Individual valves are fitted with LEDs, which represent activation of the valve.
Tip:
The valves behave inversely to the switched vacuum zones.
A switched-on valve means that this vacuum zone is inactive.
171
Vacuum system
11.2.4 Pushing the valve island backward
172
1
Support plate
2
Screws and washers (2x)
A
B
C
D
Release the screws on both sides.
Pull the support plate backward.
Tighten the screws on both sides.
Attach cover A5.
Vacuum system
11.3 Possible tests
Tip:
After leaving the menu1-8-3 Vacuum rangeall vacuum zones will be reactivated.
11.3.1 Switching individual zones
With this function individual zones can be controlled and tested.
All zones can also be activated or deactivated at the same time.
Menu no. / description
Description
1-8-3-8-3 Zone position
The desired zone number is entered via the
number field.
1-8-3-8-4 Switch on zone pos
To switch on the selected zone.
1-8-3-8-4 Switch off zone pos
To switch off the selected zone.
1-8-3-8-6 Switch on zones
To switch on all zones.
1-8-3-8-5 Switch off zones
To switch off all zones.
11.3.2 Zone test
In the zone test, the individual zones will be switched in sequence and then switched off in staggered
sequence.
Menu no. / description
Description
1-8-3-8-2 Vacuum zone test
The zone test is started.
11.4 Performing the running-in procedure
A run-in procedure must be carried out during the initial commissioning of vacuum generators. This is
carried out automatically by the cutter after calling up the function.
3-7-2 Start vacuum turbine.
Results
The vacuum generator starts and runs through the run-in procedure in the different stages.
173
Vacuum system
174
Safety device
12 Safety device
12.1 Note for the presentation conventions
Caution:
Risk of confusion due to different side specifications.
The side specifications deviate from the presentation convention.
Reason:
For reasons of reuse of ACS_C_BOARDs in other cutters, the decision was made to keep the
directional information.
The following presentation conventions apply exclusively for the arrangement of light barriers.
1
front
2
rear
3
right
4
left
X
X-axis
Y
Y-axis
175
Safety device
12.2 Overview of the light barriers
1
X-axis linear encoder
8
Receiver light barrier
2
Valve V1.0 feed system
9
Right-side reflecting light barrier
3
optional
10
Module carriage
4
ACS_CROSS_BOARD
11
Left-side reflecting light barrier
5
Y axis rotary encoder
12
Emitter light barrier
6
Y axis zero mark
13
Emitter light barrier
7
Receiver light barrier
Light barrier (front)
Board
Light barrier transmitter 1 (LSS1)
ACS_X_BOARD_S8
Light barrier, receiver 2 (LSE2)
ACS_X_BOARD_S11
Light barrier (rear)
176
Signal
Error message
Stop 2
LS=0
Safety device
Light barrier, emitter 2 (LSS2)
ACS_X_BOARD_S10
Light barrier, receiver 1 (LSE1)
ACS_X_BOARD_S9
Stop 1
SL=1
Left-side reflecting light barriers 1
ACS_X_BOARD_S2
Stop 3
LS=2
Right-hand reflecting light barriers 2
ACS_X_BOARD_S15
Stop 4
LS=3
Reflecting light barriers
177
Safety device
12.3 Replacing the left light barriers
Tip:
Observe the separate presentation conventions with regard to the light barriers.
Note for the presentation conventions on page 175
1
front cover
4
rear light barrier transmitter
2
rear light barrier transmitter
5
rear cover
3
center cover
6
Screws (3 x 4 pcs)
A
B
C
D
E
178
Remove the screws of the covers.
Remove the covers.
Remove the light barrier transmitter attachment screw.
Unplug the light barrier transmitter plug.
Replace the light barrier transmitter.
Safety device
12.4 Replacing the right light barriers
Tip:
Observe the separate presentation conventions with regard to the light barriers.
Note for the presentation conventions on page 175
1
front cover
6
rear cover
2
front light barrier receiver
7
Screws (5 pcs)
3
center cover
8
Screws (3 pcs)
4
Reflection light barrier
9
Screws (5 pcs)
5
rear light barrier receiver
A
B
C
D
E
Remove the screws of the covers.
Remove the covers.
Remove the light barrier transmitter attachment screw.
Unplug the light barrier transmitter plug.
Replace the light barrier transmitter.
179
Safety device
12.5 Setting the light barriers
Setting the light barriers
Emitter model: FSDK10D96/012174
Align emitters and receivers so that there are no reflections from reflective cutting materials.
Figure 7: Setting the safety device
1 Mount
2 Sensor
3 Fastening
Note:
The safety devices must be parallel to one another. Change their alignment if necessary.
Procedure
• Remove the light barrier covers.
• Move the receiver up at an approx. 3° angle.
• Move the emitter up as far as the stop (approx. at a 6° angle).
• Slowly turn the emitter downwards, until the receiver is receiving the emitter signal. The LED on the
receiver will illuminate as soon as the emitter signal is received.
• Turn the emitter downwards at an approx. 0.5° angle.
• On the emitter side, turn the sensor mount, and/or raise and lower it. The LED on the receiver
must be illuminated throughout the procedure. Otherwise, you should turn the emitter downwards
180
Safety device
another 0.5°. Repeat this procedure for as long as it takes for the LED on the receiver to illuminate
continuously despite the mount being twisted.
181
Safety device
182
Electrical system/electronics
13 Electrical system/electronics
13.1 Electrostatic discharge (ESD)
Caution:
Danger of damage to electrical and electronic components
Static discharge can cause damage to electrical and electronic components.
Wear an ESD wristband and connect to the earthed object.
Surges from ESD can damage electronic and electrical components. To avoid such faults, the
following guidelines must be observed when working with components at risk of ESD.
Guidelines for working on the machine
•
•
Switch off the unit and disconnect it from the mains power and from the computer network.
Make sure you are always earthed. Wear an ESD wristband and earth this on a bare, earthed
piece of metal or another earthed object.
Handling components at risk of ESD
Components at risk of ESD come in special antistatic packaging and are marked with the ESD symbol.
• Avoid surfaces which are liable to cause static electricity (e.g. carpets, plastics, synthetic clothing,
etc.).
• Only remove components from the packaging when you are ready to use them.
• Do not place electronic components on the outside of the antistatic packaging, as only the inside
offers full protection against static.
• Always touch and hold electronic printed circuit boards by their corners.
• Avoid direct contact with components.
• Never allow a printed circuit board to slide across any surface.
• Always put replaced or exchanged components back in an ESD protected bag straight away.
183
Electrical system/electronics
13.2 Description
13.2.1 Components
184
1
Emergency stop switches (3x)
7
Electronics unit
2
Maintenance unit
8
Vacuum zone control
3
Power unit
9
X-axis drive
4
Operating unit
10
Safety device
5
Cross Board
11
Y-axis drive, X-board
6
ACS_EBC_Board
12
YS_Board (module carriage)
Electrical system/electronics
13.2.2 Power unit
Overview
Power unit tasks
• Mains voltage fuse
• Mains voltage distribution
• Option switching
1
Connection options
8
Power supply connection
2
SP1
9
ACS_EMM_CON_BOARD
3
SP2
10
Emergency stop module
4
SP3
11
Emergency stop power relay
5
Fans
12
Connection strip
185
Electrical system/electronics
6
Main switch
13
Options relay
7
Main fuses
14
ACS_SYS_FUNC_BOARD
Components
Description
SP1 - SP3
Pulse 24 V/20 A power supply
Main switch
32 A circuit breaker with advanced N
Main fuses
3 x 16 A (characteristic C)
ACS_EMM_BOARD
Board for the connection of the emergency stop switches
Emergency stop module
PNOZ e1p
Emergency stop power relay
Klöckner & Möller DIL7M-01
Options relay
7 x finder coupler relay series 48
ACS_SYS_FUNC_BOARD
Board distributes and connects the system voltage. The vacuum
generator and switch valve are managed on this board (only for the
gas ring vacuum generator)
Connection options
Plug
Option
OB2_1
Extractor
OB3_1
Spare
OB3_2
Spare
OB4_1
Spare
Properties
• Forced cooling as required
• Power box division: energy, power switch, emergency stop
• Standardised industrial voltage 24 V
ACS_SYS_FUNC_BOARD functions
• Distributor voltages 53 V, 24 V
• Coupler relay control
• Power unit cooling control
• Pumps, valves, foot switch control
Mains supply
• Supply with 3 x 400 V / 3 x 208 V
• Central main switch, automatic circuit breaker
• 24 V automatic mains voltage switch, 20 A power supply units
The 3 power supply units are identical; 2 power supply units are connected in series (set to 26.5 V)
resulting in a 53 V power supply for motor activity
• Standby mode
186
Electrical system/electronics
ACS_EMM_BOARD functions
• Emergency stop module control
• Distributor release contacts
• Emergency stop switch connection
187
Electrical system/electronics
13.2.3 Electronics unit (E-box)
Overview
188
1
ACS_MC_BOARD
2
ACS_BF_BOARD
3
ACS_AMPLIFIER_XBL_BOARD
Electrical system/electronics
4
ACS_OPT_ANT1
5
Capacitor (braking energy) and discharge resistor
6
ACS_OPT_BRD1
ACS_MC_BOARD functions
• 32 bit ColdFire CPU, 150 MHz with 16 Mbyte FLASH, 16 Mbyte SDRAM
• RS232, CAN, I2C, USB, TCP/IP interfaces
• ALTERA 2C15 for hardware pre-processing, controller and synchronous connection
ACS_XBL_AMPLIFIER function
• Head supply is controlled 53 V (6 A), 24 V (6 A)
• Additional axis for vacuum slider (optional)
• Additional axes can be connected
ACS_BF_BOARD function
• Central interface board (beam, amplifier, options, operating unit, etc. )
• Preparation of DC power supplies (5 V, 3 V, 1.5 V, 1.2 V)
• Approval of the voltages and inspection of the multifuse
ACS_OPT_BRD1 functions
• AKI II connection
• Router valve connection
• Winding/unwinding unit connection
• POT maintenance unit connection
• MSENS connection (optional)
• OPT_REL1 connection
• Connection of terminal interface for IOs
• Connection of two OPT_ANT1 for the auxiliary drive and router option
189
Electrical system/electronics
13.2.4 Fuses
Where possible, no non-resettable fuses (glass fuses) are used in the cutter. If a fuse in an
independent module (e.g. power supply unit, converter, etc.) becomes defective, this module must be
replaced!
Main fuses components 16 A (Powerbox)
Low-voltage, resettable fuses (multifuse)
Carefully touching the multifuse is a way of determining if there is overcurrent (the multifuse is hot)
Main fuses - 32A components (customer)
Low-voltage, resettable electronic fuses (SWITCH)
The software gives notification of the error, LEDs are present
Non-resettable fuses are included in the following elements:
Non-resettable fuses
Item
Element
Fuse
1
ACS_AMPLIFIER BOARD
F1:
FST 6.3 A
P24 V
2
ACS_AMPLIFIER BOARD
F2:
FSF 10 A
P58 V
Tip:
3ph 200 V system:
A further fuse for the vacuum turbine is attached to the top-hat rail.
190
Electrical system/electronics
13.2.5 Beam
ACS_X_BOARD
Function
• Front/rear connection of the light barriers and the right/left reflex light barriers
• Y axis zero mark connection
• Y-encoder connection
ACS_CROSS_BOARD
Function
• Separation point of the connections between the side support and the beam
• Y-motor connection
• Relay for braking the head carriage after cutter switch off.
MTS_SENS_BOARD
Function
• Control of max. three electrically-powered tools (EOT, DRT)
• Sensors connection (laser pointer etc.)
• Camera connection
191
Electrical system/electronics
13.2.6 Side support, front
ACS_ENC_BOARD
The board is affixed to the front support at the bottom left.
Function
• Connection of position sensor and X-axis zero mark
192
Electrical system/electronics
13.2.7 Module carriage
MTS_YS_BOARD
Function
• Control and power supply of up to 3 modules and 1 fixed MAM-SE/SP module
• Control and power supply of the MTS_SENS_BOARD
193
Electrical system/electronics
13.2.8 Operating unit
ACS_PANEL_BOARD
Function
• Switches cutter on (from standby)
• Graphical LCD 128x64
• Up to 4 operating units can be connected
• Real time clock
• Connection of external control switch
13.3 Start-up
Main switch
This is used for the system's power supply. Components that are not supplied via the power unit are
not switched on or off by the power unit main switch.
In normal operation, the main switch is in the ON position.
If the switch is in the OFF position, the power unit is disconnected from the power supply.
When the main switch is ON, the 24 V main power supply (SP1) is switched on.
Main switch switch-on process, "ON"
During the switch-on process (main switch), 24 V @ 2 A (24 V_C) is enabled as CONTROL voltage.
The CONTROL voltage is an internal control voltage which is not supplied to any external devices.
At this time, the voltage is used to supply the ACS_PANEL_BOARD. Until activated, this works in
standby mode (LCD illumination dark, scrolling start-up text).
Master control panel switch-on process
Pressing the F1 key initiates the switch-on process for the entire system (ACS_POWER_ON switch
signal).
The signal starts the generation of the internal logic voltages from the 24 V_C for the electronics
system. If the logic voltages are OK, the software is started.
The electronics unit's hardware is initialised and inspected. If there is an error, the problems will be
described using appropriate error messages.
194
Electrical system/electronics
The 24 V_CSWs (CONTROL_SWITCHED) are enabled for the power controllers. This means that 24
V power (24 V_P) can be subsequently switched on and the emergency stop can be deactivated:
24 V_P segmentation
In the 24 V_P, all the current (20 A) is available. The circuits are segmented with appropriate fuse
protection:
• SYS_FUNC_BOARD ' 3 A valves
• BF_BOARD ' 4 A
• OPT_BRD ' Various fuses
• AMP ' 1.1 A internal bridge power supply
2.5 A electronics power supply of the beam (X, YM, module)
Activate emergency stop
The emergency stop module starts with a self-test (internal). If there is a complete emergency stop
circuit and an OK message from the protective forced contact, then enabling paths K1 and K2 are
activated:
The contactor is switched on with K1 ' Mains voltage devices are supplied (see exceptions). 53 V
voltage is generated for the operation of the axes.
With K2, 24 V_NA is switched on (voltage that must always be switched off during EMERGENCY
STOP, the motor activity in the case of tools).
Activate axis voltages
If all processes were OK up to this point, the voltages for the driver stages of the axes are now
enabled on the amplifier and inspected.
Start of communication to the head
The communication with the modules must be in operation before an initialisation run. The system
must know the type and number of the MTS modules.
Test light barriers
The light barriers are tested before and during an initialisation run.
Errors will trigger an appropriate notification and lead to termination of the run.
Initialisation run
The tools are initialised and brought into the parking position. The zero marks of the X and Y axes are
identified and recorded as positional references.
Tests
Various tests are started during initialisation. The functions become active if there is any erroneous
activity, the cutter is stopped and the malfunction message can be read and resolved:
• Voltage monitoring
• Current monitoring
• Temporal behaviour
• Temperature
• Emergency stop function
• Light barriers
195
Electrical system/electronics
•
196
Internal problems
Electrical system/electronics
13.4 Boards
Electronics unit
Name
Version
See
ACS_MC_BOARD
2_0
ACS_MC_BOARD V2 on page 199
ACS_BF_BOARD
1_3
ACS_BF_BOARD on page 207
ACS_AMPLIFIER_XBL_BOARD
1_2
ACS_AMPLIFIER_XBL_BOARD on page 222
ACS_OPT_BOARD1
1_1
ACS_OPT_BOARD1 on page 233
ACS_OPT_ANT1 (vacuum generator,
auxiliary drive, router)
1_1
ACS_OPT_ANT1_BOARD on page 240
ACS_CAN_PWR_DISTR_BOARD
1_0
Power unit
Name
Version
See
ACS_SYS_FUNC_BOARD
1_3
ACS_SYS_FUNC_BOARD on page 247
ACS_EMM_CON_BOARD
1_0
ACS_EMM_CON_BOARD on page 255
front side support
Name
Version
See
ACS_ENC_BOARD
1_1
ACS_ENC_BOARD on page 263
Beam
Name
Version
See
ACS_X_BOARD
1_4
ACS_X_BOARD on page 274
MTS_YS_BOARD
1_2
MTS_YS_BOARD on page 282
MTS_SENS_BOARD
1_1
MTS_SENS_BOARD on page 290
ACS_CROSS_BOARD
1_2
ACS_CROSS_BOARD_L3 on page 266
Name
Version
See
ACS_PANEL_BOARD
2_0
ACS_PANEL-BOARD on page 296
PANEL ADAPTERBOARD
1_0
ACS_PANEL-BOARD on page 296
Operating unit
197
Electrical system/electronics
13.4.1 Overview image
198
Electrical system/electronics
13.4.2 ACS_MC_BOARD V2
Function overview
The ACS_MC_BOARD V2 (hereafter referred to as ACS_MC_BOARD with USB) is used to control
the ACS200.
It consists of the following modules:
• ColdFire CPU (CF)
• Memory (Flash and SDRAM)
• Ethernet controller
• ALTERA-FPGA
• Seven-segment display
The main tasks of the CPU are:
• Control of processes (peripheral devices)
• HPGL interpretation
• Safety monitoring
• Database management (management of settings)
• Operating unit communication
• Interface management (SPI, Ethernet, CAN)
The main tasks of the Altera are:
• Analysis of position sensors X, Y, T, Z
• IO handling (BF_BOARD, Option_Boards)
• PWM (generation)
• Safety (independent of CPU and SW)
• Light barrier monitoring
• ZLINK (communication between MC_BOARD and YM_BOARD)
• Trigger units (detection of zero marks, bar codes, edge sensors and AKI)
The MC_BOARD is fitted on the BF_BOARD (piggyback). The interface modules for CAN, SPI, RS232
and IOs are located on the BF_BOARD. The linear and switch controllers for the voltages required by
the MC_BOARD (5 V, 3.3 V, 1.5 V and 1.2 V) are also located on the BF_BOARD. All voltages and
signals are transferred via the S1 and S2 female multipoint connectors of the MC_BOARD to the S1
and S2 male multipoint connectors of the BF_BOARD.
Note:
Machine-specific values are stored on the ACS_MC_BBOARD and must be updated
after replacement.
The following actions are required:
199
Electrical system/electronics
Recalibrating "cogging" on page 98
Overview
200
Electrical system/electronics
1
Interfaces (external) Ethernet
6
CPU
2
Flash memory
7
Altera
3
Interface (I2C, ZLINK, IO, Encoder, SPI,
PWM)
8
7-segment control, MAC address
4
SD_RAM memory
9
Flash memory
5
SD_RAM memory
10
Interface (I2C, CAN, BF_IO, OPT_IO)
201
Electrical system/electronics
Plug
202
Item
Plug
1
S1/S2
ACS_BF_BOARD
2
S3
Measuring point
3
S4
4
S9
Firmware update
5
S17
JTAG
6
S11
IO Expander
7
S10
uP Expander
8
X1
Error number display
9
S15
LAN
Electrical system/electronics
LEDs and visual displays
LED
Function
LD1
Illuminates during initialisation (loading Altera and saving program from Flash to SDRAM)
LD3
Ethernet collision
LD4
Full-duplex Ethernet
Seven-segment display
This displays the status of the machine and error messages. In its standard set-up, the machine will
provide the following seven-segment image (sequentially):
In the event of an error message, the following are generated sequentially on the display (example):
Error message
12C04
Subsequent error
E204
203
Electrical system/electronics
Jumpers and switches
204
Jumper
Function
J1
I2C active low write
J2
Manual reset CPU
J3
JTAG_Enable (low active)
J12
Direct DMA timer control (S10)
fitted
×
×
Electrical system/electronics
Measuring points and voltages
1
J5
5
J6
2
J11 Pin1
6
J8
3
S3 Pin1
7
J10
4
S4 Pin1
8
J7
Measuring point Signal/voltage
Tolerance
J5
GND pins
-
J6
GND pins
-
J7
GND pins
-
J8
GND pins
-
J10
GND pins
-
J11 Pin1
GND
-
J11 Pin2
1.2V
2%
J11 Pin3
1.5V
2%
J11 Pin4
3.3V
1.5%
J11 Pin5
5.1V
3%
J11 Pin6
GND
-
S3 Pin1
nCS5 (nCPU_Emergency stop)
low active
S3 Pin2
BF_OUT9 (nAltera_Emergency stop)
low active
S4 Pin1
nIRQ6
"0" / "1"
S4 Pin2
nIRQ5
"0" / "1"
205
Electrical system/electronics
Measuring point Signal/voltage
Tolerance
S4 Pin3
"0" / "1"
nIRQ4
Error symptoms
With signal SEL_BDM the pull-up (4k7) on 3V3 is absent. This is currently soldered manually between
PIN 7 and PIN 9 of multi-pin connector S9. If this resistor has not been soldered in place, errors may
occur during programming via the cyclones.
The pins from the 68-pole female multipoint connectors (S1, S2) may be badly soldered. As a result, it
may not be possible to program the MC, or malfunctions may occur.
When fitting or removing the MC_BOARD from the BF_BOARD in the E-unit, the insert plate
(interfaces) must be unscrewed. The male multipoint connector contacts on the BF_BOARD may
become warped if the MC_BOARD is not fitted or detached properly. This can cause a variety of
errors.
206
Electrical system/electronics
13.4.3 ACS_BF_BOARD
Function overview
The ACS_BF_BOARD carrier board is the interface to the connected sensors and actuators of the
basic cutter model. The most commonly used functions are combined in the basic model.
Overview
207
Electrical system/electronics
Plug
Plug
208
S1
Slide vacuum encoder
S2
Zero marks, X-encoder
S3
ACS_Cross_BOARD
S4
ACS_Cross_BOARD
S5
External SPI (e.g. Uni_BOARD)
S6
ACS_AMPLIFIER _BOARD
S7
Test plug
S8
OPTION_BOARD string 1 (FW: STR1)
S9
OPTION_BOARD string 2 (FW: STR2)
S10
OPTION_BOARD string 3 (FW: STR3)
S11
Optional BF IO expansion
S12
Optional BF IO expansion
Electrical system/electronics
Plug
S13
ACS_AMPLIFIER_BOARD supply
S14
ACS_SYS_FUNC_BOARD
S15
ACS_SYS_FUNC_BOARD (optional)
S16
ACS_PANEL_BOARD
S17
VALVE_SWITCH_BOARD
S18
COM 2 interface
S19
COM 1 interface
S20
ACS_MC_BOARD slot
LEDs and visual displays
1
LED
209
Electrical system/electronics
LEDs
Signal
Description
LD1
24V_C
24V_Control
LD2
24V_NA
24V_Emergency stop
LD3
ACS200_ON
Operating unit has released the system
LD4
3V3
-
LD5
5V
-
LD6
24VF
24V_Fused
LD7
24V_CSW
24V_Control_Switched
LD8
-
Emergency stop is not available
Jumpers and switches
210
Electrical system/electronics
Item
Jumper
Description
1
J1
Not active
2
J2
GND (for measurements)
3
J3
GND (for measurements)
4
J4
Measurement of voltages (see measuring points)
5
J5
For test purposes
6
J6
Write protect for I2C-EEPROM
7
J7
ACS200 ON - bridge Panel-ON
8
J8
GND (for measurements)
Measuring points and voltages
For error diagnostics, measure the supply on the power supply line (S13) and the connection to the
operating unit and ACS_VALVE_SWICH_BOARD or ACS_PAN_CON_BOARD. All voltages can be
monitored using the LEDs or can be measured at J4.
211
Electrical system/electronics
1
S17 pin 1
3
S13 pin 1
2
S16 pin 1
4
J4
PIN
S13
S16
S17
J4
1
PGND
CAHN
CAN+
24V_C
2
(24VF)
CANL
CAN-
24V_CSW
3
24V_NA
24V_C
24VF
24V_NA
4
PGND
PGND
24VF
5
24VF
24VF
ACS200_ON
6
ACS200_ON
NC
5V
7
CAN+
CAN_END+
3V3
8
CAN-
CAN_END-
1V5
9
1V2
10
GND
Error symptoms
No error symptoms are indicated.
13.4.3.1 Pin assignment (ACS_BF_BOARD)
13.4.3.1.1 Pin assignment S1
PIN
Name
1
TP
2
5V
3
GND
4
TP
5
EA+
6
EA-
7
EB+
8
EB-
9
EI+
10
EI-
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.2 Pin assignment S2
212
PIN
Name
1
TP
2
5V
Electrical system/electronics
PIN
Name
3
GND
4
TP
5
XA-
6
XA+
7
XB-
8
XB+
9
XI-
10
XI+
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.3 Pin assignment S3
PIN
Name
1
GND
2
YLA+
3
YLA-
4
YLB+
5
YLB-
6
XLA+
7
XLA-
8
XLB+
9
XLB-
10
YA+
11
YA-
12
YB+
13
YB-
14
YI+
15
YI-
16
FIN B+
17
FIN B-
18
STOP3
19
STOP4
20
GND
Overview image
213
Electrical system/electronics
13.4.3.1.4 Pin assignment S4
PIN
Name
1
GND
2
SYN_FRAME+
3
SYN_FRAME-
4
SYN_MOSI+
5
SYN_MOSI-
6
SYN_CS+
7
SYN_CS-
8
FOUT_A+
9
FOUT_A-
10
FOUT_B+
11
FOUT_B-
12
SYN_MISO+
13
SYN_MISO-
14
FIN_A+
15
FIN_A-
16
RES12
17
TST1
18
STOP2
19
STOP1
20
GND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.5 Pin assignment S5
214
PIN
Name
1
24VF
2
24VF
3
24VF
4
24VF
5
24VF
6
PGND
7
PGND
8
PGND
9
PGND
Electrical system/electronics
PIN
Name
10
PGND
11
SPIO_MOSI-
12
SPIO_MOSI+
13
SPIO_CLK-
14
SPIO_CLK+
15
SPIO_CS-
16
SPIO_CS+
17
SPIO_MISO-
18
SPIO_MISO+
19
PGND
20
TP23
21
PGND
22
TP23
23
PGND
24
TP23
25
EXT_STOP
26
TST2B
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.6 Pin assignment S6
PIN
Name
1
5V
2
SPI1_CLKB
3
SPI1_MISOB
4
SPI1_MOSIB
5
nSPI1_CSB
6
GND
7
AMP_RES1
8
OPT_SUM_OK
9
PWM_BLOW
10
AMP_RES2
11
PWM_YAB
12
PWM_YBB
13
PWM_XAB
14
PWM_XBB
215
Electrical system/electronics
PIN
Name
15
GND
16
nVAC_OFF
17
nAMP_OFF
18
nPOW_OFF
19
SC0
20
SD0
21
nI2C_INT_0
22
GND
23
PWM_VA
24
PWM_VB
25
GND
26
GND
Voltage
Tolerance
Overview image
13.4.3.1.7 Pin assignment S8
PIN
Name
1
OPT_SUM_OK
2
OPT_O4
3
OPT_O3
4
OPT_O2
5
OPT_O1
6
OPT_O0
7
OPT_I2
8
OPT_I1
9
OPT_I0
10
SC1
11
SD1
12
nI2C_INIT1
13
GND
14
GND
15
5V
16
24V_CSW
Overview image
216
Voltage
Tolerance
Electrical system/electronics
13.4.3.1.8 Pin assignment S9
PIN
Name
1
OPT_SUM_OK
2
OPT_O9
3
OPT_O8
4
OPT_O7
5
OPT_O6
6
OPT_O5
7
OPT_I5
8
OPT_I4
9
OPT_I3
10
SC2
11
SD2
12
nI2C_INIT2
13
GND
14
GND
15
5V
16
24V_CSW
Voltage
Tolerance
Overview image
13.4.3.1.9 Pin assignment S10
PIN
Name
1
OPT_SUM_OK
2
OPT_O14
3
OPT_O13
4
OPT_O12
5
OPT_O11
6
OPT_O10
7
OPT_I8
8
OPT_I7
9
OPT_I6
10
SC3
11
SD3
12
nI2C_INIT3
13
GND
Voltage
Tolerance
217
Electrical system/electronics
PIN
Name
14
GND
15
5V
16
24V_CSW
Voltage
Tolerance
Overview image
13.4.3.1.10 Pin assignment S11
PIN
Name
1
RES_IO0
2
RES_IO1
3
RES_IO2
4
RES_IO3
5
RES_IO4
6
RES_IO5
7
RES_IO6
8
RES_IO7
9
TP31
10
TP15
11
3V3
12
5V
13
GND
14
GND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.11 Pin assignment S12
218
PIN
Name
1
RES_IO8
2
RES_IO9
3
RES_IO10
4
RES_IO11
5
RES_IO12
6
RES_IO13
7
RES_IO14
8
RES_IO15
9
TP27
10
TP19
Electrical system/electronics
PIN
Name
11
3V3
12
5V
13
GND
14
GND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.12 Pin assignment S13
PIN
Name
1
PGND
2
24VF
3
24V_NA
Overview image
13.4.3.1.13 Pin assignment S14
PIN
Name
1
24V_C
2
24V_C
3
24V_CSW
4
nS1
5
nS2
6
nS3
7
nS4
8
nS5
9
nS6
10
nS7
11
n24V_P1
12
n24V_P2
13
n24V_V1
14
n24V_V2
15
nRES_EMM
16
nCPU_NO_EMM
17
n24V_ON
18
Y32
19
OVERTEMP
20
RES0
Voltage
Tolerance
219
Electrical system/electronics
PIN
Name
21
RES1
22
RES2
23
RES3
24
RES4
25
RES5
26
RES6
Voltage
Tolerance
Overview image
13.4.3.1.14 Pin assignment S16
PIN
Name
1
CANH
2
CANL
3
24V_C
4
PGND
5
24 V
6
ACS200_ON
7
CAN_END+
8
CAN_END-
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.15 Pin assignment S17
PIN
Name
1
CANH
2
CANL
3
24V_C
4
PGND
5
24 V
6
ACS200_ON
7
CAN_END+
8
CAN_END-
Overview image
13.4.3.1.16 Pin assignment S18
220
PIN
Name
1
DCD_1
Electrical system/electronics
PIN
Name
2
DSR_1
3
TXD_1
4
CTS_1
5
RXD_1
6
RTS_1
7
DTR_1
8
RI_1
9
GND
10
x
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.3.1.17 Pin assignment S19
PIN
Name
1
DCD_0
2
DSR_0
3
TXD_0
4
CTS_0
5
RXD_0
6
RTS_0
7
DTR_0
8
RI_0
9
GND
10
x
Overview image
221
Electrical system/electronics
13.4.4 ACS_AMPLIFIER_XBL_BOARD
Function overview
Power supplies
Distribution of the 24 V and the 24 V_NA (emergency stop) to the BF_BOARD and to the OPTIONS
board, fusing of the various input voltages.
Voltage generation 12 VF
Switching controller for the generation of the supply voltage 12 VF of the drivers (HIP4081); can be
switched on or off via I2C bus (12V_FREE). As soon as PG signal PG_12V is available, a bus driver is
enabled and the PWM signals are activated.
Voltage monitoring
2
(via I C bus)
There is binary monitoring of the following voltages (available/not available):
• VMOT = 53 V
• +12 VAn
• -12 VAn and 5 V
• 12 VF
• 24 V
• 24 V_EX
• 24 V_NA
• PGOOD (power good) outputs of all hot-swap controllers
For reasons of functional safety, the following voltages are monitored for over and undervoltage:
• - 12 VF (actual driver supply OK)
• - 24 V
H-bridge X-axis
Control X-DC motor and X-brushless motor (XBL)r
H-bridge Y-axis
Y-motor control
H-bridge vacuum motor
Only for S3fitted
Control motor for slide vacuum
Current measurement (ADC) and voltage generation ±12 VAn
±12 VAn = Supply voltage for the analogue part 13Bit, 8 channel analogue/digital converter
Output filter
Motor signals of the X, Y and vacuum axes (S3 only) can be deactivated using filter levels; smaller
slew rates result in less interference in the system.
Vacuum generator control (frequency converter)
Interface to ACS_ANT1_BOARD
Control, feeding elements
Control feeding element 1 and feeding element 2 via I2C
Detection of board temperature
2
I C temperature sensor
Interface for the detection of X-motor temperature
LM35 temperature sensor
Fan control
Fan control for the electronics unit and control of the X-motor fans
Interface to record XBL motor winding temperature
KTY sensor (x1) measured via AD converter
PT100 (x3) excess temperature: collected via I2C
222
Electrical system/electronics
Switching stages for P53V and P24V
Switching of 24 V and 53 V to ACS_CROSS_BOARD via I2C bus (SWITCH_P53V, SWITCH_P24V)
OVERLOAD function
The overload section monitors the voltage VMOT = 53 V. If energy is fed back from the motor
(generator effect), the voltage increases. As of a first threshold (approx. 61 V), performance resistance
is switched on (destruction of excess voltage). From a second limit (approx. 65 V) a message
2
(overload) is transmitted via I C bus.
Hot-swap function
The X and Y vacuum axes (only S3) and the P24V and P53V are monitored using what is known
as a hot-swap IC (= semiconductor fuse). If too much current flows into the corresponding path, it is
interrupted by this hot-swap controller and an external N-FET. This kind of interrupt is notified to the
2
system via the power good output of the hot swap and via I C-bus notified.
Motor brake function
The X-motor can be braked via the plug S11 and certain additional circuits.
The Y-motor can be braked via a special crossboard (provided with brake relay). The signal has
the name "nBrake" and is fed through the ribbon cable via S2 to the crossboard. At the same
time, in version 1.3 a signal can be fed from the crossboard to the I2C (signal: crossboard relay '
IN_24V_RES1).
Block diagram
223
Electrical system/electronics
Plug
Figure 8: Plug, fuses and LED
Blue, square edging on plugs symbolise the coding position on the plug.
224
S1
ACS_Cross_BOARD
S10
Electronics unit fan
S2
ACS_Cross_BOARD
S11
Brake resistor for NL plotter
S3
ACS_OPTION_BOARD
S12
Temperature monitor, X motor
Electrical system/electronics
S4
optional
S13
Vacuum slide
S5
Reserve I2C
S14
X-motor
S6
ACS_BF_BOARD
S15
External electrolytic converter and external
resistance
S7
ACS_ANT1_BOARD (blower
frequency converter)
S16
ACS_BF_BOARD
S8
Reserve ADC
S17
X motor (Phase C)
S9
Reserve input 24 V
S18
Temperature monitor, X motor PTC
LEDs and visual displays
See diagram:Figure 8: Plug, fuses and LED on page 224
Only red LEDs are fitted.
LED illuminates = voltage, signal available
LEDs
Signal
Description
LED1
5V
5 V available
LED2
AMP_ON
Driver for H bridge X-/Y- axis on, inverse control
brake resistance NL
LED3
VAC_ON
H-bridge vacuum slider driver on (S3 only)
LED4
POW_ON
Hot Swap controller on, voltage on the H bridges
LED5
12 VF
12 VF available
LED6
24 V
24 V available
LED7
VMOT_X
X axis voltage (VMOT_X) available
LED8
VMOT_Y
Y axis voltage (VMOT_Y) available
LED9
VMOT
53 V and therefore VMOT available
LED10
VMOT_VAC
Vacuum axis voltage (VMOT_VAC) available (S3
only)
LED11
-12 VAn
-12 VAn available
LED12
+12 VAn
+12 VAn available
LED13
P53V
Voltage P53V available
LED14
P24V
Voltage P24V available
Jumpers and switches
There are no jumpers or switches on this board.
Fuses
See diagram:Figure 8: Plug, fuses and LED on page 224
Fuse
Type
F1
F1:
225
Electrical system/electronics
Fuse
Type
FST 6.3 A
P24 V
F2
F2:
FSF 10 A
P58 V
Measuring points and voltages
226
Measuring
points
Description
TP1
GND
Reference to 5 V
TP2
nPOW_OFF
Switch axis voltage VMOT X, Y, VAC (only S3) on/off
TP3
PWMA_X1
Control signal A for
TP4
nVAC_OFF
"1" = enable / "0" = disable bridge driver, X-axis (S3
only)
TP5
PWMA_Y1
Control signal A for bridge driver, Y axis
TP6
PWM_BLOW
Control signal for vacuum turbine using Opt_Ant1
TP7
AMP_RES1
Reserved signal
TP8
PWMA_VAC
Control signal A for bridge driver, VAC-axis (S3 only)
TP9
PWMB_VAC
Control signal B for bridge driver, VAC axis (S3 only)
TP10
GND
Reference to 5 V
TP11
5V
5 V is generated on ACS_BF_BOARD
TP12
nAMP_OFF
"1" = enable/"0" = disable bridge driver for X and Y
TP13
PWMB_X1
Control signal B for bridge driver, X axis
TP14
PWMB_Y1
Control signal B for bridge driver, Y axis
TP15
PWMC_X1
Reserve signal (optional)
TP16
OPT_SUM_OK
Activation for external supply of the options
TP17
PGND
Power GND
TP18
24 V
24 V/20 A from the power supply
TP19
24 VF_EX
24 V for external functions
TP20
24 VF_AMP
24 V for functions on the ACS_AMPLIFIER_BOARD
TP21
SDA (I C)
2
Data line of the I2C
2
TP22
SCL (I C)
Clock line of the I2C
TP23
24V_NA
24 V emergency stop
TP24
12 VF
12 V for supply to amplifier
TP25
53 V
53 V / 20 A from the power supply
TP26
PGND
Power GND (reference to 53 V/VMOT)
Electrical system/electronics
Measuring
points
Description
TP27
VMOT
H-bridge voltage
TP28
PGND
Power GND
TP29
AGND
Analogue GND (reference to analogue voltage)
TP30
x
Current X axis PHASE A (ADC)
TP31
Y
Current, Y axis (ADC)
TP32
X_TEMP
X-motor temperature (ADC)
TP33
x
Current X axis PHASE B (ADC)
TP34
CH7
Reserve ADC channel 7
TP35
x
Current X axis PHASE C (ADC)
TP36
POS_VAC
Vacuum slider position (ADC) (S3 only)
TP37
I_VAC
Vacuum slider motor current (ADC) (S3 only)
TP38
AGND
TP39
-12 VAn
-Power supply to the analogue part
TP40
AGND
Analog GND
TP41
+12 VAn
+Power supply to the analogue part
TP42
GND
TP43
nCS
SPI ADC
TP44
MOSI
SPI ADC
TP45
SCK
Clock SPI ADC
TP46
MISO
SPI ADC
TP47
RES2
Spare line to the ACS_CROSS_BOARD
TP48
RES1
Spare line to the ACS_CROSS_BOARD
13.4.4.1 Pin assignment (ACS_AMPLIFIER_XBL_BOARD)
13.4.4.1.1 Pin assignment S1
PIN
Name
1
PRO1
2
PRO2
3
PGND
4
PGND
5
PGND
6
P53V
7
P53V
8
P53V
Voltage
Tolerance
227
Electrical system/electronics
PIN
Name
9
P53V
10
P53V
11
P53V
12
P53V
13
P53V
14
P53V
15
YMOT+
16
YMOT+
17
YMOT+
18
YMOT+
19
YMOT+
20
YMOT+
21
YMOT-
22
YMOT-
23
YMOT-
24
YMOT-
25
YMOT-
26
YMOT-
Voltage
Tolerance
Voltage
Tolerance
Overview imageJ
13.4.4.1.2 Pin assignment S2
228
PIN
Name
1
RES1
2
RES2
3
PGND
4
PGND
5
PGND
6
PGND
7
PGND
8
PGND
9
P24V
10
P24V
11
P24V
12
P24V
13
P24V
Electrical system/electronics
PIN
Name
14
P24V
15
P24V
16
PGND
17
PGND
18
PGND
19
PGND
20
PGND
21
24 V
22
24 V
23
24 V
24
GND
25
GND
26
GND
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.4.1.3 Pin assignment S3
PIN
Name
1
PGND
2
24 V
3
24V_NA
Overview image
13.4.4.1.4 Pin assignment S4
PIN
Name
1
PGND
2
IO_I2C_RES_4
3
IO_I2C_RES_3
4
IO_I2C_RES_2
5
IO_I2C_RES_1
6
5V
Overview image
13.4.4.1.5 Pin assignment S5
PIN
Name
1
PGND
229
Electrical system/electronics
PIN
Name
2
24 V
3
24V_NA
4
PGND
5
53V
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.4.1.6 Pin assignment S6
230
PIN
Name
1
5V
2
SCK
3
MISO
4
MOSI
5
nCS
6
GND
7
AMP_RES1
8
OPT_SUM_OK
9
PWM_BLOW
10
PWMC_X1
11
PWMA_Y1
12
PWMB_Y1
13
PWMA_X1
14
PWMB_X1
15
GND
16
nVAC_OFF
17
nAMP_OFF
18
nPOW_OFF
19
SCL
20
SDA
21
nINT
22
GND
23
PWM_VAC
24
PWM_VAC
25
GND
26
GND
Electrical system/electronics
Overview image
13.4.4.1.7 Pin assignment S8
PIN
Name
1
GND
2
AGND
3
CH7
4
5V
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.4.1.8 Pin assignment S9
PIN
Name
1
IN_24V_RES1
2
IN_24V_RES2
3
24VF_EX
Overview image
13.4.4.1.9 Pin assignment S10
PIN
Name
1
PGND activated
2
24VF_EX
Overview image
13.4.4.1.10 Pin assignment S11
PIN
Name
1
MOTOR_X+ (PH_A)
2
MOTOR_X- (PH_B)
3
24VF_EX
4
PBND_Switch
5
MOTOR_X+ (PH_C)
Overview image
13.4.4.1.11 Pin assignment S12
PIN
Name
1
PGND
2
24VF_EX
3
GND
231
Electrical system/electronics
PIN
Name
4
Analog_signal
5
5V
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.4.1.12 Pin assignment S13
PIN
Name
1
-MOT_V
2
+MOT_V
3
4
VIST
5
Overview image
13.4.4.1.13 Pin assignment S14
PIN
Name
1
Motor_X+
2
Motor_X-
3
Motor_X+
4
Motor_X-
Overview image
13.4.4.1.14 Pin assignment S15
PIN
Name
1
PGND
2
VMOT
3
VMOT
4
R-
Overview image
13.4.4.1.15 Pin assignment S16
PIN
Name
1
PGND
2
24 V
3
24V_NA
Overview image
232
Electrical system/electronics
13.4.4.1.16 Pin assignment S17
Pin
Name
1
24V_C
2
PGND
Voltage
Tolerance
Overview image
13.4.5 ACS_OPT_BOARD1
Function overview
The ACS_OPT_BRD1 board was developed for the control of basic equipment of frequently used
sensors/actuators. A maximum of three of these boards can be connected to the ACS200 (max. one
per string). As the "frequently" used IOs are connected with this board, it does not make sense to
use this card repeatedly. (Winding/tightening, roll-up, POT, MSENS, AKI-2 are only present once).
The exceptions are the drive units and the IOs of the I2C bus, which can be used once per string.
Therefore it is possible to operate up to 6 drive units (router, auxiliary drive)
Overview
The ACS_BF_BOARD and ACS_OPT_BRD1 are connected using a ribbon cable. Normally, the
signals are obtained via the defined connector plugs. A distribution board ACS_OPT_REL1 or a
UM45-FLK34 terminal board from Phoenix Contact is connected for extensions. The optional inputs/
outputs are distributed on the terminal board. Units such as the auxiliary drive and/or router are
connected in piggyback with a ACS_OPT_ANT1 board on the ACS_OPT_BRD1.
233
Electrical system/electronics
S1
ACS_BF_BOARD (S1)
S8
ACS-OPT_REL1_BOARD (winding/
unwinding unit)
S2
ACS_OPT_BRD1_BOARD (slave)
(S2)
S9
ACS_OPT_ANT1_BOARD router
connection
S3
ACS_AMPLIFIER_BOARD (S4)
supply
S10
ACS_OPT_ANT1_BOARD auxiliary drive
connection
S4
ACS_AMPLIFIER_BOARD supply
(optional)
S11
Maintenance unit (POT)
S5
Winding unit
S12
Router – sealing air valve
S6
Material sensor
S13
AKI 2
S7
UM 45-FLK34 (Varioface)
LEDs and visual displays
On the board there are 8 LEDs labelled LD1 to LD8. For the optional inputs UNI0 to UNI3 and BIP0 to
BIP3, one LED illuminates for each input if voltage is present.
234
Electrical system/electronics
LEDs
Input
Description
LD1
UNI0
Optional input with galvanic separation
LD2
UNI1
Optional input with galvanic separation
LD3
UNI2
Optional input with galvanic separation
LD4
UNI3
Optional input with galvanic separation
LD5
BIP0
Optional input with galvanic separation, bipolar
LD6
BIP1
Optional input with galvanic separation, bipolar
LD7
BIP2
Optional input with galvanic separation, bipolar
LD8
BIP3
Optional input with galvanic separation, bipolar
Jumpers and switches
There are 6 jumpers on the board. The J1 jumper is only needed if more than 3
ACS_OPT_BRD1_BOARDs are connected.
235
Electrical system/electronics
Jumper
Jumper function set
Comment
Default
J1
Address Offset - 08H
Not required
Not set / is required for slave (currently not
fitted)
J2
STOP interconnected
not set
J3 - J6
No function
not set
Measuring points and voltages
The test points must not be used because they are not equipped with a Berg pin. Voltages can be
read off from the plugs for the purpose of troubleshooting (see plug assignments)
13.4.5.1 Pin assignment (ACS_OPT_BRD1_BOARD)
13.4.5.1.1 Pin assignment S1
236
PIN
Name
1
OPT_SUM_OK
2
OPT_O4
3
OPT_O3
4
OPT_O2
5
OPT_O1
6
OPT_O0
7
OPT_I2
Voltage
Tolerance
Electrical system/electronics
PIN
Name
8
OPT_I1
9
OPT_I0
10
SC
11
SD
12
nI2C_INIT
13
GND
14
GND
15
5V
16
24V_CSW
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.5.1.2 Pin assignment S2
PIN
Name
1
OPT_SUM_OK
2
OPT_O4
3
OPT_O3
4
OPT_O2
5
OPT_O1
6
OPT_O0
7
OPT_I2
8
OPT_I1
9
OPT_I0
10
SC
11
SD
12
nI2C_INIT
13
GND
14
GND
15
5V
16
24V_CSW
Overview image
13.4.5.1.3 Pin assignment S3
PIN
Name
1
PGND
2
24 V
237
Electrical system/electronics
PIN
Name
3
24V_NA
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.5.1.4 Pin assignment S4
PIN
Name
1
PGND
2
24 V
3
24V_NA
Overview image
13.4.5.1.5 Pin assignment S5
PIN
Name
1
24 V_NA_R
2
RUP_OUT
3
PGND
Overview image
13.4.5.1.6 Pin assignment S6
PIN
Name
1
24V_NA_D
2
MSENS_IN
3
PGND
Overview image
13.4.5.1.7 Pin assignment S7
238
PIN
Name
1
24VF_S
2
24VF_S
3
P_OUT0
4
P_OUT1
5
P_OUT2
6
P_OUT3
7
PGND
8
FAST_O0
9
FAST_O1
Electrical system/electronics
PIN
Name
10
V_OUT7
11
V_OUT6
12
V_OUT5
13
V_OUT4
14
V_OUT3
15
V_OUT2
16
V_OUT1
17
V_OUT0
18
PGND
19
nIN_STOP
20
IN_A0
21
IN_A1
22
IN_A2
23
IN_A3
24
PGND
25
IN_A8
26
IN_A9
27
IN_A10
28
IN_A11
29
PGND1
30
IN_A4
31
IN_A5
32
IN_A6
33
IN_A7
34
COM
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.5.1.8 Pin assignment S11
PIN
Name
1
24VFPOT
2
POT_OUT
Overview image
239
Electrical system/electronics
13.4.5.1.9 Pin assignment S12
PIN
Name
1
24V_NA
2
24V_NA
3
24V_NA
4
Terminal_OUT
5
Winding_OUT
6
Tightening_OUT
7
PGND
8
PGND
9
PGND
10
PGND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.5.1.10 Pin assignment S12
PIN
Name
1
24V_NA_D
2
RED_V1
3
RED_V2
4
PGND
Overview image
13.4.5.1.11 Pin assignment S13
PIN
Name
Voltage
Colour
1
AKI_POWER
Connected power supply
Brown
2
AKI_ANW_IN
0V if AKI in park position
White
3
AKI:TRIG_IN
0V Beam of light interrupted
Black
4
PGND
Blue
Overview image
13.4.6 ACS_OPT_ANT1_BOARD
Function overview
The ACS_OPT_ANT1_BOARD is used as an IO expansion for the ACS_AMPLIFIER_BOARD,
ACS_OPT_BRD1. The following IO extensions are defined:
• ACS_OPT_BRD1_BOARD:
Router connection
240
Electrical system/electronics
•
Auxiliary drive connection
ACS_AMPLIFIER_BOARD:
Vacuum generator connection
Overview
Interfaces / pin assignments
1 ACS_OPT_BRD1_BOARD / ACS_AMPLIFIER_BOARD
2 Router, auxiliary drive, vacuum generator connection
The following electrically isolated signals are available:
• 3 digital outputs of 24 V @ 10 mA
• 2 digital inputs of 24 V
• 1 analog output of 0.5 V or 0.10 V (jumper)
On the board, a galvanically separated DC/DC converter (+5 V) is used to generate the 12 V required
on the secondary side for the analog output. In addition, +5 V is generated on the secondary side
from +12 V. The pin assignment on the S3 multi-pin connector is identical to the one on the S1 plug.
241
Electrical system/electronics
Multi-pin connector S3 can thus be used for measurement purposes. To create a measuring probe, for
example.
S3/S1
PIN
Signal
Router
Auxiliary drive
Comment
1
24 V_U
+24 V_R
+24 V_U
24 V from the external
device
2
O_A_SIG0
R_STOP
H_DIR
Digital output
3
O_A_SIG1
R_START
H_ENA
Digital output
4
O_A_QSTP
-
H_QSTP
Digital output
5
I_A_SIG0
R_SPEED_RDY
H_OK*
Digital input
6
I_A_SIG1
R_PRESSURE_OK -
Digital input
7
O_A_SPEED
R_SPEED
H_SPEED-
Analog output
8
A_GND
GND
GND
GND secondary side
The 24 V voltage supplied by the external device is used to control the inputs of the external device.
The voltage is forwarded for use with a switch contact (relay). No inputs can be operated without this
voltage enabled.
Note:
The outputs are not short-circuit proof!
S4
PIN
Function
Comment
1
+12 V
12 V secondary side
2
+5 V
5 V secondary side
3
A_GND
GND secondary side
LEDs and visual displays
There are no LEDs or optical indicators on this board.
Jumpers and switches
There is one jumper on the ACS_OPT_ANT1_BOARD. This jumper doubles the analog output voltage
(output range 0-10 V instead of 0-5 V).
242
Electrical system/electronics
1 J1
Jumper
Jumper function set
Comment
Default
J1
Voltage range (0-10 V)
when output is analog
is always needed for
vacuum generators,
routers and auxiliary
drives
Set
Measuring points and voltages
The voltages/signals on the S1 plug as well as on the S3 and S4 multi-pin connectors can be checked
for troubleshooting purposes. The pin allocation on the S3 connector is the same as on the S1 plug.
243
Electrical system/electronics
1
2
3
4
S3 pin 1
TP1
S4 Pin 1
S1 pin 1
Measuring points
Voltage
Tolerance
S4 pin 2
5 V secondary side (5.0 V)
S4 Pin 3
12 V secondary side (12.0 V)
S4 Pin 1
GND secondary side (0 V)
S1 pin 1
24 V external
TP1
Connected 24 V
+10% / -20%
Error symptoms
No error symptoms are indicated.
13.4.6.1 Pin assignment (ACS_OPT_ANT1)
13.4.6.1.1 Pin assignment S1
244
PIN
Name
1
+24V_U
Voltage
Tolerance
Electrical system/electronics
PIN
Name
2
H_DIR
3
H_END
4
H:QSTP
5
H_OK
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
6
7
H_SPEED
8
GND
Overview image
13.4.6.1.2 Pin assignment S2
PIN
Name
a1
A_UO
b1
A_U
a2
O_A_SIG1
b2
O_A_SIG0
a3
I_A_SIG0
b3
O_A_SIG2
a4
I_A_SIG2
b4
I_A_SIG1
a5
O_A_SPEED
b5
O_ALL_QSTP
a6
GND
b6
+5V
Overview image
13.4.6.1.3 Pin assignment S3
PIN
Name
1
A_U
2
O_A_SIG0
3
O_A_SIG1
4
O_ALL_QSTP
5
I_A_SIG1
6
I_A_SIG0
7
O_A_SPEED
8
GND
245
Electrical system/electronics
Overview image
13.4.6.1.4 Pin assignment S4
PIN
Name
1
A_GND
2
+5V
3
+12V
Overview image
246
Voltage
Tolerance
Electrical system/electronics
13.4.7 ACS_SYS_FUNC_BOARD
Function overview
The power supplies must be connected, pre-distributed and fused. The ACS_SYS_FUNC_BOARD
was developed for this purpose. The controls in the electronics unit use the
ACS_SYS_FUNC_BOARD to switch on all power supplies and the start the emergency stop module.
All 230 V/110 V options are also connected.
Overview
MP1
53 V SP2, SP3
S6
Foot switch 1
MP2
Ground SP2, SP3
S7
Vacuum pump 2
S1
ACS_BF_BOARD
S8
Foot switch 2
S2
24 V supply of power unit SP1
S9
Temperature sensor SW_50, O_Temp,
fan (power unit)
S3
ACS_AMPLIFIER_BOARD
S10
Options relay
S4
not used
S11
ACS_EMM_CON_BOARD
S5
Vacuum pump 1
247
Electrical system/electronics
LEDs and visual displays
1 LD1 - LD7
248
LEDs
Signal
Description
Action
LD1
N24V_ON
Signal activates 24 V
The LED illuminates 24 V activated
LD2
n_RES_EMM
Reset signal for EMERGENCY
STOP module
Brief illumination during start-up
LD3
n_CPU_NO_EMM
Signal activates EMERGENCY
STOP module
LED illuminates - emergency stop
OK
LD4
N24V_V2
Changeover valve 2 control signal
LD5
N24V_P2
Pump 2 control signal
LD6
N24V_V1
Changeover valve 1 control signal
LD7
N24V_P1
Pump 1 control signal
Electrical system/electronics
Jumpers and switches
Jumper
Signal
Description
J1
-
Operation/test mode configuration (system)
J2
-
Operation/test mode configuration (options)
J3
P1
Vacuum generator 1
V1
Changeover valve 1
P2
Vacuum generator 2
V2
Changeover valve 2
CNE
nCPU_NO_EMM - emergency stop activation
RES
nRES_EMM - emergency stop reset
24 V_ON
Control signal for 24 V
nS1
Compressor
nS2
Router option frequency converter
nS3
Dust extractor
nS4
Auxiliary drive frequency converter
nS5
Spare
nS6
Spare
nS7
Spare
J4
Test description with jumper
Through use of the ACS_SYS_FUNC_BOARD, the power unit can be brought fully into operation
and tested without the electronics unit. As a result, all voltages can be measured accurately and
249
Electrical system/electronics
set if necessary, without posing a risk to the electronics unit. A specific start-up sequence must be
observed.
To do this, set jumpers J1 and J2 to test mode:
Jumper
Setting
J1
J2
Use the 2 newly free jumpers and J3 to activate and start the emergency stop module.
• Set jumper J3/CNE (9-10). Power is supplied to the emergency stop module.
• Briefly set then remove jumper J3/RES (11-12). The emergency stop module checks the
emergency stop channels and switches to operational mode following a successful test. 24 V_NA
is released to the S3 plug and the contactor (K9) activates. SP2 and SP3 therefore receive mains
voltage. The emergency stop switches must be connected for this test!
• Set jumper J3/24 V_ON (13-14). 24 V is released to plug S3.
Set jumpers J1 and J2 back to operating mode:
Jumper
Setting
J1
J2
Measuring points and voltages
There are no measuring points on this board. Use the plug connectors S2 and MP1/MP2 to measure
the two system voltages.
250
Electrical system/electronics
Measuring points
Voltage
MP1
53 V
MP2
53 V_GND
S2
24 V
Tolerance
Pin assignment S3
Measuring points
Voltage
S3_1
53 V
S3_2
53 V_GND
S3_3
24 V_NA
S3_4
24 V
S3_5
GND
Tolerance
Error symptoms
No error symptoms are indicated.
Overview image
251
Electrical system/electronics
13.4.7.1 Pin assignment (ACS_SYS_FUNC_BOARD)
13.4.7.1.1 Pin assignment S1
PIN
Name
Voltage
1
24V_C1
24V_C1
2
24V_C1
24V_C1
3
24V_CSW
24V_CSW
4
nS1
5
nS2
6
nS3
7
nS4
8
nS5
9
nS6
10
nS7
11
n24_P1
12
n24_P2
13
n24_V1
14
n24_V2
15
nRES_EMM
16
nCPU_NO_EMM
17
n24V_ON
18
Y32
19
OVERTEMP
20
RES0
21
RES1
22
RES2
23
RES3
24
RES4
25
RES5
26
RES6
Tolerance
Overview image
13.4.7.1.2 Pin assignment S2
252
PIN
Name
Voltage
1
24V_IN
24V_IN
2
PGND
Tolerance
Electrical system/electronics
Overview image
13.4.7.1.3 Pin assignment S3
PIN
Name
1
PGND
2
24V_PGND
3
24V_NA
4
53V_GND
5
53V
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.7.1.4 Pin assignment S4
PIN
Name
1
24 V
2
24V_NA
Overview image
13.4.7.1.5 Pin assignment S5
PIN
Name
1
PGND
2
VAC1
3
PUMP1
4
POWER1
Overview image
13.4.7.1.6 Pin assignment S6
PIN
Name
1
Foot switch
2
FS1
Overview image
13.4.7.1.7 Pin assignment S7
PIN
Name
1
PGND
2
VAC2
3
PUMP2
4
POWER2
253
Electrical system/electronics
Overview image
13.4.7.1.8 Pin assignment S8
PIN
Name
1
Foot switch
2
FS2
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.7.1.9 Pin assignment S9
PIN
Name
1
PGND
2
Van +
3
O_Temp
4
24V_C
5
SW_50
6
24V_C
Overview image
13.4.7.1.10 Pin assignment S10
PIN
Name
1
24V_NA1
2
nS1
3
nS2
4
nS3
5
nS4
6
nS5
7
nS6
8
nS7
Overview image
13.4.7.1.11 Pin assignment S11
254
PIN
Name
1
K6B
2
TP1
3
K7B
4
TP2
5
Y32
Electrical system/electronics
PIN
Name
6
TP3
7
K2
8
TP4
9
PGND
10
TP5
Voltage
Tolerance
Overview image
13.4.8 ACS_EMM_CON_BOARD
13.4.8.1 Pin assignment (ACS_EMM_CON_BOARD)
13.4.8.1.1 Pin assignment S1
PIN
Name
1
a1
2
TP1
3
Start
4
TP2
5
Y32
6
TP3
7
24
8
TP4
9
PGND
10
TP5
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.8.1.2 Pin assignment S2
PIN
Name
1
Y5
2
S21
3
24
4
14
5
Y32
6
S22
7
S12
8
PGND
255
Electrical system/electronics
PIN
Name
9
S34
10
S11
11
Y4
12
a1
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.8.1.3 Pin assignment S3
PIN
Name
1
14
2
24
3
PGND
4
Start
5
S34 R
Overview image
13.4.8.1.4 Pin assignment S4
PIN
Name
1
14
2
24
3
PGND
4
S34 R
5
S34
Overview image
13.4.8.1.5 Pin assignment S5
PIN
Name
1
S11
2
S21
3
S12A
4
S22A
Overview image
13.4.8.1.6 Pin assignment S6
256
PIN
Name
1
S11A
Electrical system/electronics
PIN
Name
2
S21A
3
S12B
4
S22B
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.8.1.7 Pin assignment S7
PIN
Name
1
S11B
2
S21B
3
S12C
4
S22C
Overview image
13.4.8.1.8 Pin assignment S8
PIN
Name
1
S11C
2
S21C
3
S12D
4
S22D
Overview image
13.4.8.1.9 Pin assignment S11
PIN
Name
1
S12D
2
S22D
3
S12E
4
S22E
Overview image
13.4.8.1.10 Pin assignment S12
PIN
Name
1
S12E
2
S22E
3
S12F
4
S22F
257
Electrical system/electronics
Overview image
13.4.8.1.11 Pin assignment S13
PIN
Name
1
S12F
2
S22F
3
S12G
4
S22G
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.8.1.12 Pin assignment S14
PIN
Name
1
S12G
2
S22G
3
S12
4
S22
Overview image
13.4.9 ACS_VALVE_SWITCH_BOARD_3
Function overview
Print ACS_VALVE_SWITCH_BOARD was developed to control the individual vacuum zones the.
With the introduction of the new valve island with direct D-SUB connector, a new print had to be
developed, the ACS_VALVE_SWITCH_BOARD_2. With the request for control of the LED strip for the
L3 generation, the option and the interfaces for it had to be crated. A new print had to be developed
for this, the ACS_VALVE_SWITCH_BOARD_3.
Overview
258
Electrical system/electronics
P1
CAN connection
P5
Valve island
P2
BDM interface
P6
LED strips
P4
SPI interface
P7
LED strips
LEDs and visual displays
LEDs
Function
LD1
Illuminates when the processor is in reset
May not be lit in normal mode
Active states are reported via the combination of LEDs LED2 & LED3
LEDs
Function
LED2 flashes
Master without LED strips
LED2 & LED3 flash at same time
Master with LED strips
LED3 flashes
Slave 1 or Slave 2
LED2 and LED3 flash alternately
Test mode (J1 set)
LED2 & LED3 lit
Error
259
Electrical system/electronics
Jumpers and switches
Jumper
Function
J1
Test
J2
Slave1
J3
Slave2
J4
Spare
J5
Spare
-
Master
Comment
If no jumpers are fitted in J1-3
Measuring points
For measurement purposes, 2-pin Berg plugs are fitted which are connected to GND and labeled as
GND in silk-screen printing.
13.4.9.1 Pin assignment (ACS_VALVE_SWITCH_BOARD)
13.4.9.1.1 P1 pin assignment
PIN
Name
1
GND
2
24 V
3
CAN-
4
CAN+
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.9.1.2 Pin assignment P2
Pin
Name
1
MODC/BKGD
2
GND
3
-
4
nRESET
5
-
6
VDD5
Overview image
13.4.9.1.3 Pin assignment P4
260
Pin
Name
1
GND
2
A_In_0
Electrical system/electronics
Pin
Name
3
IC_OC_PWM1
4
SCK
5
MOSI
6
nSS
7
MISO
8
VDD5
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.9.1.4 Pin assignment P5
Pin
Name
1
Vent_0
2
Vent_1
3
Vent_2
4
Vent_3
5
Vent_4
6
Vent_5
7
Vent_6
8
Vent_7
9
U_VALVE
10
Vent_8
11
Vent_9
12
Vent_10
13
Vent_11
14
Vent_12
15
Vent_13
16
Vent_14
17
Vent_15
18
U_VALVE
19
Vent_16
20
Vent_17
21
Vent_18
22
Vent_19
23
Vent_20
24
Vent_21
25
Vent_22
261
Electrical system/electronics
Pin
Name
26
Vent_23
27
GND
28
GND
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.9.1.5 Pin assignment P6
Pin
Name
1
VDD5
2
SCK
3
MOSI
4
GND
Overview image
13.4.9.1.6 Pin assignment P7
Pin
Name
1
VDD5
2
MOSI
3
GND
Overview image
262
Electrical system/electronics
13.4.10 ACS_ENC_BOARD
Function overview
The ACS_ENC_BOARD together with the fork light barrier (X zero mark) generate a pulse. This pulse
is used to determine the zero position. The X axis encoder is also connected to this board. The data is
transferred to the ACS_BF_BOARD via a 10-pin ribbon cable.
Overview
263
Electrical system/electronics
1 Zero mark
2 X axis encoder
3 ACS_BF_BOARD
LEDs and visual displays
There are no LEDs or optical indicators on this board.
Jumpers and switches
There are no jumpers or switches on this board.
Measuring points and voltages
There are no measuring points on this board.
Error symptoms
No error symptoms are indicated.
13.4.10.1 Pin assignment (ACS_ENC_BOARD)
13.4.10.1.1 Pin assignment S1
264
PIN
Name
1
VCC
2
Test
3
VCC
4
TRIG
5
GND
Voltage
Tolerance
Electrical system/electronics
Overview image
13.4.10.1.2 Pin assignment S2
PIN
Name
1
x
2
VCC
3
GND
4
x
5
XA-
6
XA+
7
XB-
8
XB+
9
x
10
x
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.10.1.3 Pin assignment S3
PIN
Name
1
x
2
5V
3
GND
4
x
5
XA-
6
XA+
7
XB-
8
XB+
9
XI-
10
XI+
Overview image
265
Electrical system/electronics
13.4.11 ACS_CROSS_BOARD_L3
Function overview
The ACS_CROSS_BOARD is a separable interface of the wiring between the side supports and the
bars. All wires in the standard edition lead from the electronics unit to the ACS_CROSS_BOARD.
From the ACS_CROSS_BOARD the wires lead to the Y motor, the ACS_X_BOARD and the
MTS_YS_BOARD.
A relay (with circuit) and braking resistance on the board blocks the Y-motor in the de-energized state.
Overview
1
2
3
4
5
266
ACS_AMPLIFIER_BOARD S1 / S2
ACS_BF_BOARD S3 / S4
ACS_YS_BOARD
ACS_X_BOARD
Y motor
Electrical system/electronics
LEDs and visual displays
There are no LEDs or optical indicators on this board.
Jumpers and switches
There are no jumpers or switches on this board.
Measuring points and voltages
There are no measuring points on this board.
Error symptoms
Through frequent switching on and off or emergency switch off of the machine, the brake relay is also
switched on and off. Tests have shown that the relay can last approx. 100,000 cycles under "peak
loading" of approx. 15 A and inductive load, but there is still the possibility of sticking, even if the load
in the machine is many times smaller. However, the likelihood of a fault is very small. The user or
service technician is notified by the error message "Check axis" at start-up that this relay may be
stuck.
13.4.11.1 Pin assignment (ACS_CROSS_BOARD)
13.4.11.1.1 Pin assignment S1
PIN
Name
1
PRO1
2
PRO2
3
PGND
4
PGND
5
PGND
6
P53V
7
P53V
8
P53V
9
P53V
10
P53V
11
P53V
12
P53V
13
P53V
14
P53V
15
YMOT+
16
YMOT+
17
YMOT+
18
YMOT+
19
YMOT+
Voltage
Tolerance
267
Electrical system/electronics
PIN
Name
20
YMOT+
21
YMOT-
22
YMOT-
23
YMOT-
24
YMOT-
25
YMOT-
26
YMOT-
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.2 Pin assignment S2
268
PIN
Name
1
RES1
2
RES2
3
PGND
4
PGND
5
PGND
6
PGND
7
PGND
8
PGND
9
P24V
10
P24V
11
P24V
12
P24V
13
P24V
14
P24V
15
P24V
16
PGND
17
PGND
18
PGND
19
PGND
20
PGND
21
24 V
22
24 V
23
24 V
24
GND
Electrical system/electronics
PIN
Name
25
GND
26
GND
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.3 Pin assignment S3
PIN
Name
1
GND
2
YLA+
3
YLA-
4
YLB+
5
YLB-
6
XLA+
7
XLA-
8
XLB+
9
XLB-
10
YA+
11
YA-
12
YB+
13
YB-
14
YI+
15
YI-
16
FIN B+
17
FIN B-
18
STOP3
19
STOP4
20
GND
Overview image
13.4.11.1.4 Pin assignment S4
PIN
Name
1
GND
2
SYN_FRAME+
3
SYN_FRAME-
4
SYN_MOSI+
5
SYN_MOSI-
269
Electrical system/electronics
PIN
Name
6
SYN_CS+
7
SYN_CS-
8
FOUT_A+
9
FOUT_A-
10
FOUT_B+
11
FOUT_B-
12
SYN_MISO+
13
SYN_MISO-
14
FIN_A+
15
FIN_A-
16
RES12
17
TST1
18
STOP2
19
STOP1
20
GND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.5 Pin assignment S5
270
PIN
Name
1
TP1
2
TP2
3
P53V
4
P53V
5
P53V
6
P53V
7
PGND
8
PGND
9
PGND
10
GND
11
GND
12
SYN_MISO+
13
SYN_FRAME+
14
SYN_FRAME-
15
SYN_MOSI+
16
SYN_MOSI-
Electrical system/electronics
PIN
Name
17
SYN_MISO+
18
SYN_MISO-
19
SYN_CS+
20
SYN_CS-
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.6 Pin assignment S6
PIN
Name
1
RES1
2
RES2
3
P53V
4
P53V
5
P53V
6
P53V
7
PNGD
8
PNGD
9
PNGD
10
PNGD
11
24 V
12
GND
13
FOUT_A+
14
FOUT_A-
15
FOUT_B+
16
FOUT_B-
17
FIN_A+
18
FIN_A-
19
FIN_B+
20
FIN_B-
Overview image
13.4.11.1.7 Pin assignment S7
PIN
Name
1
P24V
2
P24V
3
P24V
271
Electrical system/electronics
PIN
Name
4
P24V
5
P24V
6
P24V
7
PNGD
8
PNGD
9
PNGD
10
PNGD
11
P24V
12
GND
13
YLA+
14
YLB+
15
YLA-
16
YLB-
17
TEST1
18
TEST2
19
TEST3
20
TEST4
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.8 Pin assignment S8
272
PIN
Name
1
STOP3
2
STOP4
3
RES12
4
TP3
5
XLB+
6
XLA+
7
XLB-
8
XLA-
9
YI+
10
YI-
11
YB+
12
YA+
13
YB-
14
YA-
Electrical system/electronics
PIN
Name
15
TST1
16
STOP1
17
STOP2
18
TEST1
19
TEST2
20
TEST3
21
TEST4
22
PRO2
23
PRO1
24
TP4
25
24 V
26
GND
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.11.1.9 Pin assignment S9
PIN
Name
1
YMOT-
2
YMOT+
Overview image
273
Electrical system/electronics
13.4.12 ACS_X_BOARD
Caution:
Risk of confusion due to different side specifications.
The side specifications deviate from the presentation convention.
Reason:
For reasons of reuse of ACS_C_BOARDs in other cutters, the decision was made to keep the
directional information.
The following presentation conventions apply exclusively for the arrangement of light barriers.
1
front
2
rear
3
right
4
left
X
X-axis
Y
Y-axis
Function overview
The ACS_X_BOARD is used as an encoder slot, a valve switch and a light barrier distributor.
The following sensors, actuators and encoders are connected to the ACS_X_BOARD:
• Y_encoder (S3)
• Y_zero mark (S12)
• Light barrier, front emitter (S8)
274
Electrical system/electronics
• Light barrier, rear emitter (S10)
• Light barrier, front receiver (S11)
• Light barrier, rear receiver (S9)
• Right-side reflex light-barrier (protection against contact between head carriage and tactiles)
• Left-side reflex light-barrier (protection against contact between head carriage and tactiles)
• Transport element 1 (S5)
• Transport element 2 (S4)
• X_linear encoder (S7)
The light barriers and the zero marks are specially synchronised to provide system reliability
(continuous monitoring).
Overview
275
Electrical system/electronics
1
X-axis linear encoder
8
Receiver light barrier
2
Valve V1.0 feed system
9
Right-side reflecting light barrier
3
optional
10
Module carriage
4
ACS_CROSS_BOARD
11
Left-side reflecting light barrier
5
Y axis rotary encoder
12
Emitter light barrier
6
Y axis zero mark
13
Emitter light barrier
7
Receiver light barrier
Light barrier (front)
Board
Light barrier transmitter 1 (LSS1)
ACS_X_BOARD_S8
Light barrier, receiver 2 (LSE2)
ACS_X_BOARD_S11
Signal
Error message
Stop 2
LS=0
Stop 1
LS=1
Light barrier (rear)
276
Light barrier, emitter 2 (LSS2)
ACS_X_BOARD_S10
Light barrier, receiver 1 (LSE1)
ACS_X_BOARD_S9
Electrical system/electronics
Reflecting light barriers
Left-side reflecting light barriers 1
ACS_X_BOARD_S2
Stop 3
LS=2
Right-hand reflecting light barriers 2
ACS_X_BOARD_S15
Stop 4
LS=3
LEDs and visual displays
There are no LEDs or optical indicators on this board.
Jumpers and switches
There are no jumpers or switches on this board.
Measuring points and voltages
The measuring points are on S13. This plug could, however, still be used as an additional connection
for sensors or actuators.
Measuring points
Voltage
Tolerance
S13 pin 1
TEST1 (Ls0)
-
S13 Pin 2
TEST2
-
S13 Pin 3
TEST3
-
S13 Pin 4
TEST4
-
S13 Pin 5
GND
-
S13 Pin 6
RES12
-
S13 Pin 7
GND
-
S13 Pin 8
GND
-
S13 Pin 9
VCC = 5V
5%
277
Electrical system/electronics
Measuring points
Voltage
Tolerance
S13 Pin 10
24V
5%
Error symptoms
No errors are known
13.4.12.1 Pin assignment (ACS_X_BOARD)
13.4.12.1.1 Pin assignment S1
PIN
Name
1
STOP3
2
STOP4
3
RES12
4
5
XLB+
6
XLA+
7
XLB-
8
XLA-
9
YI+
10
YI-
11
YB+
12
YA+
13
YB-
14
YA-
15
TST1
16
STOP1
17
STOP2
18
TEST1
19
TEST2
20
TEST3
21
TEST4
22
PRO2
23
PRO1
24
278
25
24 V
26
GND
Voltage
Tolerance
Electrical system/electronics
Overview image
13.4.12.1.2 Pin assignment S2
PIN
Name
1
24 V
2
TST1
3
GND
4
STOP3
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.12.1.3 Pin assignment S3
PIN
Name
1
x
2
VCC
3
GND
4
x
5
YA-
6
YA+
7
YB-
8
YB+
9
x
10
x
Overview image
13.4.12.1.4 Pin assignment S4
PIN
Name
1
24VS
2
PRO2
Overview image
13.4.12.1.5 Pin assignment S5
PIN
Name
1
24VS
2
PRO1
Overview image
279
Electrical system/electronics
13.4.12.1.6 Pin assignment S7
PIN
Name
1
x
2
VCC
3
GND
4
x
5
XLA-
6
XLA+
7
XLB-
8
XLB+
9
x
10
x
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.12.1.7 Pin assignment S8
PIN
Name
1
24 V
2
TST1
3
GND
Overview image
13.4.12.1.8 Pin assignment S9
PIN
Name
1
24 V
2
STOP1
3
GND
4
x
Overview image
13.4.12.1.9 Pin assignment S10
PIN
Name
1
24 V
2
TST1
3
GND
Overview image
280
Electrical system/electronics
13.4.12.1.10 Pin assignment S11
PIN
Name
1
24 V
2
STOP2
3
GND
4
x
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.12.1.11 Pin assignment S12
PIN
Name
1
VCC
2
TRIG
3
VCC
4
TAKT
5
GND
Overview image
13.4.12.1.12 Pin assignment S15
PIN
Name
1
24 V
2
TST1
3
GND
4
STOP4
Overview image
281
Electrical system/electronics
13.4.13 MTS_YS_BOARD
Function overview
The MTS_YS_BOARD is installed on the module slide on the beam. The following functions are either
intended or already exist on the MTS_YS_BOARD:
• Interface from MC to the max. 3 modules
• Interface from MC to the camera
• Interface from MC to the MTS_SENS_BOARD
• AD converter for height measurement and spare
• 24 V outputs (switchable/PWM)
• Connection of the Y linear encoder
Commands and statuses from the respective modules/camera or Sens_Board are transferred via the
ZLINK connection to/from the MC at specific time intervals.
The YS board is a smaller version of the YM board. A Cyclone IV is integrated into the YS
Overview
LEDs and visual displays
282
Item
LED
Description
1
LED error 1-7
Displays error code for YM
2
LED_Module1
Indicates whether module has been detected or displays error
code.
Electrical system/electronics
Item
LED
Description
3
LED 1.2 V
1.2 V OK
4
LED 2.5 V
2.5 V OK
5
LED 3 V
3 V OK
6
LED 5 V
5 V OK
7
LED 5 V_SW
The LED illuminates if 5V_SW has been switched on via the
MC.
8
LED 24 V_SW
The LED illuminates if 24V_SW has been switched on via the
MC.
9
LED ZLINK
Indicates whether communication has been achieved with MC.
10
LED Config
Illuminates if Altera was not loaded correctly.
11
LED_SENS_BOARD
Indicates whether the camera has been detected or shows
error code.
12
LED_Module2
Indicates whether module has been detected or displays error
code.
13
LED_Module3
Indicates whether module has been detected or displays error
code.
Jumpers and switches
There are no jumpers or switches on this board.
Plug
Plug
Description
S900
Optional (Power out)
S601b
Power for slot 1
S600
Linear encoder Y axis (optional)
S611
Plug for analog in (optional)
S300
Programming plug, firmware
283
Electrical system/electronics
Plug
Description
S602b
Power for slot 2
S602a
Data line for slot 2
S607
Connection to ACS_CROSS_BOARD
S606
Connection to ACS_CROSS_BOARD
S605
Connection to ACS_CROSS_BOARD
S612
Coax analogue camera signal
S609
Power for MTS_SENS_BOARD
S608
Data line to MTS_SENS_BOARD
S603b
Power for slot 3
S603a
Data line for slot 3
S601a
Data line for slot 1
S604
S901
S902
Measuring points and voltages
S300 Programming plug USB/Byte-Blaster
284
Measuring points
Description
TP600 Pin1
GND
TP600 Pin2
GND
TP600 Pin3
1.2 V ± 0.02 V
TP600 Pin4
GND
TP600 Pin5
2.5 V ± 0.03 V
TP600 Pin6
GND
Electrical system/electronics
Measuring points
Description
TP600 Pin7
3 V ± 0.05 V
TP600 Pin8
GND
TP600 Pin9
5.1 V ± 0.05 V
TP600 Pin10
GND
TP600 Pin11
24 V
TP600 Pin12
GND
TP600 Pin13
24 V
TP600 Pin14
PGND
TP600 Pin15
P53V
TP600 Pin16
PGND
Error symptoms
• Update problems on module slot 2
• PWM outputs on plug S900 not yet implemented
• PWM output on plug S902 not yet implemented
13.4.13.1 Pin assignment (MTS_YS_BOARD (S3))
13.4.13.1.1 Pin assignment S600
PIN
Name
1
x
2
5V
3
GND
4
x
5
YL_A-
6
YL_A+
7
YL_B-
8
YL_B+
9
x
10
x
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.13.1.2 Pin assignment S601
PIN
Name
1
YM_F_OUT
2
YM_F_nCS
285
Electrical system/electronics
PIN
Name
3
YM_MOSI
4
GND
5
PGND
6
PGND
7
P24V
8
P53V
9
YM_F_IN
10
YM_F_CLK
11
YM_MISO
12
5V
13
PGND
14
P24V
15
P53V
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.13.1.3 Pin assignment S602
PIN
Name
1
YM_F_OUT
2
YM_F_nCS
3
YM_MOSI
4
GND
5
PGND
6
PGND
7
P24V
8
P53V
9
YM_F_IN
10
YM_F_CLK
11
YM_MISO
12
5V
13
PGND
14
P24V
15
P53V
Overview image
286
Electrical system/electronics
13.4.13.1.4 Pin assignment S603
PIN
Name
1
YM_F_OUT
2
YM_F_nCS
3
YM_MOSI
4
GND
5
PGND
6
PGND
7
P24V
8
P53V
9
YM_F_IN
10
YM_F_CLK
11
YM_MISO
12
5V
13
PGND
14
P24V
15
P53V
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.13.1.5 Pin assignment S605
PIN
Name
1
TP605-1
2
TP605-2
3
P53V
4
P53V
5
P53V
6
P53V
7
PGND
8
PGND
9
PGND
10
GND
11
GND
12
SYN_MISO+
13
SYN_FRAME+
14
SYN_FRAME-
287
Electrical system/electronics
PIN
Name
15
SYN_MOSI+
16
SYN_MOSI-
17
SYN_MISO+
18
SYN_MISO-
19
SYN_CS+
20
SYN_CS-
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.13.1.6 Pin assignment S606
PIN
Name
1
TP606-1
2
TP606-2
3
P53V
4
P53V
5
P53V
6
P53V
7
PNGD
8
PNGD
9
PNGD
10
PNGD
11
24 V
12
GND
13
FOUT_A+
14
FOUT_A-
15
FOUT_B+
16
FOUT_B-
17
FIN_A+
18
FIN_A-
19
FIN_B+
20
FIN_B-
Overview image
13.4.13.1.7 Pin assignment S607
288
PIN
Name
1
P24V
Electrical system/electronics
PIN
Name
2
P24V
3
P24V
4
P24V
5
P24V
6
P24V
7
PNGD
8
PNGD
9
PNGD
10
PNGD
11
P24V
12
GND
13
YLA+
14
YLB+
15
YLA-
16
YLB-
17
TEST1
18
TEST2
19
TEST3
20
TEST4
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.13.1.8 Pin assignment S608
PIN
Name
a1
5V_SW
b1
GND
a2
IN_ADC_4
b2
AGND
a3
CGND
b3
C_Signal
a4
C_MISO
b4
C_CLK
a5
C_MOSI
b5
C_nCS
a6
nT3_ERR
b6
nT3_OVRCUR
289
Electrical system/electronics
PIN
Name
a7
T3_SPEED
b7
T3_ON
a8
nDRT_OVERTMP
b8
nDRT_OVERCUR
A9
DRT_SPEED
b9
DRT_ON
a10
TIN0_nEOT_ERR_A
b10
EOT_SPEED
a11
EOT_ON
b11
24V_I_EDGE
a12
24V_O_SENS
b12
GND
a13
24V_SW
b13
24 V
Voltage
Tolerance
Overview image
13.4.14 MTS_SENS_BOARD
13.4.15 MTS_SENS_BOARD2
Function overview
The board serves as the connection point between the connected tools, sensors, cameras and the
MTS_YS_BOARD (G3) or MTS_YW_BOARD (S3).
Compared to the MTS_SENS_BOARD, the MTS_SENS_BOARD_2 has an additional connector (blue
bushing, 8-pin) for new tools (e.g., PRT).
The following tools or sensors can be connected:
• Black bushing (4-pin): EOT
• Red bushing (5-pin): DRT
• Blue bushing (8-pin): PRT, URT
• Camera module board
• Laser pointer
290
Electrical system/electronics
Overview
291
Electrical system/electronics
S2
GND, Tool1 (EOT)
S10 Laser pointer
S3
GND, Tool2 (DRT)
S11 MTS_CAMERA_CONTROL_BOARD
S4
Tool1 (EOT)
S12 MTS_YM_BOARD (Power)
S5
Depth sensor
S13 Earth (case)
S6
Edge sensor
S14 Earth (case)
S7
Tool2 (DRT)
S17 Special systems: alternative allocation
Tool2 (plug, 8-pin: PRT, URT, …)
S8
MTS_YM_BOARD (data)
S19 Special systems: alternative allocation
Tool3 (plug, 5-pin: DRT)
S9
Tool3 (PRT, URT, ...)
LEDs and visual displays
There are no LEDs or optical indicators on this board.
292
Electrical system/electronics
Jumpers and switches
There are no jumpers or switches on this board.
Measuring points and voltages
This board is used in either the sensor or the camera module. If an error occurs in these two modules,
the whole module is replaced.
Error symptoms
No error symptoms are indicated.
Connecting bushings for tools
The pin allocation of the connecting socket is helpful for fault diagnosis:
Black socket (S4) - EOT
1
T1_24V
3
T1_SPEED
2
T1_ON -> 5 V = Tool active
4
nT1_ERROR
Case: GND
Red bushing (S7) - DRT
1
T2_53V
4
nT2_OVERCUR
2
T1_ON -> 5 V = Tool active
5
nT2_ERROR
3
T2_SPEED -> 5 V = High speed
Case: GND
Blue socket (S9) - PRT, URT, …
293
Electrical system/electronics
1
GND
5
P53V
2
T3_ON
6
nT3_ERROR
3
nT3_OVERCUR
7
T3_SPEED
4
P53V
8
GND
Case: GND
The control signals for the tools (e.g., T2_ON, T2_SPEED, …) are generated on the
MTS_YM(S)_BOARD.
With test function (ESC-3-3-20-7) the start signals can (TOOL_ON) be turned on for non-inserted
tools to check them with the measuring instrument.
5.2 NTC resistances
The NTC resistances are fitted on the back of the board but can be measured in the marked
connections on the top side.
Note:
Warning about measuring errors
294
Electrical system/electronics
Only measure NTC resistances with the cutter switched off!
Measuring point
Resistance
Tolerance
R1 / R2 / R3 / R4
5 Ohm (nominal value at 25 °C)
4.5 - 6 Ohm
295
Electrical system/electronics
13.4.16 ACS_PANEL-BOARD
The panel is the interface to the cutter. Switching on and off is carried out from the panel too. The
panel is a modular unit and is completely replaced in case of repairs.
The back of the panel is the ACS_PANEL_BOARD. This board is used to connect the operating units
(switches, rotary switches) which are located on the left-hand side of the front control panel. It also
acts as an electrical shield and as contact protection.
Function overview
The main switch activates a 24 V low power supply. This only supplies the MASTER PANEL with
power. The MASTER PANEL is now in STANDBY MODE. This mode does not allow any movements,
initializations or the like. No further power supply units are switched on.
The panel has reduced activation in standby mode. The system can be switched on from the panel
using a button (or combination of buttons). Another sequence of buttons returns the system to standby
mode.
A special display is opened when the cutter is starting up. It remains open until the system is fully
started.
Plug
296
S1
Connection to ACS_PANEL_BOARD
S2
Measuring points or illustration of S1
S3
Slot for Key_1 or key switch_1
S4
Slot for Key_2 (only if no element on S5 or S6)
S5
Optional slot for optical Encoder_1
S6
Slot for optical Encoder_1
S7
Slot for Key_3
S8
Slot for Key_4 (only if no element on S9 or S10)
S9
Optional slot for optical Encoder_2
S10
Slot for optical Encoder_2
S11
Slot for Key_5
Electrical system/electronics
TP1
Analog input on ACS_PANEL_BOARD (not used)
LEDs and visual displays
5 LEDs are fitted on ACS_PANEL_BOARD .
Name
Function
H1
Flickers during operation
H2
no function yet (off)
H3
Online
H4
Pen down
H5
Vacuum on
One LED is fitted to the ACS_Panel adapter board.
Name
Function
LED1
Not yet defined, can be controlled by SW.
297
Electrical system/electronics
Jumpers and switches
There is a DIP switch on the ACS_PANEL_Board which must always be set to 0.
298
Electrical system/electronics
Measuring points and voltages
Check the voltages on plug S2 on the ACS_PANNEL_BOARD (connection from panel to master
board) or S2 on the ACS_PANNELADAPTER_BOARD for troubleshooting. Otherwise the panel must
be completely replaced in the event of a fault.
Figure 9: ACS_PANEL_BOARD plug S2
Pin 6 can also be checked. The voltage of this pin should change from 0 V to 24 V when the cutter is
switched on (switch-on signal for the master board).
Figure 10: Measuring points ACS_PANNELADAPTER_BOARD
Measuring
points
Description
S2_8
Optical encoder 2 CHB (against GND)
S2_10
Optical encoder 2 CHA (against GND)
S2_12
Optical encoder 1 CHB (against GND)
S2_14
Optical encoder 1 CHA (against GND)
299
Electrical system/electronics
Measuring
points
Description
S2_20
5V (VDD5)
S2_22
24V (VS24)
S2_24, S2_26
GND
S2_25
5V (VAA5)
#
13.4.16.1 Pin assignment (ACS_PANEL-BOARD)
13.4.16.1.1 Pin assignment S2
PIN
Name
1
CANH
2
CANL
3
24V_C
4
PGND
5
TP5
6
ACS200_ON
7
CAN_END+
8
CAN_END-
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.16.1.2 Pin assignment S8
PIN
Name
1
VS24
2
EXT_SW
Overview image
300
Electrical system/electronics
13.4.17 ACE_PANEL
13.4.17.1 Pin assignment (ACE_PANEL)
13.4.17.1.1 Pin assignment S2
PIN
Name
1
CANH
2
CANL
3
24V_C
4
PGND
5
TP5
6
ACS200_ON
7
CAN_END+
8
CAN_END-
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.17.1.2 Pin assignment S8
PIN
Name
1
VS24
2
EXT_SW
Overview image
301
Electrical system/electronics
13.4.18 MTS_MODULE_BOARD_1
13.4.18.1 Pin assignment (MTS_MODULE_BOARD_1)
13.4.18.1.1 Pin assignment S6
PIN
Name
1
-MOTOR_T
2
+MOTOR_T
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.18.1.2 Pin assignment S7
PIN
Name
1
YM_F_OUT
2
YM_F_nCS
3
YM_MOSI
4
GND
5
PGND
6
PGND
7
P24V
8
P53V
9
YM_F_IN
10
YM_F_CLK
11
YM_MISO
12
5V
13
PGND
14
P24V
15
P53V
Overview image
13.4.18.1.3 Pin assignment S9
PIN
Name
1
Enc22_1_B
2
5V_L
3
Enc22_1_A
4
GND
Overview image
302
Electrical system/electronics
13.4.18.1.4 Pin assignment S10
PIN
Name
1
-MOTOR_T
2
-MOTOR_T
3
-MOTOR_T
4
+MOTOR_T
5
+MOTOR_T
6
+MOTOR_T
7
GND
8
5V_L
9
TB
10
TA
11
GND
12
SWITCH_5V_2
13
SWITCH_5V_2
14
ANALOG_2
15
ANALOG_1
16
ANALOG_0
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.18.1.5 Pin assignment S11
PIN
Name
1
-MOTOR_Z
2
+MOTOR_Z
Overview image
13.4.18.1.6 Pin assignment S12
PIN
Name
1
Enc22_2_B
2
5V_L
3
Enc22_2_A
4
GND
Overview image
303
Electrical system/electronics
13.4.18.1.7 Pin assignment S13
PIN
Name
1
x
2
5V_L
3
GND
4
x
5
ZA-
6
ZA+
7
ZB-
8
ZB+
9
ZI-
10
ZI+
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.18.1.8 Pin assignment S14
PIN
Name
1
JTAG_TCK
2
GND
3
JTAG_TDO
4
3V3
5
JTAG_TMS
6
x
7
x
8
x
9
JTAG_TDI
10
GND
Overview image
304
Electrical system/electronics
13.4.19 MTS_MODULE_BOARD_2
13.4.19.1 Pin assignment (MTS_MODULE_BOARD_2)
13.4.19.1.1 Pin assignment S1
PIN
Name
1
GND
2
ZPOS1
3
5V_L
4
SWITCH_5V_1
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.19.1.2 Pin assignment S2
PIN
Name
1
GND
2
ZPOS2
3
5V_L
4
SWITCH_5V_1
Overview image
13.4.19.1.3 Pin assignment S4
PIN
Name
1
-MOTOR_T
2
x
3
+MOTOR_T
Overview image
13.4.19.1.4 Pin assignment S7
PIN
Name
1
YM_F_OUT
2
YM_F_nCS
3
YM_MOSI
4
GND
5
PGND
6
PGND
7
P24V
8
P53V
305
Electrical system/electronics
PIN
Name
9
YM_F_IN
10
YM_F_CLK
11
YM_MISO
12
5V
13
PGND
14
P24V
15
P53V
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Voltage
Tolerance
Overview image
13.4.19.1.5 Pin assignment S12
PIN
Name
1
GND
2
OMARK
3
5V_L
4
x
Overview image
13.4.19.1.6 Pin assignment S13
PIN
Name
1
UVLO_24V
2
DIO0
3
UVLO_53V
4
DIO1
5
SWITCH_5V_1
6
DIO2
7
x
8
DIO3
9
3V3
10
GND
Overview image
13.4.19.1.7 Pin assignment S14
306
PIN
Name
1
JTAG_TCK
2
GND
Electrical system/electronics
PIN
Name
3
JTAG_TDO
4
3V3
5
JTAG_TMS
6
x
7
x
8
x
9
JTAG_TDI
10
GND
Voltage
Tolerance
Overview image
307
Electrical system/electronics
13.5 Connecting options to the P-box
Options may only be connected to the P unit when the following conditions are met.
Danger:
Risk of death due to electrical voltage
Work on the electrical system must only be carried out with the power disconnected.
• Disconnect from mains
• Secure against reconnection
• Verify that no voltage is present
• Cover or shield any live adjacent parts
•
•
•
•
•
•
Any work must only be carried out by personnel authorised by Zünd or by Zünd Systemtechnik
Customer Services or by contractual partners authorised by Zünd Systemtechnik.
You must ensure that spare parts meet the technical requirements laid down by the manufacturer.
Original spare parts are always guaranteed to do so.
The options to be connected may not exceed the maximum ratings specified in the technical
details.
All options connected must be earthed.
All options connected to the P-box:
• must be routed through the opening provided;
• must be secured with cable ties on the inside;
• must be secured with another cable tie on the outside.
Never squeeze or kink cables, or route them via sharp-edged panels.
Open the P-box
308
Electrical system/electronics
A Undo the screws (item 1)
B Press down the retaining lug (item 2) and open the P-box (item 3)
Cable run inside
A Loosen the screws (item 3) (2x)
B Open the piston slide (item 2) and route the cable (item 4) through
C Use a cable tie (item 1) to secure the cable to the interior
Cable run on the outside
A
B
C
D
Bend the cable into an arc (item 3)
Use a cable tie (item 2) to secure the cable to the P-box
Close the piston slide (item 1) and tighten the screws
Close the P-box
309
Electrical system/electronics
13.6 Vacuum generator
Vacuum turbine
Tip:
For more information, please see the manufacturer's documentation or theLayouts on page
327.
310
Firmware update
14 Firmware update
14.1 Firmware update with ServiceTool
Note:
Firmware updates are carried out by default using ServiceTool.
311
Firmware update
14.2 Firmware update using interface
Note:
If a firmware update is unsuccessful, it will no longer be possible to restore the most recent
functional status.
Using the Cyclone Pro, Cyclone Max and USB Blaster programming boxes, the boards can have the
current firmware installed on them directly.
14.2.1 Programming boxes
Programming boxes
Board update
Cyclone PRO
Panel board
Cyclone Max
Master board
USB Blaster
YM board, module board,
camera board
Cable: USB blaster - ICC
camera, YM board, module
board
USB Blaster - camera board
connection cable
14.2.2 Downloading installation software
Note:
This installation software is only required for initial installation or for updating theProgramming
boxes on page 312.
A Download current installation file from the Zünd homepagewww.zund.com > reseller area
312
Firmware update
B
C
D
E
F
Select language
Select "Machine type" Technology/Service
Downloads > Firmware > Progr_boxes
Download the zip file required for your operating system
Unzip the zip file toC:\pemicrounpacking
14.2.3 Downloading firmware
A Download current firmware from the Zünd homepagewww.zund.com > reseller area
B
C
D
E
F
Select language
Select "Machine type" Technology/Service
Downloads > Firmware
Download required zip file
Unzip the zip file toC:\pemicro\CyclonProgrammierung
\FilesZumProgrammierenunpacking
14.2.4 Installing the driver
Make sure that you have administrator rights on the computer.
A Start thedrivers_10_install.exeprogram in folderC:\pemicro\cyclone.
B Follow the program instructions
C Restart computer
Checking Cyclone Pro installation
A Connect the Cyclone Pro interface to the mains
B Connect the USB cable to the interface
C Connect USB cable to PC
Results
Windows recognises the device
Checking Cyclone Max installation
A Connect the Cyclone Max interface to the mains
B Connect the USB cable to the interface
C Connect USB cable to PC
Results
Windows recognises the device
Checking USB Blaster installation
A Connect USB cable to USB blaster
B Connect USB cable to PC
Results
Windows recognises the device
313
Firmware update
Procedure in the event of non-recognition
Windows cannot find or allocate the driver for the programming box.
A Allocate the driver manually
B Follow the Windows instructions
Location of driver:C:\pemicro\Drivers
14.2.5 Installing software for Cyclone MAX/PRO
14.2.5.1 Installing software for Cyclone MAX (red box)
Make sure that you have administrator rights on the computer.
Software
Source
Installation path
Cyclone_max
Zünd homepage
C:\pemicro\cyclone_max
A Run the installation file:cyclone_max_install.exe
B Follow the program instructions
Select installation pathC:\pemicro\cyclone_max.
Results
The Cyclone MAX interface is now ready for use.
Loading firmware to Cyclone MAX
Note:
This process only has to be carried out upon the initial use of the programming box.
A
B
C
D
Connect Cyclone MAX to the mains.
Connect Cyclone MAX to the PC using a USB cable.
Start theCyclone Pro Image Creation Utility.
Load Config-File
a) File > Load Cyclone ConfigurationC:\pemicro\CyclonProgrammierung
\CycloneReleaseProgrammingProtectDB.cfg
E Save Config file to Cyclone Pro
a) Selectsave Image to Cyclone
b) Selectstorefunction
Results
LEDStandbyandSuccessLEDs light up when saving is successful
Loading firmware to Cyclone MAX
Note:
Standard procedure after initial commissioning.
314
Firmware update
A Connect Cyclone MAX to the mains.
B Connect Cyclone MAX to the PC using a USB cable.
C in folderC:\pemicrorun the file"programm ProgrammMCProtectDB.bat".
The Windows console opens.
Programming starts.
Results
LEDStandbyandSuccessLEDs light up when saving is successful
14.2.5.2 Software for Cyclone PRO (blue unit)
Make sure that you have administrator rights on the computer.
Software
Source
Installation path
Cyclone_pro
Zünd homepage
C:\pemicro\cyclone_pro
A Run the installation filecyclone_pro_install.exe
B Follow the program instructions
Select installation pathC:\pemicro\cyclone_pro.
Results
The Cyclone PRO interface is now ready for use.
Save software to Cyclone PRO
A Connect Cyclone PRO to the mains.
B Connect Cyclone PRO to the PC using a USB cable.
C in folderC:\pemicrorun the file"programm Panel.bat".
The Windows console opens.
D Check that the dates of the filesPanel_Bootloader.phyandPanel_Bootloader.s19in
folderC:\pemicro\CyclonProgrammierung\FilesZumProgrammierenmatch.
a) If they do not match, cancel withNand download new files from the Zünd homepage.
b) If the dates of the two files are the same, pressJto confirm.
Note:
The Windows console also contains information about the installation of the language package.
English is installed as the default language.
Further languages can be installed using the Zünd Service Tool.
E Programming of the Cyclone PRO interface will begin.
Results
LEDStandbyandSuccessLEDs light up when saving is successful
Installation of the language package
Make sure that the Cyclone Pro is connected.
A Start Zünd Service.
315
Firmware update
B Activate machine
C Activate panel
a) Select language file
14.2.5.3 Installing Quartus II
Note:
The saving location suggested by the programC:\altera\10.0sp1must not be changed!
Carry out the installation as per the manufacturer's instructions.
Results
The programQuartus II Programmeris installed.
Checking USB Blaster installation
A Connect USB cable to USB blaster
B Connect USB cable to PC
Results
Windows recognises the device
Procedure in the event of non-recognition
Windows cannot find or allocate the driver for the programming box.
A Allocate the driver manually
B Follow the Windows instructions
Location of driver:C:\altera
14.2.6 Board updates
14.2.6.1 Updating MC board (Cyclone MAX)
A Turn off the cutter at the main switch.
B Remove cover from the electronics unit
C Connect Cyclone MAX to the mains.
316
Firmware update
D Connect Cyclone MAX to the MC board (S9). Make sure that the cable is connected correctly.
E Turn the cutter on and initialise using F1.
F As soon as theLEDs 1-3-4-5on the OF board light up, press theStartkey.
The update will begin.
The update is successfully completed if theStandbyandSuccessLEDs light up.
G Press SHIFT +
.
H Disconnect Cyclone MAX from the MC board.
Standby mode is activated.
I
SelectF1to initialise the cutter
14.2.6.2 Updating the panel board (Cyclone PRO)
A Switch off the cutter at the main switch.
B Remove the cover plate under the operating unit in the work station.
C Push the operating unit out of the bracket.
D Connect Cyclone MAX to the mains.
317
Firmware update
E Connect Cyclone PRO to the panel board (S4 plug).
F Turn on the cutter at the main switch.
The update will begin.
Results
The update is successfully completed if theStandbyandSuccessLEDs light up
14.2.6.3 Updating the module board, camera board and YM board with USB blaster
Software
Installation path
80sp1_quartus_programmer.exe
C:\altera
14.2.6.4 Updating the module board, YM board and camera board
List of files associated with the individual boards
318
File name
Board designation
CameraBoard.jic
Camera
ModuleBoard_1.jic
UM, RM
ModuleBoard_2.jic
PUM
MTS_MAM.jic
MUM-S, MUM-D
YM_Board1_1.jic
YM-Board Var. 1.1
YM_Board1_2.jic
YM-Board Var. 1.2
Firmware update
A Start the programQuartus II Programmer.
B Click onHardware Setup window(item 1)
C In theHardware Setup windowOn tabHardware Settings tab,click onAdd Hardware(item
2)
D USB Blasteras hardware (item 3)
E UseAdd File(item 1) to select the firmware files for module board, camera board and YM board
(select tick box forProgram/ConfigureandVerify).
YM board
A Turn off the cutter.
B Remove the cover on the module carriage.
C Turn on the cutter and initialise with F1.
319
Firmware update
D Plug the USB blaster cable (target side) into the module board.
E Select the update file as per the YM board version.
a) In the cutter menu1-5-6read off the version of the YM board.
b) If the YM board number is 0x0008012, select the firmwareYM_Board1_2_Vxx.
c) If a different number is displayed, select the firmwareYM_Board1_1_Vxx.
F Select Program Configuration and Verify check boxes for the YM board firmware file.
G Ensure that<none>is not ticked!
H SelectStart(item 3) to begin the update.
I The firmware is transferred to the board.
Results
If the update is successful, green messages will be displayed in the Quartus II Programmer.
Camera board
A Turn off the cutter.
B Remove the cover from the camera module.
C Turn the cutter on and initialise withF1.
320
Firmware update
D
E
F
G
H
Plug the USB blaster cable (target side) into the camera board using the connection cable.
Select Program Configuration and Verify check boxes (item 3) for the camera board firmware file.
Ensure that<none>is not ticked!
SelectStartto begin the update.
The firmware is transferred to the board.
Results
If the update is successful, green messages will be displayed in the Quartus II Programmer.
Module board
A Turn off the cutter.
B Remove the cover from the relevant module.
C Plug the module into any slot.
D Turn the cutter on and initialise withF1.
E Plug the USB blaster cable (target side) into the module board.
321
Firmware update
F The Program Configuration and Verify boxes (e.g. , item 3) should be selected for the module
board firmware file.
G Make sure that the <none> check box is not selected.
H SelectStartto begin the update.
I The firmware is transferred to the board.
Results
If the update is successful, green messages will be displayed in the Quartus II Programmer.
322
Firmware update
14.2.7 Firmware update with "Programming box G3/S3"
14.2.7.1 Programming box G3/S3
On tabProgramming box G3/S3tab, you can program the following boards:
• MC board
• BHS board
• Panel board
• Valve switch board
Programming box G3/S3
1
USB connection
2
Programming box G3/S3
3
Connection to MC board, BHS board
4
Connection to Panel board, Valve Switch board
14.2.7.2 Installing driver software
The driver for Programming Box G3/S3 must be installed manually.
A Connect Programming Box G3/S3 to PC.
B Open Windows Device Manager.
C Select Other devices > Unknown device.
D Right-click and selectUpdate driver software.
E Click onSearch computer for driver software.
F Select the saving location for the driver.
• Windows XP: ..\..\ServiceTool\ProgrammingBoxDriver
• Vista/Win7: ..\Program Files (x86)\ServiceTool\ProgrammingBoxDriver
G SelectNextto finish installing the driver.
Results
Programming Box G3/S3 is ready for use. USB LED lights up green.
323
Firmware update
14.2.7.3 Carrying out the update
The programming process is supported by ServiceTool.
Note:
Connect Programming Box G3/S3 tooneboard alone. Connecting multiple boards at the same
time will damage both the boards and the Programming Box.
A
B
C
D
E
Start ServiceTool and switch to theServicetab.
Connect Programming Box G3/S3 to PC.
Select the board to be programmed on theProgramming box G3/S3.
Follow the step-by-step ServiceTool instructions.
Carry out a firmware update for the entire cutter system after successful programming!
14.2.8 Final tasks
After the successful update
A Turn off the cutter.
B Installing the covers
C Restart cutter
324
Pneumatics
15 Pneumatics
Note:
A detailed pneumatics plan can be found in the sectionElectrical system/
electronicsLayouts
15.1 Requirements
Air flow [l/min]
Basic device
20
Oscillating cutting tool
300 - 400
1 KW routing module
40
PUM
150
15.2 Basic service unit
Item
Description
1
Compressor connection
2
Water separator
Adjusting value
Name
325
Pneumatics
326
Item
Description
Adjusting value
3
Pressure gauge
0.8 MPa
4
Stop valve
5
Adjusting wheel for pressure
6
Module carriage (PUM-S)
7
Adjusting wheel for pressure
8
Pressure gauge
9
General (module carriage)
Name
P1
0.6 MPa
P2
Layouts
16 Layouts
16.1 Contents
Pneumatics
Item no.
Name
Version
5208811
Pneumatic diagram S3 overview
A
Electrical system/electronics
Item no.
Name
Version
L3 voltage supply overview
V1_0
L3 overview
V1_1
ACS_EMMERGENCY
V1_0
ACS_CHIP_SECURITY
V1_0
327
Layouts
16.2 Pneumatics
328
L3 C-40 Vakuumelement mit Zonenvakuum Nr. 2 - 5
L3 C-56 Vakuumelement mit Zonenvakuum Nr. 2 - 7
Vakuumelement mit Zonenvakuum Nr. 1
jeweils die erste Leitung des 4fach
Schlauches beschriften
1 / 5 / 9 / 13 / 17 / 21 / 25 / 29 / 33 / 37
/ 41 / 45 / 49 / 53
1
5
V2.1
2b
einzelne Ventile beschriften gemäss Zeichnungen:
5207703 Beschriftung Ventilbatterie Nr. 1 bis 24
5207711 Beschriftung Ventilbatterie Nr. 25 bis 40
5208975 Beschriftung Ventilbatterie Nr. 41 bis 56
2a
3 (R)
1 (P)
P4
PMM-S (Ausblasen)
POT
P2
1 (P)
PPM-S (Ausblasen)
PPM-S
PMM-S
MAM-SPS/SPD
URT-S
3 (R)
2b
3 (R)
2a
9
2b
1 (P)
3 (R)
2a
2b
1 (P)
2a
3 (R)
1 (P)
17
2b
3 (R)
2a
1 (P)
25
2b
3 (R)
2a
2b
1 (P)
3 (R)
2a
1 (P)
Schlauch-Beschriftung: P2
Schnittstelleneinheit von vorne
P1
Schlauch-Beschriftung: P1
Schlauch-Beschriftung: P4
Schlauch-Beschriftung: P4
Schlauch-Beschriftung: P1
Ø4
3xØ6
Ø6
Netz für Wartungseiheit Standard und Standard/PUM:
Trennstelle nähe
ACS_X_BOARD
für Werkzeuge PPM-S / PMM-S
Liefermenge min. 300-400 l/min
Betriebsdruck min. 0.7 MPa max. 1.0 MPa
für Fräseinsatz URT-S
Liefermenge min. 30 l/min
Betriebsdruck 0.6 MPa
Schlauch-Beschriftung: P1
Schlauch-Beschriftung: P2
Ø10
Optional
Schlauch-Beschriftung: P2
2 (A)
Wartungseiheit POT
5810965
Schlauchbeschriftung mit Beschriftungsklammern
Ziffern 0-9 (5800739 - 5800748)
Ziffer P (5800767)
Schlauch-Beschriftung: P1
1 (P)
3 (R)
Ø6
Ø6
Ø4
Ähnliches Dokument
0.8 MPa
P4
P
Netz für Wartungseiheit POT:
Liefermenge min. 300-400 l/min
Betriebsdruck min. 0.8 MPa max. 1.0 MPa
0.8 MPa
P1
0.6 MPa
P2
Wartungseiheit Standard mit PUM Zusatz S3
5811071
Änderungen
A 26.02.14 eue
Projekt: L3
/ Pneumatikschema
Pneumatikschema
L3 Übersicht
P
Blatt
swiss cutting systems
1(1)
Massstab Gezeich.
Geprüft
-
20.11.13
eue
26.02.14
lre
Normgepr.
A3
Ersatz für
-
5208811
Status
A
Layouts
16.3 Electrical system/electronics
330
Page_6
06_Beam
PO24V0SWPO5V0SW POAGND
PO24VF0EX
24VF_EX
LSS
24V
GND
24V
GND
LSE
24V
GND
24V
GND
5V
GND
Y-Encoder
5V
GND
Y-Init
PGND
POP24V
P24V
POP53V
P53V
1.2V
2.5V
3V
5V
24V
P24V
P53V
GND
24V
PGND
P24V
P53V
PGND
P24V
PEN
PGND
P24V
opt. Sensor/Load
5V
GND
GND
24V
24V_SW
5V_SW
GND
AGND
Light barrier
24V
GND
P53V
P24V
PGND
GND
5V
Y-Linear Encoder
PO205VPO3V PO24V
MTS_YS_BOARD
5V
GND
24V
GND
24V
GND
RLS
P53V
P24V
PGND
24V
GND
24V
24V
RLS
P53V
P24V
PGND
24V
GND
P24V
PGND
X-Linear encoder Clamp elements
ACS_X_BOARD
24V
POGND
GND
Testpins Supply
IO (24V)
ACS_CROSS_BOARD_L3
24V
GND
LSS
LSE
24V
GND
Camera
Page_5
05_Side_Support
P53V
P24V
PGND
GND
24V
PGND
T48V
POT24V POT48V
GND
24V
PGND
T24V
GND
GND
24V
VDD5
POVD 5
VDD5
GND
X-Init
5V
GND
ACS_ENC_BOARD
5V
GND
PO5V
P53V
P24V
PGND
24V
5V
GND
addiotional ACS_VALVE_SWITCH_BOARD_2 for L3 C-56
X-Encoder
MTS_SENS_BOARD
AGND
GND
5V_SW
24V_SW
24V
EOT
DRT
24V_SW
GND
Edge sensor
24V_SW
AGND
Depth sensor
GND
5V_SW
Laserpointer
5V
GND
PO24V012V
24V/12V
ACS_VALVE_SWITCH_BOARD_3
ACS_AMPLIFIER_BOARD
for DC - motor
MTS_MODULE_BOARD_1/2
03_E_Box
Page_2
02_P_Box
24VF_EX
ACS_AMPLIFIER_BOARD_XBL_G3
5V
GND
ACS_BF_BOARD
MOTOR_XB
POMOTOR0XB
POMOTOR0XA
MOTOR_XA
5V
GND
ACS_MC_BOARD
5V
GND
POMOTOR0XC
MOTOR_XC
5V
GND
24V_CSW
5V
GND
PO24V0NA
24V_NA
24V_C
24V_CSW
24V_C
24VF
PGND
24V_C
24VF
PGND
24VF
24VF
PGND
24V_CSW
5V
GND
PO24V0CPO24VFPOPGND
5V
GND
24VF_EX
24VF_EX
P24V
PGND
24V_CSW
5V
GND
PO24V0CSW
24V
PGND
P53V
PGND
PGND
24V
24V_NA
PGND
24V
24V_NA
PO53V0GNDPO53V
ACS_OPTION_BOARD
ACS_OPT_ANT
5V
GND
24V_CSW
5V
GND
PGND
24V
24V_NA
ACS_SYS_FUNC_BOARD
ACS_EMM_CON_BOARD
Zünd Systemtechnik AG
Industriestr. 8
9450 Altstätten
Project
L3 Voltage Supply Overview
Drawn
Date
by
12.09.2013
cgr
Mod.
D:\Elektronik\ACS200\ACS_Planmappen\L3\L3_voltage_supply\01_Overview_Cutter.SchDoc
PS2, PS3 in
series (53V)
PS2
PS3
26.5
26.5
V
V
GND
5V
5V
3.3V
1.5V
1.2V
GND
PGND
24V
24V_NA
53V_GND
53V
3.3V
PO303V
1.5V
PO105V
PO102V
1.2V
PS1
24V
24V_C
24V_CSW
Page_3
04_Panel
PGND
24V
24V_NA
53V_GND
53V
Page_4
Appr.
*
Released
*
Title
Overview_Cutter
Size
A2
Drawing No.
page
Rev.
V1_0
1
of
2
PO24V0NA1
24V_NA1
24V_NA1
PO24V0NA
PGND
24V
24V_IN
53V_IN
24V_PGND
PO24V0IN PO24V0PGND
53V_PGND
PO53V0IN PO53V0PGND
24V_C
PS1
24V_NA
PS2-PS3
PGND
PGND
PIK104
COK1
K1 PIK103
PIK102
PIK101
PIMF20
PIMF301
COJ2
J2
PIMF302
PIJ201
PIK804
COMF2PIMF201
COK6
K6
PIK602
PIK601
COK8 PIK803
K8
PGND
PIK704
PIK802
24V_CSW1
PIK603
PIJ202
PFRA.040
MF2
PO53V
53V
PFRA.500
PIK604
COMF3
MF3
PIK801
COK7
K7
PIK703
24V_CSW1
24V_NA
COMF1PIMF10
PFRA.300
COMF4
MF4
CONTC1
NTC1
PO24V
24V
PINTC101
PIMF401
PIMF402
COMF5
MF5
PIMF502
PIK702
PIK701
POSTART
START
POA1
A1
COR19
R19
PIR190110M PIR1902
POK32
K32
PINTC102
1E
POK2
K2
PIMF501
PNOZ
PIMF102
PFRA.160
MF1
AMPLIFIER
PO53V0GND
53V_GND
PGND
24V_CSW1
PFRA.300
POPGND
PGND
PGND
PGND
COD2
D2
PID201 PID202
Diode 1N4004
COJ1
J1
24V_C
PIJ102
PIJ101
D:\Elektronik\ACS200\ACS_Planmappen\L3\L3_voltage_supply\02_P_Box.SchDoc
PGND
PGND
24V_VAC2
PO24V0AC2
POWER2
PGND
24V_VAC1
24V_C1
PO24V0AC1
POWER1
BF
PO24V0CSW PO24V0C
24V_C
nRES_EMM
n24V_on
PON24V0 PONCU0EM PONRES0M
24V_CSW
24V_CSW
nRES_EMM
nCPU_NO_EMM
nCPU_NO_EMM
n24V_on
PGND
Zünd Systemtechnik AG
Industriestr. 8
9450 Altstätten
Project
L3 Voltage Supply Overview
Drawn
Date
by
12.09.2013
cgr
Mod.
Title
02_P_Box
Size
Appr.
*
Released
*
Drawing No.
Rev.
V1_0
A3
page
2
of 2