cutter box v2

L E

C T

R A

S

Y S

T E

M E

S Electronic sub-assembly

Cutter Box V2

Z.I. de Marticot - BP 3433611 CESTAS Cedex - France� (33) 05 57 97 80 00 Fax (33) 05 57 97 82 32

504050 AAEdition 1

January 1998

COPYRIGHT

Any copying, reproduction or translation of all or part of the contents of this document without theexpress written permission of LECTRA SYSTEMES is strictly forbidden by the provisions of the law ofMarch 11th 1957.

GUARANTEES

LECTRA SYSTEMES reserves the right to modify, without prior notice, information relating to its productsin order to improve their reliability or operating capacity.

Publication does not imply that the contents are free of industrial patent rights and does not grantpermission in any other respect to those rights. LECTRA SYSTEMES assumes no liability for theconsequences of using this information in any way whatsoever

The LECTRA DOCUMENTATION department is always available to give you any furtherinformation you may require and remains open to any suggestions you may wish to make.

CutterBox V2

Update follow-up

Edition n° Purpose of the update Pages modified

1

January 1998

First edition of the document

CutterBox V2 v

January 1998 - Edition 1 504050

Contents

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

1. CutterBox V2.......................................................................................................................................1

1.1 Introduction.......................................................................................................................................1

1.1.1 Generalities ............................................................................................................................1

1.1.2 New features...........................................................................................................................1

1.2 Technical data sheet .........................................................................................................................2

1.2.1 Cutter Box...............................................................................................................................3

1.3 Principles ...........................................................................................................................................4

1.3.1 General principles ..................................................................................................................4

1.4 Motor control .....................................................................................................................................5

1.4.1 DC motor control ....................................................................................................................5

1.4.2 "Brushless" synchronous motor control ................................................................................7

1.5 Automatic control and regulation for DC motors............................................................................8

1.5.1 Automatic control for DC motors ..........................................................................................8

1.5.2 Automatic control of the synchronous brushless motors .....................................................9

1.5.2.1 Operating modes........................................................................................................10

1.6 Motherboard function .....................................................................................................................12

1.6.1 Synopsis of the motherboard ...............................................................................................12

1.6.2 Central unit ..........................................................................................................................12

1.6.3 System memories .................................................................................................................13

1.6.4 Input / Output Management ...............................................................................................13

1.6.5 Digital Signal Processor (DSP)............................................................................................14

1.6.6 Automatic Position Control .................................................................................................14

1.6.7 Motor Control (PWM)...........................................................................................................15

1.6.8 Motor Control (Power stage)................................................................................................17

1.6.9 Speed regulation...................................................................................................................18

1.6.10 Current monitoring and short circuit protection .............................................................18

1.6.11 Vibration motor ..................................................................................................................19

2. Appendix contents.............................................................................................................................20

vi CutterBox V2

504050 January 1998 - Edition 1

Table of illustrations

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

Figure 1 Presentation of the CutterBox ............................................................................................... 3

Figure 2 General synopsis of the cuter electronic control systems ..................................................... 4

Figure 3 Principle of the DC motor control (H-stage).......................................................................... 5

Figure 4 Motor control timing diagram ................................................................................................ 6

Figure 5 Timing diagram of motor response to a specific instruction level ....................................... 6

Figure 6 Principle of the rotating field ................................................................................................. 7

Figure 7 Resulting field generated by the field present in each coil in one t moment ...................... 7

Figure 8 Power stage associated to a Brushless motor........................................................................ 8

Figure 9 Automatic digital control ........................................................................................................ 8

Figure 10 Synopsis of the brushless motor speed controller ............................................................... 9

Figure 11 Synopsis of the CutterBox V2............................................................................................. 11

Figure 12 Mother board synopsis ........................................................................................................ 12

Figure 13 Signals produced by the encoders ...................................................................................... 14

Figure 14 Internal structure of a counter........................................................................................... 15

Figure 15 Internal PWM structure ..................................................................................................... 16

Figure 16 Power stage with IGBT....................................................................................................... 17

Figure 17 Protection in braking phase ............................................................................................... 17

Figure 18 Position of the LEM ............................................................................................................ 18

CutterBox V2 1


CutterBox V2

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆

1. CutterBox V2

1.1 Introduction

1.1.1 Generalities

The V2 CutterBox regroups all the electronics which are required to control the different motorspresent on a cutter or a Lectra plotter. These electronics also enable managing all theinputs/outputs linked to these electronics (switches, relay control, etc.).This CutterBox version has enabled a certain number of developments, in particular :

- an increase in the calculation power

- a possibility of remote-maintenance

- an increase in the analogue power (motor control power)

- more options in maintenance

- a simplification of the cabinet's electric cabling

The V2 CutterBox can be mounted on different machines (VT2500, Vt5000, FlyPen,...). Theelectronic modules which are integrated can be interchanged according to the motors mounted onthe different machines.

1.1.2 New features

The CutterBox is now equipped with electronic modules which can be interchanged easilyproviding more flexibility in use and maintenance.Each controlled axis has its power module (X, Y, R, Z).The Mosfet transistors of the power boards have been replaced by the IGBT.The motor protection has been revised and improved. The management of the disjunction isintegrated in the power modules.The CutterBox V2 now integrates the brushless motor control.The power of the computer board has been increased by the passage of a 68020 20 MHz to a 6804033 MHz (Motorola).The memory size has been increased and is now 16 Mbytes (4 Mbytes in standard).The program and the adjustment parameters of the machine are in a Flash memory module.When a computer board is replaced, just place the Flash memory module on the old board ontothe new one to have the machine adjustment parameters. The maintenance is now much easier.Using the Flash memory enables tele-loading the program evolution. The maintenance is nowmuch easier.A new program in the Flash memory can be tele-loaded by serial port or by floppy.A PWM control for the laser has been integrated.A PWM control for the ink jet has been added.The management of interruptions has been revised and improved

2 CutterBox V2


1.2 Technical data sheet

Electrical power supply Control line

Voltage ............... 230 VAC, 1 phase + neutral + ground

Frequency ..........................................................50/60 Hz

Max. consumption. ............................................. 1.2 kVA

Power line

Voltage .............................. 400 VAC, 3 phases + ground

Frequency ..........................................................50/60 Hz

Max. consumption. ...............................................3,3 kW

Environment Temperature .................................................. 10 to 40 °C

Hygrometry ................ 30 to 80 % without condensation

Dimensions Height ..................................................................817 mm

Width ...................................................................400 mm

Depth ...................................................................120 mm

Operating Cutter Box

characteristics - 68040 Processor .............................................. 33 MHz

- Data bus ....................................................... 32 bits

- Dynamic RAM ............... 4 Mb extensible to 16 Mb

- DSP56002 signal processor............................ 40 MHz

- Data bus ....................................................... 24 bits

- RAM ..............................................................96 KB

- PC type power .................................................230 W

- 96 signals managed in Input/Output

- 4 series links managed by means of 2 DUARTs

(a link with PC or OpenCad)

- Management of two 7 key keyboards (1 fixed and 1 mobile)

Vibration management by means of a brushless / non-stopcurrent module

Up to 2 conveyor management by frequency variator

CutterBox V2 3


1.2.1 Cutter Box

The "CutterBox" is a metal box, with a flexible conductor seal on the cover side (the seal ensuresthe electromagnetic compatibility creating a Faraday cage).

The connectors are on the left of the Cutter box, and on the right are :

- 2 ventilators

- the braking resistance (if this resistance is required)

- the temperature safety thermo-switch associated to the braking resistance.

- PC type 230 W supply.

On the left-hand side :

- The connection enabling the link between the power modules and the motors.

- 2 ventilators

At the bottom :

- The control board

At the top :

- The power modules which control the different motors

Figure 1 Presentation of the CutterBox

Input/Outputconnections

Control board (micro-plotter)PC supply

Brakingresistance (option)

Thermic sensor

Power Modules (motor controls)

Inputs/Outputs board

2259722635

or22631

22636 22636

22615 22613

✎ For a more detailed diagram refer to the appendix.

4 CutterBox V2


1.3 Principles

1.3.1 General principles

The control electronics receives instructions on the shapes to be cut or plotted from theworkstation associated to the machine.

They ensure :

- a "motherboard" function to exchange data with the workstation computer and interpret theinformation received. This computer section also processes input/output information (keyboard, end stops, positionswitches, controls, etc.).

- a "motor control" function to pilot the motors installed on the cutter.These motors use different technologies : DC motors, three-phase motors, brushless motors. Someare equipped with one or more automatic controls, while others are controlled directly by ON/OFFrelays.

This function may therefore be divided into the following sections :

- an automatic control section for the DC motors (X and Y axes, Blade rotation of the VT5000 andVT7000),

- an automatic control section for the AC motors via the frequency variators for the Bladevibration of the VT2500 and VT2500XXL, the conveyor, the Coda in automatic mode and Vacuum(VP Control option).

- a control section for the ON/OFF control motors (Vacuum, (2 speed motor), Blade sharpening,Coda in manual mode and Vacuum fan).

Figure 2 General synopsis of the cuter electronic control systems

Operator's station

Control electronics Cutter

Central unit

Inputs / Outputs

Motherboard function

Motor Control Function

Inputs / Outputs

DC motor automatic control

AC motor automatic control

ON / OFF Control

X motorY motorRotation motor

Vibration motor (VT2500)Conveyor motorCoda motor (auto)Vacuum motor (option VP Control VT5000, VT7000)

2 speed vacuum motor (VT2500)Sharpening motorCoda motor (manual)

Vibration motor (VT5000, VT7000)

CutterBox V2 5


1.4 Motor control

1.4.1 DC motor control

The motor is controlled by means of a PWM and an H-stage of 4 transistors and diodes.

Figure 3 Principle of the DC motor control (H-stage)

D1

D4D2

D3T1

T2

T3

T4

Um

Im

0V

Valim

The direction in which the motor rotates is fixed by the direction in which the mean current set bythe "H" stage circulates. It is determined by the switching transistors T1 and T3.The torque developed by the motor depends directly on the mean current which crosses.The speed at which it rotates depends directly on the average value of the voltage applied to themotor. This is determined by the control signal mark space ratio of the hatching transistorassociated with the rotation direction (T4 in the first case, otherwise T2).The average value is established by a series of motor charges and discharges.

Charging occurs when the hatching transistor is saturated :

If the average voltage applied to the motor terminalsis greater than the counter-electromotive force Eg(motor phase), the charging current crosses T1 andT4.

T1

T4

Um

Im

0V

Valim

Eg + ri

If the average voltage applied to the motorterminals is less than the counter-electromotiveforce Eg (braking phase), the charging currentcrosses D1 and D4.

D1

D4

Um

Im

0V

Valim

Eg + ri

The discharge occurs when the hatching transistor is locked :

If the average voltage applied to the motor terminalsis greater than the counter-electromotive force EG(motor phase), the discharge current crosses T1 andD3.

D3T1

Um

Im

Valim

Eg + ri

If the average voltage applied to the motorterminals is less than the counter-electromotiveforce Eg (braking phase), the discharge currentcrosses D1 and T3.

D1 D3 T3

Um

Im

Valim

Eg + ri

6 CutterBox V2


Figure 4 Motor control timing diagram

T1

T2

T3

T4

UM

IM

Hatching dead bands

0V

0V

0V

0V

0V

0

Imoyen

15V

15V

15V

15V

120V

Figure 5 Timing diagram of motor response to a specific instruction level

Im = -Eg/r

Im = Um/r

Eg = UmVmax

Um = Vmoy

Vmax

Theoretical instruction

Hatching signal

Average theretical voltagedefined in relation to the cyclic ratio of the hatching signal

Average voltage at themotor terminals

Average current at themotor terminals

"motor" phase "Braking" phase

An average voltage is applied to the motor for a given time interval. This voltage is determinedby the mark space ratio of the hatching signal.

The mean current circulating in the motor is calculated by the formula i=(Um - Eg)/rWhen the speed instruction is applied, the counter-electromotive force of the motor (Eg) is zeroand the ringing current is maximum (Um/r). When the motor reaches the rotation speedcorresponding to the instruction, the counter-electromotive force is approximately equal to themean voltage, and the mean current is practically zero.

When the instruction is no longer applied, the mean voltage applied to the motor falls to zero.This initiates a braking phase as Eg> Um. The current is reversed and flows in the opposite, from-Eg/r to 0.

CutterBox V2 7


1.4.2 "Brushless" synchronous motor control

"Brushless" motors are synchronous, master-controlled motors with commutator brushes. Theflux is generated by the rotor and permanent magnets, providing a very high power-weight ratio.

The motor has a three-phase wound coil stator whereas the DC motor coil is on the rotor.

The rotating field which turns the Rotor is obtained by applying three-phase power to the motorcoil.

Figure 6 Principle of the rotating field

t2 t3t1

AB CA Coil

B Coil

C Coil

A Coil

B CoilC Coil

Time

Intensity

The three coils A, B and C are each powered by one phase of the power supply, so the currentthrough the coil is as shown in the diagram above.The magnetic field induced in the 3 coilsThe magnetic field induced in the 3 coils varies in the same way as the intensity which traversesthe different coils.

The total field in the centre is obtained by the vectorial sum of the 3 fields induced by each ofthese coils as shown above for the 3 moments in time t1, t2, and t3.

Figure 7 Resulting field generated by the field present in each coil in one t moment

A Coil

B CoilC Coil

A Coil

B CoilC Coil

A Coil

B CoilC Coil

t1 t2 t3

Indicates the intensity (arrow length) and the direction of the magneticfield in each coil of the motor at a t instant

Indicates the intensity (arrow length) and the direction of the magneticfield result of the 3 motor coils at a t instant

In practice, the result field follows the variation of the field in coil at each moment. There aretherefore many intermediate stages between the states t1 and t2 or t2 and t3, etc. represented inthe previous figure. The result field is a rotating field. The drive force of the rotor follows thefield generated by the various coils which cause the rotor to rotate.

8 CutterBox V2


The three-phase current of a "Brushless" motor is controlled by a 6-transistor power stage.

Figure 8 Power stage associated to a Brushless motor

Q1

Q4

Q2

Q5

Q3

Q6

A Coil

B Coil C Coil

Braking circuit

0V

V+

The switching of the 6 transistors Q1 -Q6 as described in the above timingdiagram, makes it possible to convert aDC power supply to three-phase power,thus setting up a rotating field.

The speed at which the rotor rotatesdepends on the mean voltage applied.The torque depends on the value of thecurrent.

Each of the 6 possible conductioncombinations of the pairs of transistorsdetermine a 60° sector in which therotor is located. Rotor position

Q1

Q2

Q3

Q4

Q5

Q6

AB

AC

BC

1.5 Automatic control and regulation for DC motors

1.5.1 Automatic control for DC motors

In the new electronic system, including a dedicated signal processor (Digital Signal ProcessorDSP), the automatic control and regulation functions are digitally operated as follows :

Figure 9 Automatic digital control

DSP

CAN

CAN

Counter

numericPWM

Motor commandMotherboardPowerstage

Current sensor

Motor

Tachometer

CoderCurrent regulation

Speed regulation

Automatic position control

µProcessor

The motherboard is to move to a specific point. It sends the co-ordinates of this point to the DSPwhich controls and regulates the movements as necessary.

CutterBox V2 9


The DSP controls the position automatically by calculating a speed instruction from the differencebetween the required position and the true position provided by the encoder.

In order to ensure that the motor is operating correctly, the DSP monitors the current valuesmeasured by the current sensor (LEM).

Due to the mechanical stresses on cutters, speed is controlled automatically by the tachometersconnected to the motors.

The digital PWM transforms the control calculated by the DSP into the corresponding mark spaceratio signal, which, applied at the power stage, generates the required mean voltage across themotor terminals.

This "fully digital" management of the motor control laws, means that the system can be run bythe micro-program in EPROM, without modifying the hardware.

1.5.2 Automatic control of the synchronous brushless motors

For optimum control of the rotating field, brushless motors are connected to a sensor called aResolver. This determines the angular position of the rotor by induction and encodes by meansof 2 signals : sine and cosine.

This information is transmitted to a speed controller, known as the Brushless module whichcontrols the motor automatically, as a function of the speed instruction transmitted by themotherboard.

Figure 10 Synopsis of the brushless motor speed controller

Speedinstruction

DC Powersupply

Speed signal

Coil switching

Currentinstruction

LEMs

Rotor position (Sin and Cos)

Brushless module

Switchinglogic

Currentcontrol PWM Power

stage

Digitalresolver converter

Resolver

M

Motor

Rotor

Stator

From the consin and sine signals, a converter determines :

- the rotation speed, necessary for the automatic speed control and also to inform themotherboard (via an ADC) that the vibration motor is not operating correctly.

- the sector where the rotor is located, which enables the switching logic to determine the powerstage transistor switching combination.

From the difference in speed between the motherboard instruction and the feedback measured bythe resolver, the speed controller then develops three analog current instructions via a high-grain, wide-band speed loop. These instructions control a "PWM" which operates the 6-transistorpower stage.Two built-in LEMs monitor the current.

The speed controller is adapted to the motor by programming it according to the number of polesin the motor and resolver, and the phase angle of the resolver in relation to the motor shaft.

10 CutterBox V2


1.5.2.1 Operating modes

The control electronics are capable of operating the machine in 2 modes :

- the automatic mode (by default), when the system receives data from the main computer of theworkstation, and executes it

- the maintenance mode (standby mode) when access is made either by using the controlkeyboards (fixed or mounted), or by the CNUM maintenance mode (cf. CNUM documentation).

- the motherboard section is organized around an MC68020 micro-processor with a frequency of33 MHz, communicates with the control station, the various inputs/outputs of the cutter and themotor controls.

- the DC motor control section is organized around a DSP56002 signal oriented processor. TheDSP56002 receives plotting orders from the 68040, processes them via the digital PWM's andcounters, and sends commands to the different X, Y and blade rotation axes.

- the AC motor control section is operated directly by the MC68040 micro-processor inconjunction with the CNA and CAN, while the "power" section is provided by specialized modules(brushless module, frequency variator, etc.).

- finally, some motors are controlled in "ON/OFF" mode by relays operated as "outputs" by the"motherboard" section.

CutterBox V2 11


Figure 11 Synopsis of the CutterBox V2

Fla

shep

rom

Epr

omR

am n

vD

ynam

icR

amµ p

roce

ssor

6804

0

Du

art

1D

uar

t2

82C

5582

C55

82C

5582

C55

C.N

.A.

Cou

nte

r- c

onve

yor

- su

p. s

uppl

y

C.A

.N.

DS

P56

002

Ram

D

SP

J8J7

J6J5

2261

3

2261

5

J24

Conveyor instruction

J20 VP Control

instruction

J25 Conveyor

encoder return

J200 Head and carriage

unit

J19

Can bus

Vector controlstation

An

ti r

ebou

nds

MC

1449

0In

terf

aces

RS

232

Rel

ays

Cu

rren

tge

ner

ator

s

Bru

shle

ssm

odu

le(v

ibra

tion

)

J32,

J33

, J34

, J35

, J36

, J37

, J38

, J39

con

nec

tors

J1

Relay plateinputs

J2

Relay plateouputs

J3

supp. link commandoutlets

Xco

unt

erY

cou

nter

Rco

unt

erZ

cou

nter

J7

mst Z

PWMZ

mst XPWM

X

PWMY

mst Y

PWMR

mst R

XPowerstage

XlemXvpu

T1 to T4

YPowerstage

YlemYvpu

RPowerstage

RlemRvpu

J1J2

J3J4 Unused

T1 à T4

T1 à T4

CANZ

Zlem

ZspeedCAN

RRlem

RspeedCAN

YYlem

YspeedCAN

XXlem

Xspeed J10

J122

J123

J

Xtachometer

Ytachometer

Rtachometer

Ztachometer

J16

Y encoder

J17

R encoder

J18

Z encoder

J8J9

Boa

rd p

ower

su

pply

F

lopp

y

mst

pow

erau

thor

isat

ion

5v o

k

X encoderJ9

J11

Bur

n-i

n

J5Brushless board

power supplyJ1

2

Thermocontact

J15 Power supply

ouput options

J12

Z motor output

Brushless motoroutputJ1

1

J13, J14

J1, J2

J11,

J21

Pow

erm

odu

le

2259

7

2264

2

BrakingresistorJ22

J7

igbt time fanpower supply

J6

J10 Brushless board

power supply

J21

Vacuum can

J22 Ink jet

input/ouput

J23

Display output

J27 supp. loading

encoder

J26 supp. loading

instruction outlet

J31 Fixed keyboard

inlet

J311

J312

Coherent laserinterface

J303

J302

J301

J300

Cu

tter

Box

V2

Wag

oJ1

22J1

23

PC

Pow

er s

upp

ly

Sec

torBoard power supply

Laser lights &shutter security

J1J1

J1

J2

Brakingresistor

22631 or 22635

22636

22636

X motor

Y motor

Rotation motor

X tachometer

Y tachometer

R tachometer

Z tachometer

12 CutterBox V2


1.6 Motherboard function

1.6.1 Synopsis of the motherboard

Figure 12 Mother board synopsis

Micro 68040

Ram 4M0 (16M0)

Flash128 Ko Eprom Ram nV

32 KoInt. //82c55

2 duarts MC68681

Display 2 x 24

charact.CAN

max 1804x CAN AD767

2Counters

DSP56002-40

Ram96 Ko

4 countersFPG

3 pwmFPG

Encoder current tachometer T1 T2 T3 T4

CANmax 180

Bus 56002 (24 bits)

Bus 68040 (32 bits)

1.6.2 Central unit

The central unit is organized around a micro-processor 68040.The micro-processor has a control bus, a 32 bit data bus and a 32 bit address bus.The extension connectors for daughter boards to make the buses availableThe address and data bits used internally by the majority of peripherals (LSB's) are buffered.

Various peripherals concerning the main unit provide the following functions :

- Memories (RAM, EPROM, FLASH EPROM),- Serial link management RS232 (UARTs),- Parallel link management (programmable circuits),- AC motor operating instructions management by means of CNAs.- Automatic motor control management by means of counters (position) and CAN (speed- "DC motor control" management by means of a signal processor (DSP), connected toother peripherals :

• DSP RAM• 24 bit counter• Pulse Width Modulator (PWM)• Analog Digital Converters (ADC)

✎ The DSP56002 is a peripheral of 68040.

All of the clocks required by the various circuits are obtained by means of 3 quartz oscillatorsassociated with the counters.

CutterBox V2 13


1.6.3 System memories

The 68040 has several memories :

- Dynamic RAMThis is a SIMM connector bar which may be plugged into a 72-point connector (MOD1).The built-in module has a capacity of 4 Mb and an access time of 70 ns.The dynamic memory capacity can be upgraded to 16 Mb by replacing the memorymodule.The dynamic RAM is managed by a specialized circuit (memory manager) whichexecutes all of the read, write and refresh operations.

- EPROM,This memory has various programs which are not likely to vary. These programs arereserved for maintenance (monitor and de-bugger).

- Non volatile RAM (RAMNV) and Time-KeeperThis consists of a MK48T08 box with a capacity of 8 Kb. The contents (parameters, date,time, validation word for the program contained in the EPROM flash) are saved thanks toa long-life battery (5 years) when the board is not connected to the power supply.

- Flash EPROM,This memory contains the program (if required, tele-loaded during the maintenanceoperations) as well as the machine adjustment parameters.

Remark :During a maintenance operation, if the motherboard is to be replaced, just transfer theEPROM-flash module and the non volatile RAM from the old board onto the new one tokeep all the machine settings (including the previously installed program version).

1.6.4 Input / Output Management

The input signals to the 22615 board are associated to the LED displays for the active signals. Aninterface ensures the voltage adaptation (12V input, 5V output) and the insulation between theinput signals and the input/output circuits on the motherboard. The input signals are dealt withby anti-rebound circuits.

14 CutterBox V2


1.6.5 Digital Signal Processor (DSP)

The DSP is a specialized micro-processor. It has its own control, data (24 bit) and address (16 bit)buses so it is capable of accessing peripherals.It also has a dedicated 8-bit port (host port) and special signals enabling it to send an interruptionand to communicate directly with the 68040 of which it is a peripheral.

✎ It cannot communicate with any peripherals from the 68040

The DSP micro-program is in the EPROM of the 68040. When the board is switched on, the68040 transfers this micro-program to the DSP RAM via the host port. When the loading hasfinished, the DSP automatically starts its program and communicates with the 68040 to receivethe required theoretical positions and provide feedback on any errors.

✎ One set of EPROM is required for the micro-programs of both the 68040 and DSPmicro-processors

The DSP has an internal RAM and an external RAM of 24 bits..

The other DSP peripherals are as follows :- the PWM to which it transmits on 9 bits (8 for value, 1 for direction) the speedinstructions for the X, Y and R axes, as well as the tracking pressure for the pen (or theblade)- the counters, from which it receives 24-bit position information transmitted by theencodes associated with the X, Y and R motors.- the CAN from which it receives on 12 bits the value of the current transmitted by theHall effect sensors (LEM) associated with the X, Y and R motors..

The DSP peripherals are decided by a PAL.

✎ The PWM function is integrated in the programmable circuits.Likewise, the counters are integrated in the programmable circuits.

1.6.6 Automatic Position Control

The automatic position control is provided by the DSP on the basis of information transmitted bythe encoders associated with the motors.These encoders built into the motors (X, Y and R) produce 2 different signals, phase-shiftedsignals : A, /A and B, / B with a resolution of 1000 step / revolution.The phase-shift of the signals depends on the direction in which the motors are rotating (the Bsignal appears to be reversed when the rotation changes direction).These signals are formatted by the different repeaters which generate the A and B signals andtransmit to the counters.

Figure 13 Signals produced by the encoders

Reverse rotation direction A

B

Normal rotation direction

A

B

The directional information deduced from the signals transmitted by the encoder depends on thetype and wiring. In order to alleviate this problem, the counters receive the DIRECTION X,DIRECTION Y and DIRECTION R signals from the 68040, so that the metering direction isaltered in function of the direction in which the motors are rotating.

CutterBox V2 15


Figure 14 Internal structure of a counter

2 channelsof 24 bits

multiplexer

Resetmanagement

24 bitslatch

24 bits3 stateoutput

X axis24 bitscounter

X axisA and Bdecoder

Bx UP

Down

Clock

Load X

Reset X clock Mult X

Ax

Direction

Y axis24 bitscounter

Y axisA and Bdecoder

By UP

Down

Clock

Load Y

Reset Y clock Mult Y

Ay

Direction

A0 A1

Reset X

Reset Y

Load X

Load Y

ResetA0A1

Count*Write*

clock

Read* Count*

✎ The figure above shows the principle of the counter associated to the X and Yaxes. The same principle is applied for the R and Z axes. .

All the counter circuits are set to the same clock frequency.For each axis, the signals A and B are decoded and the result is oriented to input UP or DOWN onthe counter depending on the direction. The counter counts up (or counts down) and produces avalue on 24 bits.During a reading, depending on the address bits A0 and A1 provided by the DSP andcorresponding to the required axis, the multiplexer transfers the counter result to a toggle whereit is "locked" by the READ* signal so that it can be read.Reading the counter (with COUNT* and READ* active) releases the "3 state" output in order tomake the value available to the DSP data (DD0 to DD23).When a Reset command is given, a circuit resets the counters.The counters may be loaded asynchronously by writing at a selected address (active signalsCOUNT*, WRITE*, A1 and A0). The value is presented on the selected counter and thecorresponding LOAD signal is activated.

1.6.7 Motor Control (PWM)

The PWM receives input data from the DSP on 9 bits (DD0 - DD7 for speed instructions andDD23 for the rotation direction).The role of this circuit is to produce a signal for each axis, with a mark space ratio calculated onthe basis of the instruction transmitted by the DSP.This signal controls the H power stage hatching transistors and sets the value of the mean voltageapplied to the motor and therefore its motor speed.This direction signal controls the switching transistors that set the current direction in the Hstage. The circulation direction of the current in the H stage determines the circulation directionof the current in the motor and therefore the rotation direction of the motor.The PWM receives the Clock from the main unit, which is used internally to time the variouscounters in the system.An 8 bit reference down counter counts down constantly from 255 to 0 and generates a start markspace ratio signal.For each channel, data (DD0 - DD7) is stored in a register, then sent to an 8 bit down counter (255- 0) which generates an end mark space ratio signal.The start and end mark space ratio signals, associated with the DD23 direction bit, are used togenerate the control signals for the transistors T1 - T4 which make up the power stage.For safety reasons, a dead band has been introduced in the generation of signals T1 - T4 to avoidshort circuiting the power supply by simultaneous saturation of the pairs of transistors T1 / T2and T3 / T4 during the hatching or switching.The hatching frequency is 4.88 kHz (1.25 MHz / 256).

16 CutterBox V2


Figure 15 Internal PWM structure

X axis register

9 Bits register X axis

8 bits down counter X axis

T1 to T4 generation with deadband integration

8 bits referencecounter

Start mark space ratio signal

Write*Read*

A1A0

PWM* X axis register

Y axis register

R axis register

Z axis register

ResetManagement

T1

T2

T3

T4

X axis end mark ratiosignal

X AxisX Direction

Y axis register

9 Bits registerY axis

8 bits downcounter Y axis

T1 to T4 generation with dead bandintegration

T1

T2

T3T4

Y axis end mark ratiosignal

Y AxisY Direction

R axis register

9 Bits registerR axis

8 bits down counter R axis


T1

T2

T3

T4

R axis endmark ratio signal

R AxisR Direction

Z axis register

9 Bits register Z axis

8 bits downcounter Z axis


T1

T2

T3T4

Z axis endmark ratiosignal

Z AxisZ Direction

Clock 1.25 Mhz

CutterBox V2 17


1.6.8 Motor Control (Power stage)

The T1, T2, T3 and T4 signals provided by the PWM, are presented to the primary of a newcomponent which integrates both an apto-coupler, for galvanic insulation, and a high voltageoutput push-pull capable of loading the rather high capacity input of the IGBT.The 4 IGBT power transistors make up an H-stage powered by the voltage +VPU and withoutputs to the connectors J1 (X), J2 (Y) and J3 (R) ).Each transistor has a built-in recovery diode so that it can produce charging or dischargingcurrent.

Figure 16 Power stage with IGBT

-Vp

M

5V

DC/DC5v/15v

DC/DC5v/15v

Um

LEM

VlemIm

DC/DC5v/15v

5V Basv

0V

General auxiliarypower supply

Basv5V

Opto-coupler Opto-coupler

0V

Opto-couplerOpto-coupler

0V0V

5V



5V

T1

T1

T2

T2

T3

T3T4

T4

Basv

U

The auxiliary power voltages are floating power supplies provided by DC / DC 5 / 15 V converters.Each control channel for the switching transistors (T1 and T3) on each axis has its own auxiliarypower.All the control channels for the hatching transistors (T2 and T4) have the same auxiliary power(BASV).The voltage +VPU is equipped with a protection and filter cell consisting of a resistor, a capacitorand a TRANSIL diode which clips peaks above 180 V and burns out at 210 V.When a motor is in a braking phase, the counter-electromotive force is greater than the powersupply voltage, so that the current flows back to the power stage power supply.A protection system, re-directs this current to a 250W braking resistor.When there is a braking current on one of the X, Y, R or Z axes, it is transmitted by the diode, tothe capacitor which is charged. When the voltage across the terminals of this capacitor reaches athreshold of 155V, a comparator toggles and controls an MOSFET which sends the current to thebraking resistance connected to J10. The led lights up at the same time.When the voltage across the terminals drops below 143V, the comparator toggles back and theresistors are removed from the circuit.

Figure 17 Protection in braking phase

A Voltage Braking phase

Upper trigger threshold

Lower trigger threshold

Level of voltage innormal conditions

State of the braking transistor

saturated

Blocked

18 CutterBox V2


1.6.9 Speed regulation

Speed regulation is necessary, due to the major mechanical stresses involved in cutter operationsand is controlled on the basis of information from the tachometers located on the motors.This information is processed by an Analog Digital Converter, which transmits the valueconverted into 12 bits to the DSP.The speed is automatically controlled for the X, Y, R and Z axes, although the Z axis is not usedfor the Vector® 2500, VT2500XXL, VT5000, VT7000 cutters.

1.6.10 Current monitoring and short circuit protection

The currents circulating in the motor control are monitored in two places :- on one side an LEM is placed on one of the power supplies of the motor measuring the crossingcurrent.- on the other side a 2nd LEM measures the current supplying the power transistors of the motorcontrol.These two measurements make it possible to know the current which crosses any controltransistor (including the current which crosses the motor).The LEM modules use the hall-effect to measure the current which crosses through.

Figure 18 Position of the LEM

M

T1 i

LEM

1 2

T4

+ 1 2 0 D C

iLEM

T3

- When the motor is operating normally, the currents generated in each LEM are identical.- If terminal 1 of the motor is accidentally grounded, the current crossing LEM1 is very highwhereas the current crossing LEM2 is nil.- If terminal 2 of the motor is accidentally grounded the current crossing LEM1 and LEM2 is veryhigh. This current is the same in both LEMs.The measured value of the current is constantly compared to a reference value for the axes X, Tand R. When the measured value exceeds the reference value, the comparator activates amonostable which produces the short trip signal (DJC*) during 230 µs. This signal is sent to PWMwhich cuts the controls of the 4 transistors.The DJC* signal also charges a capacitor. If this capacitor receives several charges in succession,the voltage at these terminals reaches a threshold which activates the long trip signal (DJL*) for3,62s. This signal is sent to the PWM which cuts the controls of the 4 transistors.According to the motor involved, it also generates the XOFF*, YOFF* or POFF* signal indicatingan operating anomaly to the DSP, which lights the corresponding red error LED.If one of the motor terminals is accidentally grounded, as the cut-off is tripped in relation to themeasured value, the real current value will be 3 or 2 times lower, depending on the particularcause. The cut off will therefore trip sooner, making the protection system even more effective.

Trip value under normal operating conditions

✎

After filtering, the current value measured by the LEM is also transmitted to anAnalog Digital Converter which digitizes it on 12 bits and sends it to the DSP formonitoring.

CutterBox V2 19


1.6.11 Vibration motor

Depending on the type of machine, the vibration motor is a brushless motor or amaster-controlled motor, operated by the brushless module.

The 0-20mA speed instruction is supplied by the motherboard. This instruction is transmitted tothe brushless module via the 22615 Input/Output board which controls the motor automatically.

The speed information provided by the resolver associated with the motor (VT2500) or thetachometer (VT5000 and VT7000), transits via the 22615 board prior to reaching the brushlessmodule.

The 120V DC power supply of the variator is done when a relay is closed by "switching on thepower part supply"

The brushless module also provides speed information, transmitted to the 22613 board. Thisinformation is used to check that the system is operating correctly.

20 CutterBox V2


2. Appendix contents

2.1 Presentation of the 22597 board.................................................................................................A1.1

2.2 List of connectors on the 22597 board (740497) ........................................................................A1.2

2.3 Signals on the connectors of the 22597 board (740497)............................................................A1.3

2.4 Diagrams of the 22597 board......................................................................................................A1.5

2.5 Presentation of the 22613 board.................................................................................................A2.1

2.6 22613 board test points and switches (740513).........................................................................A2.2

2.7 List of connectors on the 22613 board (740513) ........................................................................A2.3

2.8 Signals on the connectors of the 22613 board (740513)............................................................A2.4

2.9 Diagrams of the 22613 board (740513) ......................................................................................A2.9

2.10 Presentation of the 22615 board...............................................................................................A3.1

2.11 List of connectors on the 22615 board (740515) ......................................................................A3.2

2.12 Signals on the connectors of the 22615 board (740515)..........................................................A3.4

2.13 State of the leds on the 22615 board (740515) (standard functioning)..................................A3.9

2.14 Diagrams of the 22615 board (740515) ..................................................................................A3.13

2.15 Presentation of the 22642 board...............................................................................................A4.1

2.16 Diagrams of the 22642 board (740542) ....................................................................................A4.2

2.17 Motor drives 740531, 740535, 740536......................................................................................A5.1

2.18 Signals on the connectors of the 22631, 22635, 22636 board .................................................A5.1

2.19 Signals on the connectors fixed to the CutterBox V2 box.......................................................A5.1

2.20 Presentation of the 22631, 22635, 22636 boards.....................................................................A5.2

2.21 Presentation of the 22631, 22635, 22636 boards (740531, 740535, 740536) .........................A5.3

2.22 Brushless motor drive 50A (vibration).....................................................................................A6.1

2.23 Diagram of the 22648 board (740548)......................................................................................A7.1

2.24 Diagram of the 22614 board (740514)......................................................................................A8.1

2.25 Reference of the spare parts .....................................................................................................A9.1

2.26 Detailed view of the CutterBox V2.........................................................................................A10.1

CutterBox V2 - 22597 Board $��


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A1.2 CutterBox V2 - 22597 Board


2.2 List of connectors on the 22597 board (740497)

Type Function

J 1 Din96MC Supply and outputs to motorJ 2 Din48MC Control and motor return signalJ 6 WAGO2MCC Auxiliary supplyJ 7 MCV1.5-8-G-3,81 fan supply - igbt temperature measureJ 11 Din48FD brushless power module signalJ 21 Din48FD brushless power module supplyJ 22 WAGO2MCC braking resistance

CutterBox V2 - 22597 Board A1.3


2.3 Signals on the connectors of the 22597 board (740497)

J1-A J1-B J1-C J6Sup - Motor Sup - Motor Sup - Motor Auxiliary sup

1 gnd 1 1 gnd 1 (+) sup2 cos- 2 cos+/ehu 2 gnd 2 0V

3 sin- 3 sin+/ehv 3 gnd

4 ref-/alimeh 4 ref+/ehw 4 gnd J75 gnd 5 gnd 5 gnd Sup - fan6 6 6 1 vdd7 sup2 7 sup2 7 sup2 2 vcc8 sup2 8 sup2 8 sup2 3 gnd9 sup2 9 sup2 9 sup2 4 vbb

10 10 10 5 gnd11 ind+ 11 ind+ 11 ind+ 6 thermistance12 ind+ 12 ind+ 12 ind+ 7 gnd13 13 13 8 time mes.input

14 ind- 14 ind- 14 ind-

15 ind- 15 ind- 15 ind- J2216 16 16 Brake resist.17 w 17 w 17 w 1 (+) sup18 w 18 w 18 w 2 cmd transistor

19 19 1920 v 20 v 20 v21 v 21 v 21 v22 22 2223 u 23 u 23 u24 u 24 u 24 u25 25 2526 gnd 26 gnd 26 gnd27 gnd 27 gnd 27 gnd28 gnd 28 gnd 28 gnd29 29 2930 sup1 30 sup1 30 sup131 sup1 31 sup1 31 sup132 sup1 32 sup1 32 sup1

J2-A J2-B J2-CSignals Signals Signals

1 led0 1 led1 1 gnd2 led2 2 led i2t 2 gnd3 ledcc 3 led bru 3 gnd4 gnd 4 gnd 4 gnd5 tz1# 5 iz 5 gnd6 tz2# 6 disjz# 6 gnd7 tz3# 7 freinz# 7 gnd8 tz4# 8 ledz 8 gnd9 disj bru# 9 instruction 1 9 gnd

10 speed return 10 instruction 2 10 gnd11 current return 11 reset# 11 gnd12 tachometer+ 12 enable 12 gnd13 tachometer- 13 common + 12 13 gnd14 top+ 14 top- 14 gnd15 vb+ 15 vb- 15 gnd16 va+ 16 va- 16 gnd



J11-A J11-B J11-Cbrush mod signal brush mod signal brush mod signal

1 BU 1 BU 1 BU2 EU 2 EU 2 EU3 3 34 BW 4 BW 4 BW5 EW 5 EW 5 EW6 6 67 BV 7 BV 7 BV8 EV 8 EV 8 EV9 9 9

10 10 1011 0V 11 0V 11 0V12 BZ 12 BZ 12 BZ13 0V 13 0V 13 0V14 BY 14 BY 14 BY15 0V 15 0V 15 0V16 BX 16 BX 16 BX

J11-A J11-B J11-CBrush mod supply Brush mod supply Brush mod supply

1 W 1 W 1 W2 W 2 W 2 W3 3 34 (+)supp 4 (+)supp 4 (+)supp5 (+)supp 5 (+)supp 5 (+)supp6 (+)supp 6 (+)supp 6 (+)supp7 7 78 U1 8 U1 8 U19 U1 9 U1 9 U1

10 10 1011 0V 11 0V 11 0V12 0V 12 0V 12 0V13 0V 13 0V 13 0V14 14 1415 V1 15 V1 15 V116 V1 16 V1 16 V1



2.4 Diagrams of the 22597 board



2.5 Presentation of the 22613 board



2.6 22613 board test points and switches (740513)

Designation Signals

XA, XB X axis encoder signals

YA, YB Y axis encoder signals

RA, RB, RTOP R axis encoder signals

ZA, ZB, ZTOP Z axis encoder signals

+Tx, -Tx X axis tachometer

+Ty, -Ty Y axis tachometer

+Tr, -Tr R axis tachometer

+Tz, -Tz Z axis tachometer

Ix X axis LEM current

Iy Y axis LEM current

Ir R axis LEM current

Iz Z axis LEM current

CNA-VIB Vibration instruction (+/- 10V)

CNA SUP Sup. Supply instruction (+/- 10V)

CNA CONV Conveyor instruction (+/- 10V)

CNA VPC Vacuum Pressure Control instruction

Rx, Tx Unused

IN-Dep CAN Vacuum Input (VPC)

SP-V Speed Vibration (CAN input)

I-V Current Vibration (CAN input)

CA Channel A conveyor encoder signal

AA Channel A sup. supply encoder signal.

AB Channel B sup. supply encoder signal

CB Channel B conveyor encoder signal

VCC, VBB, VDD, GND +5V, -12V, +12V, ground

Switches configuration

S1

1234

ON

1-8 on2-7 off3-6 off

33 Mhz 5-4 on25 Mhz 5-4 off

Off On




TYPE FUNCTION N°J 1 26 PTS HE10 STRAIGHT PC BOARD CONNECTOR X AXIS BOARD LINK 1J 2 26 PTS HE10 STRAIGHT PC BOARD CONNECTOR Y AXIS BOARD LINK 2J 3 26 PTS HE10 STRAIGHT PC BOARD CONNECTOR R AXIS BOARD LINK 3J 4 26 PTS HE10 STRAIGHT PC BOARD CONNECTOR Z AXIS BOARD LINK 4J 5 MCV 1.5/6-G-3.81 STRAIGHT PC BOARD CONNECTOR 6 POINTS 22597 BRUSHLESS BOARD SUPPLY 5J 6 4 PTS HE10 STRAIGHT PC BOARD CONNECTOR VENTILATOR 68040 6J 7 34 PTS HE10 STRAIGHT PC BOARD CONNECTOR FLOPPY 7J 8 8 PTS MOLEX MALE RIGHT CONNECTOR 8619-0602 PC TYPE SUP INPUT +5/+12/-12 8J 9 8 PTS MOLEX MALE RIGHT CONNECTOR 8619-0602 PC TYPE SUP INPUT +5/-5 9J 10 MCV 1.5/2-G-3.81 STRAIGHT PC BOARD CONNECTOR 2 POINTS X TACHOMETER 10J 11 4 PTS HE10 STRAIGHT PC BOARD CONNECTOR BURN IN 11J 12 MCV 1.5/2-G-3.81 STRAIGHT PC BOARD CONNECTOR 2 POINTS THERMOCONTACT 12J 13 48 PTS MIPAC RIGHT ANGLE STEP 2mm DAUGHTER BOARD INTERCONNECTION 13J 14 48 PTS MIPAC RIGHT ANGLE STEP 2mm DAUGHTER BOARD INTERCONNECTION 14J 15 48 PTS MIPAC RIGHT ANGLE STEP 2mm DAUGHTER BOARD INTERCONNECTION 15J 16 48 PTS MIPAC RIGHT ANGLE STEP 2mm DAUGHTER BOARD INTERCONNECTION 16J 32 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 17J 33 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 18J 34 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 19J 35 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 20J 36 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 21J 37 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 22J 38 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 23J 39 48 PTS MIPAC RIGHT ANGLE STEP 2mm MICRO BOARD LINK 24J 122 MCV 1.5/2-G-3.81 STRAIGHT PC BOARD CONNECTOR 2 POINTS Y TACHOMETER 25J 123 MCV 1.5/2-G-3.81 STRAIGHT PC BOARD CONNECTOR 2 POINTS ROTATION TACHOMETER 26



2.8 Signals on the connectors of the 22613 board (740513)

J1 J2 J3 J4X Axis 22631 Y Axis 22631 R Axis 22631 Z Axis 22631

1 gnd 1 gnd 1 gnd 1 gnd2 T1_in_X 2 T1_in_Y 2 T1_in_R 2 T1_in_Z3 gnd 3 gnd 3 gnd 3 gnd4 T2_in_X 4 T2_in_Y 4 T2_in_R 4 T2_in_Z5 gnd 5 gnd 5 gnd 5 gnd6 T3_in_X 6 T3_in_Y 6 T3_in_R 6 T3_in_Z7 gnd 7 gnd 7 gnd 7 gnd8 T4_in_X 8 T4_in_Y 8 T4_in_R 8 T4_in_Z9 gnd 9 gnd 9 gnd 9 gnd

10 MST_in_X 10 MST_in_Y 10 MST_in_R 10 MST_in_Z11 gnd 11 gnd 11 gnd 11 gnd12 Reset_in_X 12 Reset_in_Y 12 Reset_in_R 12 Reset_in_Z13 gnd 13 gnd 13 gnd 13 gnd14 DJC_mot_out_X 14 DJC_mot_out_Y 14 DJC_mot_out_R 14 DJC_mot_out_Z15 gnd 15 gnd 15 gnd 15 gnd16 DJL_mot_out_X 16 DJL_mot_out_Y 16 DJL_mot_out_R 16 DJL_mot_out_Z17 gnd 17 gnd 17 gnd 17 gnd18 DJL_bus_out_X 18 DJL_bus_out_Y 18 DJL_bus_out_R 18 DJL_bus_out_Z19 gnd 19 gnd 19 gnd 19 gnd20 I_mot_X (info lem) 20 I_mot_Y (info lem) 20 I_mot_R (info lem) 20 I_mot_Z (info lem)21 gnd 21 gnd 21 gnd 21 gnd22 (+)5v (vcc) 22 (+)5v (vcc) 22 (+)5v (vcc) 22 (+)5v (vcc)23 gnd 23 gnd 23 gnd 23 gnd24 (+)12v (vdd) 24 (+)12v (vdd) 24 (+)12v (vdd) 24 (+)12v (vdd)25 gnd 25 gnd 25 gnd 25 gnd26 (-)12v (vbb) 26 (-)12v (vbb) 26 (-)12v (vbb) 26 (-)12v (vbb)



J7 J5 J6 J8floppy supply 22597 fan 68040 supply inlet

1 GND 1 12 1 12 1 power good2 2 5 2 gnd 2 53 GND 3 5 3 3 12

4 4 gnd 4 4 -125 GND 5 gnd 5 gnd

6 6 -12 J10 6 gnd

7 GND X tachometer8 index J9 1 (-) X tachometer J129 GND supply inlet 2 (+) tachometer thermocontact

10 DR0 1 gnd 1 thermocontact

11 GND 2 gnd J11 2 gnd12 DR1 3 -5 burn in 313 GND 4 5 1 input burn in 4

14 5 5 2 gnd15 GND 6 5 3

16 mot 4 gnd

17 GND

18 dir J13-A J13-B J13-C19 GND daughter board daughter board daughter board20 step 1 5 1 CA01-A2 121 GND 2 gnd 2 CA01-A1 2 CA01_IT!22 wdata 3 gnd 3 CA01-A0 3 CA01_A1123 GND 4 gnd 4 CA01-SIZ0 4 CA01_A1224 wgate 5 5 5 CA01-SIZ1 5 CA01_A1325 GND 6 gnd 6 CA01_pr_le_read! 6 CA01_A1426 TRK0 7 gnd 7 CA01_loc_ack! 7 CA01_A1527 GND 8 5 8 CA01_reset_ec! 8 1228 wrtprt 9 gnd 9 EXT_CA01_dec! 9 1229 GND 10 CA01-bclk 10 10 1230 rdata 11 gnd 11 CA01_read 11 1231 GND 12 5 12 CA01_sec_as! 12 12

32 hdsel33 GND J122 J12334 dsxchg Y tachometer rotation tachometer39 1 (+) Y tachometer 1 (+) R tachometer

2 (-) tachometer 2 (-) R tachometer

J14-A J14-B J14-C J14-Ddaughter board daughter board daughter board daughter board

1 gnd 1 CA01-D15 1 CA01-D11 12 5 2 CA01-D14 2 CA01-D10 23 gnd 3 CA01-D13 3 CA01-D9 34 gnd 4 CA01-D12 4 CA01-D8 4 CA01_res-asyn!5 5 5 CA01-A10 5 CA01-D7 5 CA01_ind06 gnd 6 CA01-A9 6 CA01-D6 6 CA01_ind17 gnd 7 CA01-A8 7 CA01-D5 7 CA01_ind28 5 8 CA01-A7 8 CA01-D4 8 -59 gnd 9 CA01-A6 9 CA01-D3 9 -5

10 gnd 10 CA01-A5 10 CA01-D2 10 -511 gnd 11 CA01-A4 11 CA01-D1 11 -512 5 12 CA01-A3 12 CA01-D0 12 -5




1 5 1 CA02-A2 1 1 -122 gnd 2 CA02-A1 2 CA02_IT! 2 -123 gnd 3 CA02-A0 3 CA02_A11 3 -124 gnd 4 CA02-SIZ0 4 CA02_A12 4 -125 5 5 CA02-SIZ1 5 CA02_A13 5 -126 gnd 6 CA02_pr_le_read! 6 CA02_A14 6 -127 gnd 7 CA02_loc_ack! 7 CA02_A15 7 -128 5 8 CA02_reset_ec! 8 12 8 129 gnd 9 EXT_CA02_dec! 9 12 9 12

10 CA02_bclk 10 10 12 10 1211 gnd 11 CA02_read 11 12 11 1212 5 12 CA02_sec_as! 12 12 12 12


1 gnd 1 CA02-D15 1 CA02-D11 12 5 2 CA02-D14 2 CA02-D10 23 gnd 3 CA02-D13 3 CA02-D9 34 gnd 4 CA02-D12 4 CA02-D8 4 CA02_res-asyn!5 5 5 CA02-A10 5 CA02-D7 5 CA02_ind06 gnd 6 CA02-A9 6 CA02-D6 6 CA02_ind17 gnd 7 CA02-A8 7 CA02-D5 7 CA02_ind28 5 8 CA02-A7 8 CA02-D4 8 -59 gnd 9 CA02-A6 9 CA02-D3 9 -5

10 gnd 10 CA02-A5 10 CA02-D2 10 -511 gnd 11 CA02-A4 11 CA02-D1 11 -512 5 12 CA02-A3 12 CA02-D0 12 -5

J32-A J32-B J32-C J32-DICB 22615 ICB 22615 ICB 22615 ICB 22615

1 led1 1 (-)tz1 1 (+) X tachometer 1 gnd2 led I2T 2 (-)tz2 2 (-) X tachometer 2 gnd3 led BRU 3 (-)tz3 3 3 gnd4 led0 4 (-)tz4 4 (+) Y tachometer 4 gnd5 led2 5 lem Z 5 (-) Y tachometer 5 gnd6 ledCC 6 disj Z 6 6 gnd7 enable 7 7 (+) R tachometer 7 vcc1 (5v j15)8 disj brushless 8 current return 8 (-) R tachometer 8 vcc19 9 speed return 9 9 vcc1

10 10 brushless instruction 10 (+) Z tachometer 10 vcc111 12V laser 11 brushless reset 11 (-) Z tachometer 11 vcc112 shutter on 12 12 12 vcc1


1 +X keyboard 1 drill switch 1 up 1 inkjet down 1 input 1 gnd2 -X keyboard 2 drill switch 1 down 2 inkjet down 1 input 2 gnd3 +Y keyboard 3 drill switch 2 up 3 power presence 3 gnd4 -Y keyboard 4 drill switch 2 down 4 compressed air presence 4 gnd5 keyboard shift 5 inhibit coda input 5 irq switch 5 gnd6 keyboard val 6 add head switch 6 vacuum default input 6 gnd7 keyboard quit 7 add plate 1 input 7 7 vdd1 (12v j19 bus can)8 left/right keyboard 8 add plate 2 input 8 8 vdd19 blade switch up 9 inkjet down switch 9 9 vdd1

10 blade switch down 10 inkjet rotation switch 10 10 vdd111 sharpener switch up 11 inkjet up 1 input 11 can_low 11 vdd112 sharpen. switch down 12 inkjet up 1 input 12 can_high 12 vdd1




1 ev blade plunge 1 (+) A cod X 1 (+) A cod R 1 gnd2 ev press. foot plunge 2 (-) A cod X 2 (-) A cod R 2 gnd3 ev sharpener plunge 3 (+) B cod X 3 (+) B cod R 3 gnd4 ev drill 1 plunge 4 (-) B cod X 4 (-) B cod R 4 gnd5 ev drill 1 rotation 5 (+) A cod Y 5 (+) TOP0 cod R 5 gnd6 ev drill 2 plunge 6 (-) A cod Y 6 (-) TOP0 cod R 6 gnd7 ev drill 2 plunge 7 (+) B cod Y 7 (+) A cod Z 7 vbb1 (-12 j15, j21)8 viewer 2/pen control 8 (-) B cod Y 8 (-) A cod Z 8 vbb1 (-12 j15, j21)9 viewer control 9 9 (+) B cod Z 9 vdd3 (-12 j15, j21)

10 ev inkjet rotation 10 10 (-) B cod Z 10 vdd311 ev inkjet plunge 11 11 (+) TOP0 cod Z 11 vdd2 (12 j200)12 ev flip flop 12 12 (-) TOP0 cod Z 12 vdd2


1 dcd channel 1 1 rts channel 2 1 txd channel 4 1 gnd2 rxd channel 1 2 cts channel 2 2 dtr channel 4 2 gnd3 txd channel 1 3 dcd channel 3 3 rts channel 4 3 gnd4 dtr channel 1 4 rxd channel 3 4 cts channel 4 4 gnd5 dsr channel 1 5 txd channel 3 5 5 gnd6 rts channel 1 6 dtr channel 3 6 6 gnd7 cts channel 1 7 dsr channel 3 7 7 vcc3 (5v j17, j18, j26)8 ri channel 1 8 rts channel 3 8 8 vcc39 dcd channel 2 9 cts channel 3 9 (+)A cod sup. load 9 vcc3

10 rxd channel 2 10 tri channel 3 10 (-)A cod sup. load 10 vcc2 (5v j9, j16, j27)11 txd channel 2 11 dcd channel 4 11 (+)B cod sup. load 11 vcc212 dtr channel 2 12 rxd channel 4 12 (-)B cod sup. load 12 vcc2


1 ev blade plunge 1 auto/manual coda rel. led 1 led disj X 1 gnd2 ev press. foot plunge 2 vacuum gv/pv relay led 2 led disj Y 2 gnd3 ev sharpener plunge 3 time meter led 3 led disj R 3 gnd4 ev drill 1 plunge 4 + sharpener relay led 4 led disj Z 4 gnd5 ev drill 1 rotation 5 sharpener relay led - 5 5 gnd6 ev drill 2 plunge 6 plate 1 sup. ctrl led. 6 6 gnd7 ev drill 2 rotation 7 plate 2 sup. ctrl led. 7 7 vdd4 (+12 j1, j22, j31)8 viewer 2/pen control 8 led quick ink jet output 8 8 vdd49 viewer control 9 led quick ink jet output 2 9 9 vdd4

10 ev ink jet rotation 10 led mst vp control 10 10 vcc4 (5v j23)11 ev ink jet plunge 11 led forward sup. load 11 led forward conveyor 11 vcc412 ev flip flop 12 led reverse sup. load 12 led reverse conveyor 12 vcc4


1 led laser 0 input 1 led laser power output 1 rw display 1 gnd2 led laser 1 input 2 led laser indicator 2 DB0 2 gnd3 led laser 2 input 3 led 5v ok 3 DB2 3 gnd4 led laser 3 input 4 led irq keyboard key irq 4 DB4 4 gnd5 led laser alert input 5 led irq power + air 5 DB6 5 gnd6 led laser shut. input 6 led irq bus scan 6 A0 display 6 gnd7 led laser shut. output 7 7 CS display 7 gnd8 led laser drive A

output8 led disjv 8 DB1 8 gnd

9 led laser drive Boutput

9 9 DB3 9 gnd

10 led laser AIM 10 led power presence (cdp) 10 DB5 10 gnd11 led clear fault laser 11 led compressed air ON 11 DB7 11 vee1 (-5v j15)12 led rf enc laser 12 led DirqA 12 led DirqB 12 vee1



J38-A J38-BICB 22615 ICB 22615

1 conveyor instruction +/-20mA 1 sup. supply instruction +/-20mA2 reverse relay rest contact conveyor 2 reverse relay rest contact sup. load3 reverse relay work contact conveyor 3 reverse relay work contact sup. load4 forward relay work contact conveyor 4 forward relay work contact sup. load5 reverse relay common conveyor 5 reverse relay common sup. load6 forward relay common conveyor 6 forward relay common sup. load7 forward relay rest contact conveyor 7 forward relay rest contact sup. load8 89 (+)A motor C 9 led reset

10 (-)A motor C 10 led halt11 (+)B motor C 11 bp reset12 (-)B motor C 12 bp abort

J38-C J38-DICB 22615 ICB 22615

1 vp control instruction +/- 20mA 1 gnd2 vp control relay rest contact mst 2 2 gnd3 vp control relay work contact mst 2 3 gnd4 vp control relay work contact mst 1 4 gnd5 vp control relay common mst 2 5 gnd6 vp control relay common mst 1 6 gnd7 vp control relay rest contact mst 1 7 vcc (+5v leds and miscellaneous)8 8 vcc9 9 vcc

10 10 vcc11 11 vcc12 vacuum can input +/- 10V 12 vcc

J39-A J39-BICB 22615 ICB 22615

1 48v pc2 1 laser 0 input2 info 5v ok 1 2 laser 1 input3 info 5v ok 2 3 laser 2 input4 auto/manual coda output 4 laser 3 input5 gv/pv vacuum 5 laser alert input6 time meter 6 laser shutter input7 sharpening output + 7 laser shutter output8 sharpener output - 8 output laser drive A9 output 1 high 9 output laser drive B

10 output 1 low 10 output laser aim11 output 2 high 11 output laser clear fault12 output 2 low 12 output laser rf enc

J39-C J39-DICB 22615 ICB 22615

1 laser power output 1 gnd2 out rfd drive (pwm laser) 2 gnd3 inkjet open 1 quick collector output 3 gnd4 inkjet open 2 quick collector output 4 gnd5 5 gnd6 6 gnd7 led input IN6 laser 7 vcc (5v leds and miscellaneous)8 led input IN7 laser 8 vcc9 9 vcc

10 10 vcc11 input IN6 laser 11 vcc12 input IN7 laser 12 vcc



2.9 Diagrams of the 22613 board (740513)




TYPE FUNCTION LIEU N°J 1 9 PTS STRAIGHT FEMALE SUBD DE9SD INPUTS FROM THE RELAY PLATE EXTERNE 1J 2 8 PTS STRAIGHT MALE SUBD POWER DB8W8PD OUTPUTS TO THE RELAY PLATE EXTERNE 2J 3 5 PTS STAIGHT MALE SUBD POWER DB5W5PD SUPPLEMENTARY RELAY CONTROL OUTPUTS EXTERNE 3J 5 9 PTS STRAIGHT FEMALE SUBD DE9SD SERIAL CHANNEL 1 EIA PC TYPE EXTERNE 4J 6 9 PTS STRAIGHT FEMALE SUBD DE9SD SERIAL CHANNEL 2 EIA PC TYPE EXTERNE 5J 7 9 PTS STRAIGHT FEMALE SUBD DE9SD SERIAL CHANNEL 3 EIA PC TYPE EXTERNE 6J 8 9 PTS STRAIGHT FEMALE SUBD DE9SD SERIAL CHANNEL 4 EIA PC TYPE EXTERNE 7J 9 9 PTS STRAIGHT FEMALE SUBD DE9SD X ENCODER EXTERNE 8J 10 3 PTS MALE ANGLE SUBD POWER DSUB3W3PD BRUSHLESS BOARD SUPPLY EXTERNE 9J 11 3 PTS STRAIGHT FEMALE SUBD POWER DSUB3W3SD BRUSHLESS MOTOR OUTPUT EXTERNE 10J 12 7 PTS STRAIGHT FEMALE SUBD POWER DB7W2SD Z MOTOR OUTPUT EXTERNE 11J 13 DIN41612 96PTS FEM ANGLE TYPE R HART 09731967801 BRUSHLESS BOARD SUPPLY MOTOR LINK INTERNE 12J 14 DIN 41612 48 PTS FEM ANGLE TYPE R HARTING 09 28 148 7801 BRUSHLESS BOARD SIGNAL LINK INTERNE 13J 15 9 PTS STRAIGHT FEMALE SUBD DE9SD SUPPLY OUTPUT OPTION EXTERNE 14J 16 9 PTS STRAIGHT FEMALE SUBD DE9SD Y ENCODER EXTERNE 15J 17 9 PTS STRAIGHT FEMALE SUBD DE9SD ROTATION ENCODER EXTERNE 16J 18 9 PTS STRAIGHT FEMALE SUBD DE9SD Z ENCODER EXTERNE 17J 19 9 PTS STRAIGHT FEMALE SUBD DE9SD CAN BUS EXTERNE 18J 20 9 PTS STRAIGHT FEMALE SUBD DE9SD OUTPUT INSTRUCTION TO VP CONTROL EXTERNE 19J 21 9 PTS STRAIGHT FEMALE SUBD DE9SD VACUUM CAN INPUT EXTERNE 20J 22 9 PTS STRAIGHT FEMALE SUBD DE9SD INJET INPUT OUTPUTS EXTERNE 21J 23 15 PTS STRAIGHT FEMALE SUBD DA15SD DISPLAY OUTPUT EXTERNE 22J 24 9 PTS STRAIGHT FEMALE SUBD DE9SD INSTRUCTION OUTPUT TO CONVEYOR EXTERNE 23J 25 9 PTS STRAIGHT FEMALE SUBD DE9SD CONVEYOR ENCODER EXTERNE 24J 26 9 PTS STRAIGHT FEMALE SUBD DE9SD SUPPLEMENTARY LOAD INSTRUCTION EXTERNE 25J 27 9 PTS STRAIGHT FEMALE SUBD DE9SD SUPPLEMENTARY LOAD ENCODER EXTERNE 26J 31 15 PTS STRAIGHT FEMALE SUBD DA15SD FIXED KEYBOARD INPUT EXTERNE 27J 32 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 28J 33 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 29J 34 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 30J 35 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 31J 36 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 32J 37 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNE 33



J 38 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNAL 34J 39 48 PTS MALE ANGLE MIPAC STEP 2mm MICRO BOARD LINK INTERNAL 35J 200 50 PTS STRAIGHT FEMALE SUBD DB50SD CUTTING HEAD INPUT OUTPUT CONNECTION EXTERNAL 36J 300 9 PTS MALE ANGLE SUBD DE9PD X TACHOMETER EXTERNAL 37J 301 9 PTS MALE ANGLE SUBD DE9PD Y TACHOMETER EXTERNAL 38J 302 9 PTS MALE ANGLE SUBD DE9PD ROTATION TACHOMETER EXTERNAL 39J 303 9 PTS MALE ANGLE SUBD DE9PD Z TACHOMETER EXTERNAL 40J 311 37 PTS STRAIGHT FEMALE SUBD DB37SD COHERENT LASER INTERFACE EXTERNAL 41J 312 9 PTS STRAIGHT FEMALE SUBD DE9SD LASER LIGHT AND SHUTTER SAFETY EXTERNAL 42



2.12 Signals on the connectors of the 22615 board (740515)J1 J2 J3 J5

Relay input Output to relay Supp. relay control ELA serial channel 11 power presence 1 48v pc2 1 output 1 high 1 DCD channel 12 compressed air presence 2 info 5v ok 1 2 output 1 low 2 RXD channel 13 inhibit coda 3 info 5v ok 2 3 output 2 high 3 TXD channel 14 vacuum defect 4 auto/manual coda 4 output 2 low 4 DTR channel 15 sup. input plate 1 5 gv/pv vacuum 5 5 gnd

6 sup. input plate 2 6 time meter 6 DSR channel 17 vdd4 (+12v) 7 + sharpener output 7 RTS channel 18 vdd4 (+12v) 8 - sharpener output 8 CTS channel 1

9 gnd 9 RI channel 1

J6 J7 J8 J9serial channel 2 EIA EIA serial channel

3EIA serial channel 4 X encoder

1 DCD channel 2 1 DCD channel 3 1 DCD channel 4 1 (+)A cod X2 RXD channel 2 2 RXD channel 3 2 RXD channel 4 2 (-)A cod X3 TXD channel 2 3 TXD channel 3 3 TXD channel 4 3 vcc24 DTR channel 2 4 DTR channel 3 4 DTR channel 4 4 (+)B cod X5 gnd 5 gnd 5 gnd 5 (-)B cod X6 6 DSR channel 3 6 6 gnd7 RTS channel 2 7 RTS channel 3 7 RTS channel 4 7 gnd8 CTS channel 2 8 CTS channel 3 8 CTS channel 4 89 9 RI channel 3 9 9

J10 J11 J12 J15brushless supply / Z brushless outputs DC motor Z axis supply option

1 0v power 1 W phase A1 (+) Z motor induit 1 vcc1 (+5v)2 supply 1 (brushless) 2 V phase A2 (-) Z motor induit 2 gnd3 supply 2 (Z motor) 3 U phase 1 (+) Z motor induit 3 vdd3 (+12v)

2 (-) Z motor induit 4 vbb1 (-12v)3 5 vee1 (-5v)4 6 vcc1 (+5v)5 7 gnd

89

J14-A J14-B J14-C J16brushless signals daughter board daughter board Y encoder

1 1 1 gnd 1 (+)A cod Y2 2 2 gnd 2 (-)A cod Y3 3 3 gnd 3 vcc24 (-)Z tachometer 4 4 gnd 4 (+)B cod Y5 (+)Z tachometer 5 enable (active at +12) 5 gnd 5 (-)B cod Y6 current return 6 brushless reset 6 gnd 6 gnd7 speed return 7 brushless instruction 7 gnd 7 gnd8 brushless disjunction 8 8 gnd 89 (-)TZ4 9 9 gnd 9

10 (-)TZ3 10 10 gnd

11 (-)TZ2 11 disj Z (fis) 11 gnd J1712 (-)TZ1 12 lem Z 12 gnd R encoder13 gnd 13 gnd 13 gnd 1 (+)A cod R14 led cc 14 led bru 14 gnd 2 (-)A cod R15 led 2 15 led I2T 15 gnd 3 vcc316 led 0 16 led 1 16 gnd 4 (+)B cod R

5 (-)B cod R6 gnd7 gnd8 (+) top 0 cod R9 (-) top 0 cod R


January 1998 - Edition 1

J18 J19 J20 J21Z encoder can bus cons. -> vp ctrl in can depression

1 (+)A cod Z 1 1 1 vdd3 (+12v)2 (-)A cod Z 2 can_low 2 control vp instruction 2 vbb1 (-12v)3 vcc3 3 gnd (can) 3 relay rest mst2 vp ctrl 3 gnd4 (+)B cod Z 4 4 work relay. mst2 vp ctrl 4 vacuum can input5 (-)B cod Z 5 gnd (can shield) 5 work relay. mst1 vp ctrl 56 gnd 6 gnd 6 gnd 67 gnd 7 can_high 7 common relay mst2 vp ctrl 78 (+) top 0 cod Z 8 8 common relay mst1 vp ctrl 89 (-) top 0 cod Z 9 vdd1 (+12v) 9 rest relay mst1 vp ctrl 9

J23 J25 J24 J22display output conveyor encoder ins. -> conveyor inkjet out

1 gnd 1 (+)A cod C 1 1 inkjet input 1 up2 vlc display contrast 2 (-)A cod C 2 conveyor instruction 2 inkjet input 2 up3 rw display 3 vcc3 3 rest relay mst2 conveyor 3 quick out co. 1 inkjet4 DB0 4 (+)B cod C 4 work relay mst2 conveyor 4 quick out co. 2 inkjet5 DB2 5 (-)B cod C 5 work relay mst1 conveyor 5 vdd4 (+12v)6 DB4 6 gnd 6 gnd 6 inkjet input down 17 DB6 7 gnd 7 common rly mst2 conveyor 7 inkjet input down 28 8 8 common rly mst1 conveyor 8 gnd9 vcc4 (+5v) 9 9 rest relay mst1 conveyor 9 gnd

10 A0 display

11 CS display J27 J26 J3112 DB1 supp load encoder ins. -> supp load fixed keyboard input13 DB3 1 supp load encod A (+) 1 1 +X keyboard input14 DB5 2 supp load encod A(-) 2 supp load instruction 2 -X keyboard input15 DB7 3 vcc2 3 relay rest rev. supp load 3 +Y keyboard input

4 supp load encod B (+) 4 work rel. rev. supp load 4 -Y keyboard input5 supp load encod B (-)B 5 work rel. fwd. supp load 5 shift keyboard input6 gnd 6 gnd 6 val keyboard input7 gnd 7 common rel rev. supp load 7 quit keyboard input8 8 common rel fwd. supp load 8 vdd4 (+12v)9 9 relay rest fwd. supp load 9

10 infra-red 111 infra-red 112 infra-red 113 left/right keyboard input1415 gnd

J32-A J32-B J32-C J32-Dmicro dsp board micro dsp board micro dsp board micro dsp board

1 led 1 1 (-)tz1 1 (+) X tachometer 1 gnd2 led I2T 2 (-)tz2 2 (-) X tachometer 2 gnd3 led brushless 3 (-)tz3 3 3 gnd4 led 0 4 (-)tz4 4 (+) Y tachometer 4 gnd5 led 2 5 lem Z 5 (-) Y tachometer 5 gnd6 led cc 6 disj. Z (fis) 6 6 gnd7 enable (active to +12v) 7 7 (+) R tachometer 7 vcc1 5v J18 disj. brushless 8 current return 8 (-) R tachometer 8 vcc19 9 speed return 9 9 vcc1

10 10 brushless instruction 10 (+) Z tachometer 10 vcc111 laser +12v indicator 11 brushless reset 11 (-) Z tachometer 11 vcc112 open shutter 12 12 12 vcc1



J33-A J33-B J33-C J33-Ddsp micro board dsp micro board dsp micro board dsp micro board

1 +X keyboard key 1 drill 1 high switch 1 inkjet low input 1 1 gnd2 -X keyboard key 2 drill 1 low switch 2 inkjet low input 2 2 gnd3 +Y keyboard key 3 drill 2 high switch 3 cdp power presence 3 gnd4 -Y keyboard key 4 drill 2 low switch 4 compressed air presence 4 gnd5 shift keyboard key 5 inhibit coda 5 irq switch 5 gnd6 val keyboard key 6 sup head switch 6 vacuum defect 6 gnd7 quit keyboard key 7 7 7 vdd1 12 v J19 (bus can)8 left/right keyboard 8 current return 8 8 vdd19 blade high switch 9 speed return 9 9 vdd1

10 blade low switch 10 brushless instruction 10 10 vdd111 sharpener high switch 11 brushless reset 11 low can 11 vdd112 sharpener low switch 12 12 high can 12 vdd1


1 ev blade down 1 (+)A cod X 1 (+)A cod R 1 gnd2 ev presser foot down 2 (-)A cod X 2 (-)A cod R 2 gnd3 ev sharpener down 3 (+)B cod X 3 (+)B cod R 3 gnd4 ev drill 1 down 4 (-)B cod X 4 (-)B cod R 4 gnd5 ev drill 1 rotation 5 (+)A cod Y 5 (+)Top0 cod R 5 gnd6 ev drill 2 down 6 (-)A cod Y 6 (-)Top0 cod R 6 gnd7 ev drill 2 rotation 7 (+)B cod Y 7 (+)A cod Z 7 vbb1 (-12v j15 & j21)8 viewer 2 / pen control 8 (-)B cod Y 8 (-)A cod Z 8 vbb19 viewer control 9 9 (+)B cod Z 9 vdd3 (+12v j15 & j21)

10 ev inkjet rotation 10 10 (-)B cod Z 10 vdd311 ev inkjet down 11 11 (+)Top0 cod Z 11 vdd2 (+12v J200)12 ev flip flop 12 12 (-)Top0 cod Z 12 vdd2


1 DCD channel 1 1 RTS channel 2 1 TXD channel 4 1 gnd2 RXD channel 1 2 CTS channel 2 2 DTR channel 4 2 gnd3 TXD channel 1 3 DCD channel 3 3 DSR channel 4 3 gnd4 DTR channel 1 4 RXD channel 3 4 RTS channel 4 4 gnd5 DSR channel 1 5 TXD channel 3 5 CTS channel 4 5 gnd6 RTS channel 1 6 DTR channel 3 6 6 gnd7 CTS channel 1 7 DSR channel 3 7 7 vcc3 (5v J17, J18, J26)8 RI channel 1 8 RTS channel 3 8 8 vcc39 DCD channel 2 9 CTS channel 3 9 (+)A cod sup load 9 vcc3

10 RXD channel 2 10 RI channel 3 10 (-)A cod sup load 10 vcc2 (5v J9, J16, J27)11 TXD channel 2 11 DCD channel 4 11 (+)B cod sup load 11 vcc212 DTR channel 2 12 RXD channel 4 12 (-)B cod sup load 12 vcc2


1 led ev blade down 1 led rel. auto/man coda 1 led disj X 1 gnd2 led ev presser foot down 2 led rel. gv/pv vac 2 led disj Y 2 gnd3 led ev sharpener down 3 led time meter 3 led disj R 3 gnd4 led ev drill 1 down 4 led + sharpener relay 4 led disj Z 4 gnd5 led ev drill 1 rotation 5 led sharpener relay - 5 5 gnd6 led ev drill 2 down 6 led sup plate 1 control 6 6 gnd7 led ev drill 2 rotation 7 led sup plate 2 control 7 7 vdd4 (+12v J1, J22, J31)8 led viewer 2 / pen control 8 led quick out ink jet 1 8 8 vdd49 led viewer control 9 led quick out ink jet 2 9 9 vdd4

10 led ev inkjet rotation 10 led mst vp control 10 10 vcc4 (+5v J23)11 led ev inkjet down 11 led forward sup load 11 led forward conveyor 11 vcc412 led flip flop control 12 led reverse sup load 12 led reverse conveyor 12 vcc4


January 1998 - Edition 1


1 rw display 1 gnd 1 rw display 1 gnd2 DB0 2 gnd 2 DB0 2 gnd3 DB2 3 gnd 3 DB2 3 gnd4 DB4 4 gnd 4 DB4 4 gnd5 DB6 5 gnd 5 DB6 5 gnd6 A0 display 6 gnd 6 A0 display 6 gnd7 CS display 7 gnd 7 CS display 7 gnd8 DB1 8 gnd 8 DB1 8 gnd9 DB3 9 gnd 9 DB3 9 gnd

10 DB5 10 gnd 10 DB5 10 gnd11 DB7 11 vee1 (-5v j15) 11 DB7 11 vee1 (-5v J15)12 led dirqB 12 vee1 12 led dirqB 12 vee1


1 conveyor instruction 1 supp load instruction. 1 control vp instruction 1 gnd2 rest rel. rev. conveyor 2 rep. rel. rev supp load 2 rest rel. mst2 vp control 2 gnd3 work rel. rev. conveyor 3 wrk rel rev supp load 3 work rel. mst2 vp control 3 gnd4 work rel. fwd. conveyor 4 wrk rel fwd supp load 4 work rel. mst1 vp control 4 gnd5 com. rel. rev. v 5 com rel rev supp load 5 common rel. mst2 vp

control5 gnd

6 com. rel. fwd. conveyor 6 com rel fwd supp load 6 common rel. mst1 vpcontrol

6 gnd

7 rest rel. fwd. conveyor 7 rep rel fwd supp load 7 rest rel. mst1 vp control 7 vcc (+5v leds and misc)8 8 8 8 vcc9 (+)A mot C 9 reset led 9 9 vcc

10 (-)A mot C 10 halt led 10 10 vcc11 (+)B mot C 11 reset bp 11 11 vcc12 (-)B mot C 12 abort bp 12 vacuum can input 12 vcc


1 48 v pc2 1 laser 0 input 1 laser power output 1 gnd2 info 5v ok1 2 laser 1 input 2 laser rfd drive (pwm)

output2 gnd

3 info 5v ok2 3 laser 2 input 3 quick out CO1 inkjet 3 gnd4 auto/manual coda output 4 laser 3 input 4 quick out CO2 inkjet 4 gnd5 vacuum gv/pv output 5 laser alert input 5 5 gnd6 time meter output 6 laser shutter input 6 6 gnd7 + sharpener output 7 laser shutter output 7 led laser IN6 input 7 vcc (+5v leds et divers)8 - sharpener output 8 laser drive A output 8 led laser IN7 input 8 vcc9 output 1 high 9 laser drive B output 9 9 vcc

10 output 1 low 10 laser AIM output 10 10 vcc11 output 2 high 11 laser clear fault

output11 laser IN6 input 11 vcc

12 output 2 low 12 laser rf enc output 12 laser IN7 input 12 vcc

J300 J301 J302 J303X tachometer Y tachometer rotation tachometer Z tachometer

1 (+)X tachometer 1 (+)Y tachometer 1 (+)R tachometer 1 (+) Z tachometer2 (-)X tachometer 2 (-)Y tachometer 2 (-)R tachometer 2 (-) Z tachometer3 gnd 3 gnd 3 gnd 3 gnd4 4 4 45 5 5 56 6 6 67 7 7 78 8 8 89 9 9 9



J200 J311 J312X tach X tach X tach

1 vdd2 (+12v) 1 gnd 1 laser indicator (+12v)2 vdd2 (+12v) 2 laser 3 input 23 irq input switch 3 gnd 3 open shutter/shutter info4 blade high input switch 4 laser shutter input 45 blade low input switch 5 gnd 5 cover switch (serial depart)6 sharpener high switch 6 laser alert input 6 gnd7 sharpener low switch 7 78 drill 1 high switch 8 gnd 89 drill 1 low switch 9 laser shutter output 9 cover switch (serial return)

10 drill 2 high switch 10 gnd11 drill 2 low switch 11 output laser drive A12 + X keyboard key 12 gnd13 - X keyboard key 13 output laser drive B14 + Y keyboard key 14 gnd15 - Y keyboard key 15 laser AIM output16 quit keyboard key 16 gnd17 val keyboard key 17 laser clear fault outpt18 shift keyboard key 18 gnd19 ev blade down 19 laser rf enc output20 ev pressure foot down 20 laser 2 input21 ev sharpener down 21 gnd22 ev drill 1 down 22 laser IN6 input23 ev drill 1 rotation 23 laser IN7 input24 ev drill 2 down 24 laser 1 input25 ev drill 2 rotation 25 gnd26 viewer 2/pen ctrl output 26 laser 0 input27 viewer control output 27 gnd28 (+)sin resolver 28 analog instruction29 (-)sin resolver 29 gnd30 (+)cos resolver 3031 (-)cos resolver 3132 (+)ref resolver 32 strap with pin 3333 (-)ref resolver 33 strap with pin 3234 gnd 34 gnd35 gnd 35 output rfd drive pwm36 gnd 36 gnd37 gnd 37 laser power output

38 inkjet down switch39 inkjet rotation switch40 supp head switch41 ev inkjet rotation42 ev inkjet down43 ev flip flop44 infra-red 145 infra-red 246 infra-red 347 vdd2 (+12v)48 vdd2 (+12v)49 gnd50 gnd



2.13 State of the leds on the 22615 board (740515) (standard functioning)

D : n° diode - C. : R -> red, V -> green, J -> yellow

FCT : function - Origin : signal origin board

D Designation C. Fct. Origin Comments

1 LED 0 ( VIBRATION BOARD 22597 ) R 22615 ON after tripping (the combination of leds 1, 2, 3 indicates the trip type).

2 LED 1 (VIBRATION BOARD 22597 ) R 22615 ON after tripping (the combination of leds 1, 2, 3 indicates the trip type).

3 LED 2 (VIBRATION BOARD 22597 ) R 22615 ON after tripping (the combination of leds 1, 2, 3 indicates the trip type).

4 LED DISJV (INCL. BRUSHLESS DISJ. AND ENABLE) R 22613 OFF if MST active. ON if MST off OR if tripped

5 LED DISJX ( INCL. FIS, DJC, DJL AND LED MST ) R 22613 OFF if MST active. ON if MST off OR if tripped

6 LED DISJY ( INCL. FIS, DJC, DJL AND LED MST ) R 22613 OFF if MST active. ON if MST off OR if tripped

7 LED CONVEYOR REVERSE V 22613 ON during a conveyor reverse

8 LED SUP LOAD REVERSE V 22613 unused at present

9 LED LASER 7 INPUT V IN 22613

10 LED LASER ALERT INPUT V IN 22613 OFF if default on the laser

11 LED LASER 2 INPUT V IN 22613 DC10 rofin -> High voltage ON / Coherent -> laser status Bit

12 LED LASER 0 INPUT V IN 22613 DC10 Rofin -> State contact shutter close (relay contact) / Coherent -> Laser status Bit

13 LED LASER CLEAR FAULT OUTPUT V OUT 22613 DC10 Rofin -> Light up viewer / Coherent -> "laser error" erase impulsion

14 LED LASER B DRIVE OUTPUT V OUT 22613 DC10 Rofin -> Engage high voltage / Coherent -> output B "request laser status page"

15 LED LASER SHUTTER OUTPUT V OUT 22613 DC10 Rofin -> Engage shutter / Coherent -> Shutter control

16 LED LASER POWER OUTPUT V OUT 22613 DC10 Rofin -> Selection of the laser emission program / Coherent -> high voltage control

17 LED VCC 1 V 22615 Led OFF if short circuit on VCC1. Switches back on as soon as the short circuit isresolved.

18 LED VCC 2 V 22615 Led OFF if short circuit on VCC2. Switches back on as soon as the short circuit isresolved..



21 LED VEE 1 V 22615 Led OFF if short circuit on VEE1. Switches back on as soon as the short circuit isresolved.

22 LED 5V OK V 22613 ON if supply "power fail" not released AND if the thermo contact of the brakingresistance is ON



23 LED POWER PRESENCE INPUT (CDP) R 22613 ON if power default (no power).

24 LED IRQ POWER + AIR J 22613 ON if power default or no compressed air.

25 LED LIMIT STOP IRQ INPUT J 22615 ON if limit stop detection.

26 LED IRQ KEYBOARD KEY IRQ J 22613 ON if the strike on a keyboard key is detected.

27 LED DIRQB J 22613 ON if a supply default is detected (power fail active) or if motor trips

28 LED +X KEYBOARD KEY INPUT V IN 22615 ON if the +X on the keyboard is struck.

29 LED -X KEYBOARD KEY INPUT V IN 22615 ON if the -X on the keyboard is struck.

30 LED +Y KEYBOARD KEY INPUT V IN 22615 ON if the +Y on the keyboard is struck.

31 LED -Y KEYBOARD KEY INPUT V IN 22615 ON if the -Y on the keyboard is struck.

32 LED SHIFT KEYBOARD KEY INPUT V IN 22615 ON if the SHIFT on the keyboard is struck.

33 LED VAL KEYBOARD KEY INPUT V IN 22615 ON if the VAL on the keyboard is struck.

34 LED QUIT KEYBOARD KEY INPUT V IN 22615 ON if the QUIT on the keyboard is struck.

35 LED LEFT / RIGHT KEYBOARD KEY INPUT V IN 22615 ON if the LEFT/RIGHT on the keyboard is struck.

36 LED BLADE HIGH SWITCH INPUT V IN 22615 ON when the blade is detected in high position

37 LED BLADE LOW SWITCH INPUT V IN 22615 ON when the blade is detected in low position.

38 LED SHARPENER HIGH SWITCH INPUT V IN 22615 ON when the sharpener is detected in high position

39 LED SHARPENER LOW SWITCH INPUT V IN 22615 ON when the sharpener is detected in low position

40 LED EV INKJET DOWN V OUT 22613 ON during the control of the "inkjet" down electrovalve .

41 LED VIEWER CONTROL V OUT 22613 ON during the viewer control.

42 LED EV DRILL 2 ROTATION V OUT 22613 ON during the control of the "drill 2 rotation" electrovalve

43 LED EV DRILL 1 ROTATION V OUT 22613 ON during the control of the "drill 1 rotation" electrovalve

44 LED EV SHARPENER PLUNGE V OUT 22613 ON during the control of the sharpener plunge electrovalve

45 LED EV BLADE PLUNGE V OUT 22613 ON during the control of the "blade plunge" electrovalve

46 LED INKJET 1 QUICK OUTPUT V OUT 22613 ON during the "inkjet" quick output control

47 LED PLATE 1 SUP CONTROL V OUT 22613 ON if the supplementary control of plate 1 is activated (not used).

48 LED VACUUM GV/PV RELAY V OUT 22613 ON when the vacuum GP/PV control relay is activated

49 LED SHARPENING RELAY - V OUT 22613 ON during the sharpener relay control.

50 LED CC ( VIBRATION BOARD 22597 ) V 22615 ON if the motor control is config "DC motor".

51 LED BRU (VIBRATION BOARD 22597 ) V 22615 ON if the motor control is config "brushless motor".

52 LED I2T (VIBRATION BOARD 22597 ) J 22615 ON briefly if the nom current is exceeded (ex: accelerated). Permanent light -> default.

53 LED DISJR ( INCLU FIS, DJC, DJL AND LED MST ) R 22613 OFF if MST active. ON if MST off OR if tripped.



54 LED DISJZ ( INCLU FIS, DJC, DJL AND LED MST ) R 22613 OFF if MST active. ON if MST off OU if tripped.

55 LED CONVEYOR FORWARD V 22613 ON during a conveyor advance.

56 LED SUP LOAD FORWARD V 22613 ON if supply advance (supplementary input not used).

57 LED MST VP CONTROL V 22613 ON when switching on "VP Control".

58 LED LASER 6 INPUT V IN 22613

59 LED LASER SHUTTER INPUT V IN 22613 Re-copy the shutter position

60 LED LASER 3 INPUT V IN 22613 DC10 Rofin -> Low voltage ON / Coherent -> Laser status bit

61 LED LASER 1 INPUT V IN 22613 DC10 Rofin -> Shutter opening contact state (rel. contact) / Coherent -> Laser status bit

62 LED LASER ENC RF OUTPUT V OUT 22613 RF emission authorization (laser beam emission)

63 LED LASER SUPPLY OUTPUT V OUT 22613 DC10 Rofin -> High voltage release pulse / Coherent -> Viewer lights up

64 LED LASER DRIVE A OUTPUT V OUT 22613 DC10 Rofin -> Shutter control pulse / Coherent -> Output A request status page

65 LED LASER LIGHT V OUT 22613 Presence of the laser beam of the cutting table (laser beam ON and shutter open).

66 LED VDD 1 V 22615 Led OFF if short circuit on VDD1. Lights up as soon as the short circuit is resolved.




70 LED VBB 1 V 22615 Led OFF if short circuit on VBB1. Lights up as soon as the short circuit is resolved.

71 LED HALT R 22613 ON if the micro board is on HALT (functioning default).

72 LED RESET J 22613 ON when the micro reset key is struck.

73 LED COMPRESSED AIR PRESENCE INPUT R 22613 ON if default (no compressed air).

74 LED VACUUM DEFAULT IRQ INPUT J 22615 ON if vacuum default (no vacuum).

75 LED IRQ BUS CAN J 22613 Not used.

76 LED DIRQA J 22613 ON if limit stop detection (idem led 25).

77 LED DRILL 1 HIGH SWITCH INPUT V IN 22615 ON if detection of drill 1 in high position.

78 LED DRILL 1 LOW SWITCH INPUT V IN 22615 ON if detection of drill 1 in low position.

79 LED DRILL 2 HIGH SWITCH INPUT V IN 22615 ON if detection of drill 2 in high position.

80 LED DRILL 2 LOW SWITCH INPUT V IN 22615 ON if detection of drill 2 in low position

81 LED CODA INHIBIT INPUT V IN 22615 ON if CODA inhibit switch is detected.

82 LED HEAD SWITCH SUPPLEMENTARY INPUT V IN 22615 ON if supplementary head switch is detected (not used).

83 LED PLATE 1 SUPPLEMENTARY INPUT V IN 22615 ON if plate 1 supplementary switch is detected (not used).

84 LED PLATE 2 SUPPLEMENTARY INPUT V IN 22615 ON if plate 2 supplementary switch is detected (not used).



85 LED INKJET LOW SWITCH INPUT V IN 22615 ON if detection of the "inkjet" down switch

86 LED INKJET ROTATION SWITCH INPUT V IN 22615 ON if detection of the "inkjet" rotation switch ".

87 LED INKJET HIGH INPUT 1 V IN 22615 ON if detection of "inkjet 1" in high position.

88 LED INKJET HIGH INPUT 2 V IN 22615 ON if detection of "inkjet 2" in high position

89 LED FLIP FLOP CONTROL V OUT 22613 ON if flip flop control is activated.

90 LED EV INKJET ROTATION V OUT 22613 ON if the "inkjet" rotation electrovalve control is activated.

91 LED VIEWER 2 / PEN CONTROL V OUT 22613 ON if the control "viewer 2 / pen" is activated.

92 LED EV DRILL 2 PLUNGE V OUT 22613 ON if the drill 2 plunge control is activated.

93 LED EV DRILL 1 PLUNGE V OUT 22613 ON if the drill 1 plunge control is activated.

94 LED EV PRESSER FOOT PLUNGE V OUT 22613 ON if the presser foot plunge electrovalve control is activated.

95 LED QUICK INKJET 2 OUTPUT V OUT 22613 ON if the "inkjet 2" quick control is activated.

96 LED PLATE 2 SUP CONTROL V OUT 22613 ON if the supplementary control of plate 2 is activated (not used).

97 LED TIME METER V OUT 22613 ON as soon as the time meter starts (machine operating time).

98 LED AUTO/MANUAL CODA RELAY V OUT 22613 ON when the AUTO/MANUAL CODA is activated

99 LED + SHARPENING RELAY V OUT 22613 ON during the sharpening relay control .

CutterBox V2 - 22631, 22635 and 22636 Boards A5.1


2.17 Motor drives 740531, 740535, 740536

Reference board 740531A 740535A 740536A

Features X axis 100A +brake

X axis 50A + brake axes Y & rotation 50A

I max (motor current) 100A 50A 50AI trip (disj. "motor") 100A 50A 50AI trip (disj. "bus") 110A 110A 110ASpeed control input interface +/- 20mA interface +/- 20mA interface +/- 20mABreaking (limit) 154V (option 190V) 154V (option 190V) nonPresence + 5V led green led green led greenPresence + 12V led green led green led greenPresence - 12V led green led green led greenPresence + 120V (power) led yellow led yellow led yellowBraking led yellow (braking) led yellow (braking)MST motor led green led green led greenDisj. motor (disj. locg) led red led red led redDisj. supply (+120v) led red led red led red

Board Usable motor references Machine740531A, 740535A,740536A BMR55C4-11, HD55C4-11, LX220BG VT2500

HD70C4-16, LX320BK VT5000, VT7000

2.18 Signals on the connectors of the 22631, 22635, 22636 board

J1 J2dsp2213 board link R breaking

1 gnd 14 DJC_mot_out 1 Resistance2 T1-in 15 gnd3 gnd 16 DJL_mot_out4 T2-in 17 gnd5 gnd 18 DJL_bus_out6 T3-in 19 gnd7 gnd 20 I_mot (info lem)8 T4-in 21 gnd9 gnd 22 5V (vcc)

10 mst-in 23 gnd11 gnd 24 12V (vdd)12 reset-in 25 gnd13 gnd 26 (-)12V (vbb)

2.19 Signals on the connectors fixed to the CutterBox V2 box

J7 J122 J123 wago connectorY & R motor supply Y motor R motor X motor

1 (+)130V A1 (+) motor A1 (+) motor ground2 (+)130V A2 (-) motor A2 (-) motor 1 (+)130V3 gnd 1 (+) tachometer 1 (+) tachometer 2 0V4 gnd 2 (-) tachometer 2 (-) tachometer 3 (+) motor

3 3 4 (-) motor4 4 55 5 6

A5.2 CutterBox V2 - 22631, 22635 and 22632 Boards


2.20 Presentation of the 22631, 22635, 22636 boards

CutterBox V2 - 22631, 22635 and 22636 Boards A5.3


2.21 Presentation of the 22631, 22635, 22636 boards (740531,740535, 740536)

A5.4 CutterBox V2 - 22631, 22635 and 22632 Boards


CutterBox V2 - Brushless motor 50A A6.1


2.22 Brushless motor drive 50A (vibration)

The variator has :

- a motor control card code 740497- a power board 6 IGBT 25A 600V code 740542- a temperature sensor board code 740548

The power board is connected by its connectors, the internal wiring to the module is done byconnecting the supply to the control board.

All the settings (currents and speed) are made using switches, no measuring devise is required toconfigure the variator. A visual motor stop setting is made with a potentiometer on the controlboard.

The variator can commute currents up to 25 amps, which enables controlling the "vibration"motor of the VT2500 (BMR55C4-11, HD55C4-11, LX220BG) as well as those of the futureVT5000/7000 (HD70C4-16, LX320BK).The current protection of the power stages is fixed (40A) and adapted to the IGBT capacity. A thermic protection of the power stage is ensured should it reach 78°C (+ or - 1°C)The braking of the blade vibration is ensured by the braking electronics which is general for allaxes, and located on the rotation axis board.

This variator can be configured to control a 4 pole brushless module with a resolver, or a DCmotor with a tachometer. By changing the programmable circuit it can also respond to the 6 poleand 8 pole brushless motor requirements.

A braking unit is integrated in the variator. It only becomes operational after a power resistancehas been added to the box.A +12 VDC fan can be added should any thermic problems arise.

The speed control is carried out by a ±20ma inlet.An "encoder" outlet is available should any positioning be required.A "speed return" outlet supplies an analog signal of 5.8v for 8000 trs/mn.A "return current" outlet enables visualizing the current in the motor. (0.15v/amp)

The state of the variator, as well as diagnostic trouble-shooting help are available on the frontside in led type.

A6.2 CutterBox V2 - Brushless motor 50A


GENERAL CONFIGURATION : ( X = SWITCH "ON")

S2 Loop and direction ON OFF

1 Brushless gain Motor gain CC2 n.u. n.u.3 Open loop Closed loop4 Anti-clockwise direction Clockwise direction

S3 Speed1 2 3 4 AC MOTOR trs/mn DC MOTOR trs/mn

X 2000 1000 X 3000 1500

X X 4000 2000 X 5000 2500

X X 6000 3000 S5 nominal current

X 7000 3500 1 2 3 4 I nominal

X X X 7500 3750 X X X X 1A X X 8000 4000 X X X 2A

X X X 3A

S4 current limit and AC/DC X X 4A

1 2 3 x I nominal X X X 5A X X X 1 X X 6A X X 1.5 X X 7A X X 2 X 8A X 2.5 X X X 9A

X X 3 X X 10A X 3.5 X X 11A

X 4 X 12A4.5 X X 13A

4 X 14AX DC Motor X 15A

Brushless 16A

SPECIFIC CONFIGURATIONS: ( X = SWITCH "ON")

Depending on which machine the CutterBox is mounted, the configuration of the brushless motor controlwill be different. The table below indicates the configuration adapted to each type of machine.

motor I nominal (A) I limit (A) Speed for instruction 20mA or 10V (trs/mn)

VT2500 Brushless 5 7,5 7500

VT5000 DC 14 21 4000

Switches configuration depending on the machine type:

S2 S3 S4 S5 S2 S3 S4 S5

VT2500 VT5000

Off On



SIGNALISATION:

Leds green:These leds indicate the operating mode of the variator, depending on the state of the S4 switch 4.

- Piloting a brushless motor (AC Motor)- Piloting a DC motor (DC Motor)

Leds yellow:These leds must only light up for a very short time.

- Led "I2T" indicates that the nominal current fixed by S5 has been exceeded.This excess are normal during acceleration or deceleration phases of the motor.

Leds red:

3 error leds (LO,L1,L2) enable diagnosing a problem when the variator trips. To re-initialize the variator after an error, just switch the supply off and on.

L0 L1 L2 ERRORS COMMENTS - all switched off - no error

X 1 short circuit detection on the power X 2 thermic overload (I2T)

X X 3 supply default -12v X 4 short circuit detection of the resolver supply

X X 5 variator over heated (>78°C) X X 6 supply default +12v

X X X 7 general reset or supply default +5v C C C 8 detection of an overload on the power (>400v)

X = led lit upC = led flashing



DIAGNOSTIC HELP:

ERROR 1 A short circuit has been detected by the power stages. Disconnect the powerconnector at the motor and test it with an the ohm-meter :

- each phase in relation to the frame, then the phases together.- disconnect the power connector by the variator and test the beam.- open the variator and remove the 740542A power board.- test each phase in relation to the + and - of the connector.- Test the phases together.

ERROR 2 A thermic overload has been detected..- the motor rotor may be blocked. Check manually- one of the phases may not be supplied. Disconnect the power connector by the variatorand check the continuity between phases.- The resolver might be disconnected or might not be receiving the supply correctly.Open the variator and check the REF, SIN, COS signals on the 740497A control board. - The sinusoids must be at a frequency of 5 kHz.

REF DETAILS

1 >

2 >2 >

3 >

REF (14 vcàc)

SIN (7 vcàc)

COS (7 vcàc)

- The programmed nominal current has been under estimated. Check that the S5 switchconfiguration corresponds to the nominal current. Check that the S5 switchconfiguration corresponds to the current on the motor plate

ERROR 3 A supply default -12v has been detected.

ERROR 6 A supply default +12v has been detected.



ERROR 7 A supply default +5v has been detected.- Open the CutterBox.- Check the supply voltage on the J7 connector.

ERROR 4 A short circuit on the resolver supply has been detected.- Check that the connector of the resolver is connected correctly. - Check the beam resolver.

ERROR 5 An overheating of the variator has been detected- The temperature of the power module radiator 78°c.- Check the ventilation and that the filters are dirt free.- Check the IGBT are saturated correctly by controlling the gate voltage on the 740542Aboard. They must go to +13v minimum.

ERROR 8 An over voltage of the supply (>400v) has been detected.- Check the braking circuit on the rotation axis board inside the CutterBox



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2.23 Diagram of the 22648 board (740548)



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2.24 Diagram of the 22614 board (740514)



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CutterBox V2 - Spare parts list A9.1


2.25 Reference of the spare parts

Code Designation Quantity topographic mark740513A DSP micro board 1 Mother board740514A SIMM flash board 1 MOD2740535A IGBT 50A driver board + brake 1 R Mot740536A IGBT 50A driver board 2 X Mot / Y Mot740531A IGBT 100A driver board + brake 1 Mot. X308002 26 pts Female/Female ribbon cableL=100mm 3 X Mot / Y Mot / R Mot308165 Cap 26 pts Female for DSP micro 1 J4 (DSP micro board)

740497B Brushless motor control board 1 blade vibration motor740542B Brushless motor power module board 1 blade vibration motor302390 filter with support for fan 120 x 120 2307998 resistance PU 47 ohms 200W on frame 1 R1305630 Supply 230W PC type 1 sup 1

☞ The boards 740497B + 740542B must be mounted on the CutterBox V2 and they can beused for a 780121C brushless module.

On the other hand, the 740497A + 740542A boards cannot be mounted in the CutterBox V2.

A9.2 CutterBox V2 - Spare parts list


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CutterBox V2 - Detailed view A10.1


2.26 Detailed view of the CutterBox V2

A10.2 CutterBox V2 - Detailed view


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cutter box v2

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