5 - Manual Software Duplomatic
5 - Manual Software Duplomatic
5 - Manual Software Duplomatic
Linha GLM
DM*-TURRETS
FW 1.1x
FW 2.1x
The information described in this manual may be subject to variations due to technical modifications.
DUPLOMATIC AUTOMAZIONE S.p.A. reserves the right to modify the contents of this manual without prior notice.
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Contents
1. GENERAL INFORMATION 4
CODE OF THE CONTROL UNIT 4
IMPORTANT NOTE FOR SAFETY 4
CE COMPLIANCE 5
CAUTIONS PERFORMING VOLTAGE TEST 5
ROHS AND WEEE DIRECTIVES 5
CHARACTERISTICS OF THE CONTROL UNIT 6
TECHNICAL CARACTERISTICS OF THE CONTROL UNIT 6
2. ELECTRICAL CONNECTIONS 7
SUPPLY 7
POWER SUPPLY 230 VAC 3 ~ 7
SUPPLY 24 VDC 7
PROTECTION EARTH (PE) 7
FUNCTIONAL EARTH 7
SHIELD CONNECTION 7
TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMER DESIGN 7
I/O SIGNALS 8
OUTPUTS TO CNC (FROM I/O) 8
OUTPUTS TO ELECTROVALVE (FROM I/O) 8
INPUTS FROM CNC (TO I/O) 8
INPUTS FROM TURRET (TO DRIVER) 8
SELECTION OF THE NUMBER OF POSITIONS 9
SELECTION OF LOW/HIGH INERTIA 9
SELECTION OF STANDARD/MAINTENANCE SPEED 9
HARDWARE DISABLE 9
3. INTERFACING TO CNC 10
OPERATING FUNCTIONS 10
OPERATING FUNCTIONS DESCRIPTION 10
OPERATING FUNCTION N°0: EMERGENCY / RESET 12
OPERATING FUNCTION N°1,2,3: AUTOMATIC 12
4. TURRET START-UP PROCEDURE 13
5. DIAGNOSTIC 14
ALARMS AND WARNINGS 14
6. SCHEMATICS AND DRAWINGS 16
FITTING INTO THE ELECTRICAL CABINET 16
OVERALL DIMENSIONS 16
GENERAL DRAWING FOR FITTING INTO THE ELECTRICAL CABINET 17
DRIVER SUPPLY FOR FITTING INTO THE ELECTRICAL CABINET 17
DRIVER SUPPLY FOR FITTING INTO THE ELECTRICAL CABINET 18
SERVOMOTOR CABLE FOR FITTING INTO THE ELECTRICAL CABINET 19
RESOLVER/SWITCHES CABLE FOR FITTING INTO THE ELECTRICAL CABINET. 20
DIGITAL INPUT AND OUTPUT FOR FITTING INTO THE ELECTRICAL CABINET 20
DIGITAL INPUT AND OUTPUT FOR FITTING INTO THE ELECTRICAL CABINET 21
SERVICE SERIAL CONNECTION 22
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1. GENERAL INFORMATION
The Duplomatic TMC control unit is a compact system that controls all functions regarding positioning and
driving of the Duplomatic DM* turrets. The interfacing to the lathe is powerful and simplified for an easy
installation. Serial line RS232 is set for diagnostic and remote control by PC.
MODEL:TMC-14-230-12-16-1.2/11
Code: 0497012251
S/N *********
SET FOR: DM-16 S/N XXXXXXXX
The control unit, even after the power off of the supply, stores internally electric
power until the power capacitors are charged.
Be careful when operate on it.
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CE COMPLIANCE
The TMC controller has been tested with a turret under the condition reported as follows and obtained the
compliance for: CEI EN 61800-2 and CEI EN 61800-3 and CEI EN 61800-5-1.
The utilization class for this device is C3 (use in ‘second environment’ or use in industrial network line not
connected to civil environment).
This type of device is not intended to be used on a low-voltage public network which supplies domestic
premises. Radio frequency interference is expected If used on such a network.
Therefore, the use in civil environment could generate disturbance to some electrical and electronic equipment
and it needs to provide additional solutions to avoid this effect.
Before main voltage power supply of TMC controller, an external filter (non supplied) is necessary for EMC
compliance when TMC controller + turret are tested as stand-alone component. A ‘FINMOTOR FIN 1200-
010V’ EMC filter or better must be used.
The TMC controller, being transistorised drive for brushless motor, is not a safety device, and cannot work in
stand-alone mode because requires supply and wiring by the installer. So it is not subject to the CE mark
requirement.
By the way the CE mark is placed to show the compliance to the low-voltage directive about the electrical
safety of the component. The compliance of EMC and general safety standard is in charge of the machine
builder as stated also in the 2006/42/CE directive. The instruction stated in this installation manual provide a
line-guide to keep the EMC compliance in almost all applications.
The TMC controller must be connected in a TT or TN earthing system in industrial fixed network,
providing Overvoltage Category III or better.
The TMC controller must be fitted into a cabinet which provide Pollution Degree II or better, so a
minimum protection degree of IP54 is required.
The 24V DC supply (CN8) and all low voltage I/O (CN1,CN2,CN7) must be provided by ‘PELV’ circuits.
An external circuit breaker (Fuses) and a power contactor must be provided on the TMC threephase
main power supply.
The cabinet must be designed in order to protect people against direct contact when the voltage is
present: so mechanical interlock or automatic door-open switch-off devices must be foreseen.
After power-off, wait more than 5 minutes before handling the TMC controller.
The TMC controller is checked in factory for voltage insulation (AC voltage routine test). So disconnect the
controller when performing voltage test on the cabinet. By the way it is possible to perform standard insulation
resistance test on the threephase line up to 500 VDC as stated by EN 60204-1 Standard.
Due to the presence of internal overvoltage suppressor, it is necessary to remove the FUSE Fz located on
the bottom side of the TMC controller before performing Voltage Test.
The voltage test must not exceed 1500V AC for 1 sec. (as stated in EN61800-5-1).
The TMC controller is a variable speed motor driver intended to be used only in large fixed machine tools, thus
does not fall into the scope of ROHS and WEEE directives.
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Parameters of the system are optimised and cannot be modified by the customer.
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2. ELECTRICAL CONNECTIONS
Refer to the annex diagrams at section 5:
1. : wiring diagrams for installation into the electrical cabinet.
SUPPLY
POWER SUPPLY 230 VAC 3 ~
(see tab1)
The control unit requires a three-phase 230 VAC input for the power card.
A power contactor on the 230 AC line must be used for emergency stop (see wiring diagram).
The 230 VAC line must be protected with external fuses 16 A. (suggested 16 A motor start).
An external filter is required to meet E.M.C. compliance (not supplied).
SUPPLY 24 VDC
(see tab1)
The control unit requires an external 24V DC supply to build up all auxiliary supply necessary for the driver
section. An external slow-type fuse of 3 A must be used to protect this supply.
FUNCTIONAL EARTH
A M3 screw is present on the front cover of the controller, close to CN1 connector: This is not intended to be
used as PE but only for connect the shield of the cable used to connect CN1 and CN2.
SHIELD CONNECTION
Terminal 3 (‘SG’) of CN8 collects the metal body and inner shields of cable connected to CN7.
This terminal must be connected to a ‘signal ground’.
Important: check the voltage drop on the 230 VAC supply during acceleration, to be sure that this doesn’t
approach the indicated voltage limits. The centre of the star connection of the transformer’s secondary must be
connected to ground.
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I/O SIGNALS
OUTPUTS TO CNC (FROM I/O)
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HARDWARE DISABLE
This input can be used to secure disable the power stage in order to avoid unexpected movement of motor.
This does not disconnect electrically the motor, so any maintenance to the turret requires to disconnect the
three-phase power supply by means a power contactor or circuit breaker
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3. INTERFACING TO CNC
OPERATING FUNCTIONS
The control unit offers several operating functions (also called MODES).
Setting MODE01, MODE02 signals can make the selection of the operating functions.
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It is required to keep position bits and parity code set to the called position until the turret send back
the end of cycle.
The PSTART signal can be reset after the confirmation of the reception, typically it must stay on for at least
30 ms (T2).
Important: the end of cycle must be detected by the LOCKED signal that changes from low to high and
with the INDEXD signal high and no alarms are present.
In case of the turret is already in the position called (for example change in tool offset T1.01 ..T1.02) the turret
will not move or unlock/lock but the INDEXD and LOCKED signals will have the same behaviour as a normal
rotation (INDEX and LOCKED low after the PSTART and then after approx. 200ms the INDEX goes HIGH and
after 50 ms more the LOCKED signal goes HIGH).
INDEXD SIGNAL
The INDEXD signal must be used with the LOCKED signal to detect the end of cycle of the turret and can be
ignored once the turret is locked.
The INDEXD output goes and stay LOW also when the emergency mode is set and if the three-phase power
supply is OFF.
In this case, if the turret management from PLC/CNC uses the emergency mode or open the power contactor,
the INDEXD signal must be used only when the turret is in cycle and then ignored.
The CNC/PLC program must check the LOCKED signal while the turret is not in cycle: if this signal goes LOW
stop immediately the machine and check the cause.
ALARM CONDITIONS
When an alarm condition is detected, READY signal goes low and the INDEXD signal is low.
ALPOSxx outputs give the alarm code.
In this case the machine must be immediately stopped.
Important: the turret can show alarms in any time (also if it is not on cycle) so check always the alarm output
of the turret.
For some kind of alarm due to the power section, it is strongly recommended to switch-off the threephase
supply as soon as possible. (See alarm description).
If the turret is not in cycle and in automatic mode, any variation in POSITION BITS and PARITY must be
followed by the PSTART signal.
If the PSTART does not came in about 5 seconds (T1) an alarm 5.3 is output from the turret.
Avoid to change the position code just after the turret LOCKED signal goes high (end of cycle) because this
can be detected as a new position request.
See the diagnostic section to have more details.
The turret will attempt three times to lock or unlock before giving an alarm 4.2
If the operator hear the valve operated more timed during the tool change it is necessary to check the cause of
the problem and remove it before a permanent failure happens.
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3. Set the position code: (use PBIT16 only for turrets with 16 tools or more).
POSITION
CODE 1 2 3 4 5 6 7 8 9 10 11 12
PBIT01 0 1 0 1 0 1 0 1 0 1 0 1 0
PBIT02 0 0 1 1 0 0 1 1 0 0 1 1 0
PBIT04 0 0 0 0 1 1 1 1 0 0 0 0 1
PBIT08 0 0 0 0 0 0 0 0 1 1 1 1 1
(PBIT16) 0 0 0 0 0 0 0 0 0 0 0 0 0
PARITY 0 1 1 0 1 0 0 1 1 0 0 1 0
POSITION
CODE 13 14 15 16 17 18 19 20 21 22 23 24
PBIT01 1 0 1 0 1 0 1 0 1 0 1 0
PBIT02 0 1 1 0 0 1 1 0 0 1 1 0
PBIT04 1 1 1 0 0 0 0 1 1 1 1 0
PBIT08 1 1 1 0 0 0 0 0 0 0 0 1
(PBIT16) 0 0 0 1 1 1 1 1 1 1 1 1
PARITY 1 1 0 1 0 0 1 0 1 1 0 0
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Every time a new TMC driver is connected to a turret, it is necessary to perform a set-up procedure in order to
detect the optimal phase shift to control the turret motor.
Moreover the start-up procedure will check the position of all the tools and compensate any small error in fixing
the transducer.
The start-up procedure is necessary only one time and the parameters are then stored in a permanent
memory of TMC controller. It must be performed again if the TMC is moved to another turret.
By the way any TMC controller is already set-up for the DM turret delivered with in DUPLOMATIC.
The S/N of the turret is printed on the TMC controller label.
Moreover, the most important parameter will be printed on the turret certificate, in order to allow to set it in the
TMC memory in case of problems.
The Start-Up procedure must be performed by the help of the Duplomatic Turret Interface Software (DTI) and
described in its instruction manual.
In brief, it is necessary to install the DTI software and connect to the TMC controller.
After it needs to link to the controller and go in ‘FORCE’ mode.
Select the ‘Service’ option, select ‘unlocking’ and press start.
Once the turret is unclamped, press the ‘menu’ button and press the ‘autotuning’ button.
The ‘autotuning’ windows opens.
Press ‘Tuning resolver’ and wait the turret makes about 3 rouns CW, 3 rounds CCW and again 3 rounds CW.
Press then the ‘Tuning tools’ button: the disk is moved step by step in all positions to get the exact clamping
position.
At the end the turret is ready to be used and parameters are automatically stored in TMC controller.
WARNING: the autotuning procedure must be performed with the disk applied to the turret.
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5. DIAGNOSTIC
Turret is in normal operation if READY= ON: in this case the ALPOSxx outputs give the code of the
current position.
When an alarm occours the READY = OFF: in this case ALPOSxx outputs give the alarm code in
binary format (ALPOS01= LSB).
(READY= OFF)
(READY= OFF)
DESCRIPTION
ALARM CODE
(READY= ON)
ALPOS16
ALPOS08
ALPOS04
ALPOS02
ALPOS01
ALPOS32
ALARM
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Display:
A 7-segment display is available.
When the driver is in normal condition all the segments are blinking in sequence.
When the alarm is present, the display will show in sequence, A->(first alarm digit)-> (second alarm digit)
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CN9 RS-232
CN8
10 min
MADE IN ITALY
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DIGITAL INPUT AND OUTPUT FOR FITTING INTO THE ELECTRICAL CABINET
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DUPLOMATIC AUTOMAZIONE Intruction Manual diagnostic software DTI rel 2.x
DTI 2.x
Diagnostic Software for DM-*-*/* Turrets
Equipped with TMC Electronic Units
Preliminary 10/10/08
The information in this Manual is given only as a guideline and may be changed without prior notice. It is not subject to
any obligation from Duplomatic Automazione SpA.
Duplomatic Automazione SpA. does not assume any responsibility for errors or imprecise information contained herein.
The software contains commercial secrets and confidential !"#$%&'(!$" which are subject to copyrights in
other countries.
Any unauthorized use of the software and of the respective documentation may violate civil laws and have
penal consequences.
TRADE NAMES
Microsoft Windows is a registered trade-name of Microsoft Co.
All other names of products and companies are trade-names of Duplomatic Automazione SpA.
EDITION CHRONOLOGY
Printed in ITALY
Index
Software requirements 5
INSTALLATION OF DTI 7
AUTOMATIC SETUP. 23
ALARMS MANAGEMENT 25
TROUBLESHOOTING 27
NOTES: 28
Chapter
1
The software DTI 2.x Lite has been developed by DUPLOMATIC in order to supply a simple
and flexible basis for installation, configuration and diagnostics of the electronic TMC electronic
unit, which is part of the turrets using direct direct drive servomotor technology (DM**).
This program enables access to the complete functions of the turret, to which extended
operation modes have been added, thus offering a gradual operation sequence. This program
allows access to the archive of extended alarms. The real condition of all input and output
signals pertaining to the turret is displayed during use.
Index
Chapter
2
Hardware & Software requirements
Hardware requirements
The software DTI 2.x Lite requires an IBM COMPATIBLE PC with at least one free RS232 serial
port, at least 20 MBYTE free memory on the hard disk for the operating system, 1900 kbyte on
the hard disk for applications and 20 MBYTE additional space for storing the temporary data for
the installation. The system requires the use of a mouse. The serial connection consists of a
DTE-DCE cable. Not all signals are necessary. For preparing the connection cables, the
following diagrams must be taken into account.
2 2
3 3
5 5
Software requirements
The software DTI2.X Lite has been developed in the 32-bit technology and therefore runs under
the operating systems Microsoft Windows 95, Microsoft Windows 98, Microsoft Windows 2000
and Microsoft Windows XP. The memory requirements depend on the operating system. These
values are listed below as a guideline.
When installing the system under Windows 2000 SP3 some incompatibilities occurred, which
are now being subject to a solution.
Requirements on the RAM memory for the operating systems
Windows 95 4 Mbytes
Windows 98 32 Mbytes
Windows 2000 32 Mbytes
Windows XP 64 Mbytes
Microsoft Windows offers a simple user’s surface, where however some users may have certain
difficulties. Here in the following you can find the basic information about Windows.
1) Window : A part of the screen which is surrounded by a frame. The entire program takes
place on the respective window.
2) Nearly every window has a menu, i.e. a list of options, which by selection via mouse will
show another menu or enable another step. If the mouse is not being used, the Alt+Tab
keys can be pressed.
3) Keys, Text boxes, Check boxes : The user can interact with the program by using either
keys or icons. For example, the user can press a key and select it with the L.H. mouse key
or move along by means of the keys or other objects using the Tab key and then press the
SPACE BAR for confirming the step. At the same manner, a check box can either be
highlighted or the text can be selected for being modified inside of the text box.
4) Therefore, when speaking about “Click”, “Double-Click”, “Select”, “Press” in this Manual, we
refer to one of the operation modes described before.
Index
Chapter
3
Installation of DTI
The software DTI is supplied on a CD-ROM or as an installation file of the CABINET type
(*.CAB).
(Before carrying out the installation, make sure that all applications previously opened have
been closed in order to avoid any conflict).
To begin the installation, put the CD into the respective drive. From the window “My computer”,
select the respective drive (normally D) and click the file which is called “Setup”.
The file can be also be executed in the following manner. From the Start-menu bar, click “Start”
and immediately after this click “Run”. Then enter the following command line:
D:\Setup
Note: The letter “D” refers to the CD-ROM drive.
After a few seconds, the screen will show the first window, which enables the installation of the
program.
The use can decide whether to interrupt the installation by clicking the “Exit Setup” button or to
continue the installation by clicking the “OK” button.
Note: If the message shown in this figure is displayed, please go on. This message means that the installation program
has found some files which must be installed. In this case, by selecting “OK” , the existing files will be replaced by the
latest version.
To accept the default directory, click on the big button with the pciture of a PC.
After a while, the setup program will ask in which ‘program group’ has to put the
link of the program.
Even if it is possible to give a different group, it is suggested to keep the default
selection. Click on ‘continue’ to go ahead in the setup process.
The setup process will end in few minutes and will show the following message.
If the setup has been performed using defaults, the program files are placed in
“(disk):\program files\DTI” and the program can be started from menu
“Start>programs->Duplomatic Turret Interface”.
Index
Chapter
4
In this chapter it will be explained how to use in correct way the diagnosis
software for TMC driver, how to handle Inputs and Outputs status, how to get
information from alarms and how to take control of the turret by PC.
By pressing the ‘Menu’ button it is possible to open the list of all commands
windows of the software.
To open a command windows, press the related button.
Before to connect to the TMC control unit, check if the serial cable is properly
connected on both ends.
Select the right serial port from the “Comm. Control” menu.
Index
Index
Autotest
Graphics
Index
Info
The Info window (ATD status) shows the Firmware release and other
informations. These informations are not directly useful but can be important to
have a better picture of the system in case of problems.
If the ‘Wait DC_BUS stab’ mark is RED, check the threephase supply.
Index
Tools
In this window it is possible to load, save, change parameter inside the TMC
control unit. To avoid mistakes made by customer, this page is protected.
Index
Electrical
Take care that the DC-BUS is not available on all controllers. If a fixed ‘0’ is
present, means that the value is not available.
See the ‘Wait DC_BUS stab’ mark in ‘Info’ window: if it is RED the threephase
supply is OFF or there is failure inside the controller.
Index
Events History
The Events History windows can show the list of last 50 alarms and the lis of
last 440 cycles.
Records are stored in a permanent memory so can be retrieved also if the TMC
unit has been switched off after the failure.
These information are useful in order to troubleshoot any problem related to the
turret.
Index
Virtualscope
There are two pages: the configuration page (settings) looks like the following.
Double click the variable to be traced form the list: it will be placed in the
first free slot on the left. To delete, double click on the slot.
Select the trigger variable from the drop-down list, check the tigger
activation mode and the activation threshold. (suggested Inverter_state
>1)
Select the undersample value: this value must be chosen according to
the last of the event and the frequency of the signal to be traced.
o 1= samples every 0,125ms->256 ms max for 1 channel, 64 ms for
4 channels
o 20 = samples every 2,5 ms>5 s max for 1 channel, 1,25 s for 4
channels
The Grapich page (Virtualscope) shows the commands to start the logging of
data and print the collected waveforms.
To get a waveform, press ‘START ACQ’, and wait until the trigger has ben
activated “WAITING………ON SAMPLING”. At this point it is possible to get
data from PC by pressing ‘READ DATA’ button
“WAITING………DOWNLOADING SAMPLES”
Autotuning
Index
Chapter
5
Automatic setup.
The resolver (position transducer) mounted on the back of the turret has two
important task:
give the absolute position of the disk.
give information in order to drive correctly the torque motor of the turret
(commutation angle).
In order to simplify the adjustment of the resolver in case of factor assembly and
in case of extraordinary maintenance, its electrical and mechanical zero is
adjusted and fixed manually in order to be very close to the tool n° 1 of the disk
when the turret is clamped.
In this way, there is no any mechanical alignment with the magnetic field of the
motor, so it needs to perform a ‘commutation angle detection’.
Preliminary tasks:
The TMC driver is installed and connected properly as specified in
instruction manual.
The 24VDC and the threephase supply are fed correctly to the TMC unit,
the ENABLE input is at 24VDC.
Hydraulic circuit connected and pressure available.
TMC controller connected to a PC with the DTI software running.
Once the previous operations have been performed and checked, it is possible
to start the commutaition angle detection.
1. Prss the “Force” button in“TMC Manual mode” window to take control
from PC.
2. Delect the “Service” operating mode.
3. Select “Unlocking” command.
4. Press “Start” to send the command to the controller.
5. If the turret unclamps without alarms, press the “Autotuning” button from
command menu: the Autotuning window will open (see related chapter).
6. Press the “Autotune RESOLVER” button: the disc will make three
rounds in one direction and three rounds in the other. Wait until the label
under the button becomes green.
Index
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DUPLOMATIC AUTOMAZIONE Intruction Manual diagnostic software DTI rel 2.x
1. Open “TMC Manual mode” window and select “Speed Loop Test”.
2. Press “Start” button to send the command to the controller.
3. Wait the end of rotation.
The last operation required for startup is the tuning of the exact tool position.
This will compensate the small position mistake that can occur when the
resolver is fixed manually to the motor. It also compensate the small non-
linearity of the resolver, in order to get a more precise positioning before
clamping. The values detected are stored inside the non-volatile memory of
TMC controller and there is no need to set again unless the turret is
disassembled or the TMC is replaced.
Index
Chapter
6
ALARMS MANAGEMENT
The TMC control unit executes every time self-diagnosis routines and set different
alarm codes to give more information about the problem detected.
On the digital outputs of TMC controller, the working condition is signalled when
READY is HIGH. In this case ALPOSXX signals show the current turret position.
If an alarm is present, the READY signal is LOW and there is at least one ALPOSXX
signal HIGH. The alarm code is in binary format (with ALPOS01= LSB)
The alarm code and its description will appear on DTI screen.
The alarm can be reset form DTI by pressing the ‘STOP’ button. (it will take a while to
complete the operation)
OUTPUTS
(READY= OFF)
(READY= OFF)
DESCRIPTION
ALARM CODE
Actual position
(READY= ON)
ALPOS16
ALPOS08
ALPOS04
ALPOS02
ALPOS01
ALPOS32
ALARM
Index
Chapter
7
Troubleshooting
No serial connection has been established:
Make sure that the cable is connected to the correct PC serial port.
Make sure that at least the 24V powering unit is connected to the
electronic unit of the turret.
Check the set-up values of the serial port:
Baud rate: 19200
Parity: none
Bits: 8
Stop bits: 1
Some signals (for example the EVLOCK signal) always remain off:
This is due to the reduced time available, at which the signal remains in the
active state (less than 1 sec.).
As the software reads the information from the control unit at regular intervals, it
may occur that the software is reading the data when these are not active. You
must wait for the right moment in order to have the data read in.
Index
Notes: