TPC-Jr G Series

Users Manual
Overview Program Operation Extended Functions Parameter Maintenance

E Apr, 2002

TSUDAKOMA Corp.

CONTENTS

I. OVERVIEW__________________________________________________ I-1
1. SYMBOLS REGARDING SAFETY _______________________________________I-2 2. OUTLINE OF THIS MANUAL ___________________________________________I-2 3. SAFETY INSTRUCTIONS ______________________________________________I-3 4. SPECIFICATIONS ____________________________________________________I-5 4-1. STANDARD SPECIFICATION LIST ___________________________________I-5 4-2. OPTIONS________________________________________________________I-9 5. CONFIGULATIONS AND EXTERNAL DIAGRAMS _________________________I-10 5-1. STANDARD CONFIGURATION OF THE TPC-JR________________________I-10 5-2. EXTERNAL DIAGRAMS OF CONTROL UNITS _________________________ I-11

IIPROGRAM ________________________________________________ II-1

1. PROGRAM CONFIGURATION _________________________________________ II-2 1-1. PROGRAM NUMBER (WORK NUMBER)______________________________ II-2 1-2. PROGRAM CODE ________________________________________________ II-2 1-3. TPC-JR PROGRAM STORAGE STRUCTURE__________________________ II-3 1-4. MAIN PROGRAM AND SUBPROGRAMS______________________________ II-5 1-5. INCREMENTAL COMMANDS AND ABSOLUTE COMMANDS _____________ II-6 1-6. UNIT FOR ANGLE SETTING _______________________________________ II-7 2. G CODES __________________________________________________________ II-8 2-1. G0: DIRECT ANGULAR POSITION COMMAND _______________________ II-10 2-2. G1: DIRECT INDEXING POINT NUMBER COMMAND __________________ II-12 2-3. G2: ARC-INDEXING POINT NUMBER COMMAND _____________________ II-13 2-4. G3: LEAD CUTTING COMMAND ___________________________________ II-13 2-5. G4: ORIGIN RETURN COMMAND __________________________________ II-16 2-6. G5: SUBPROGRAM CALL COMMAND ______________________________ II-17 2-7. G6: SUBPROGRAM RETURN COMMAND ___________________________ II-17 2-8. G7: WORK COORDINATE END COMMAND __________________________ II-17 2-9. G8: WORK COORDINATE SET COMMAND __________________________ II-18 2-10. G9: DECLARATION COMMAND___________________________________ II-19 3. F CODES FOR FEED FUNCTIONS_____________________________________ II-22 3-1. FAST FEED (0) ________________________________________________ II-22 3-2. CUTTING FEED ________________________________________________ II-22 3-3. UPPER LIMIT OF THE CUTTING FEEDRATE _________________________ II-22 3-4. SETTING A CUTTING FEEDRATE __________________________________ II-22

3-5. DWELL________________________________________________________ II-23

IIIOPERATIONS _____________________________________________ III-1

1. CONTROL UNIT_____________________________________________________III-3 1-1. POWER SUPPLY ON/OFF _________________________________________III-3 2. DETAILS OF OPERATION PANEL______________________________________III-4 2-1. LCD SCREEN ___________________________________________________III-4 2-2. LED INDICATORS ________________________________________________III-6 2-3. OPERATION MODE DISPLAY AND SWITCHING _______________________III-6 2-4. PROGRAM EDITING KEYS ________________________________________III-6 2-4-1. KEYS USED FOR PROGRAM EDITING MAINLY IN THE PROG OR CHECK MODE. ___________________________________III-7 2-4-2. KEYS USED FOR OTHER THAN PROGRAM EDITING MAINLY IN THE SINGLE OR AUTO MODE ____________________________________III-8 2-5. OPERATION KEYS _______________________________________________III-9 3. OVERVIEW OF OPERATION MODES __________________________________III-10 3-1. AUTO MODE ___________________________________________________III-10 3-2. SINGLE MODE _________________________________________________III-10 3-3. PROG MODE___________________________________________________III-10 3-4. CHECK MODE__________________________________________________III-10 3-5. MDI MODE_____________________________________________________III-10 3-6. JOG MODE ____________________________________________________III-10 4. AUTO AND SINGLE MODES__________________________________________ III-11 4-1. OVERVIEW ____________________________________________________ III-11 4-2. START INPUT SIGNAL ___________________________________________III-12 4-3. START KEY ____________________________________________________III-12 4-4. REFERENCE POINT RETURN KEYS ______________________________III-12 4-5. STOP KEY _____________________________________________________III-12 4-6. MACHINE LOCKING _____________________________________________III-12 4-7. DISPLAY SWITCHING ___________________________________________III-13 4-8. DGN __________________________________________________________III-13 5. PROGRAM / CHECK MODES _________________________________________III-14 5-1. OVERVIEW ____________________________________________________III-14 5-2. ENTERING A PROGRAM _________________________________________III-15 5-2-1. PROCEDURE FOR ENTERING A PROGRAM ______________________III-15 5-2-2. ENTERING DATA FOR THE FIELD ___________________________III-16 5-2-3. SCROLLING A PROGRAM______________________________________III-16 5-2-4. SAMPLE G CODE DISPLAY ____________________________________III-16 5-3. SETTING AND SELECTING A WORK NUMBER _______________________III-17

5-4. INSERTING A BLOCK ____________________________________________III-18 5-5. DELETING A BLOCK_____________________________________________III-18 5-6. DISPLAYING THE DIRECTORY ____________________________________III-19 5-7. COPYING A PROGRAM __________________________________________III-19 5-8. DELETING A PROGRAM _________________________________________III-19 5-9. DELETING ALL PROGRAMS IN EDIT RAM AND THE FILE ______________III-20 5-10. SETTING A FEEDRATE _________________________________________III-20 5-11. INPUT/OUTPUT & STORAGE OF PROGRAMS TO THE EXTERNAL COMPONENTS. _______________________________________________III-21 5-12. SETTING PARAMETERS ________________________________________III-21 5-13. INPUTTING AND OUTPUTTING PARAMETER DATA TO AND FROM THE EXTERNAL COMPONENTS __________________________________III-22 5-14. SELF-DIAGNOSIS______________________________________________III-22 5-15. ADJUSTING CONTRAST ON THE LCD DISPLAY _____________________III-24 6. MDI MODE ________________________________________________________III-25 6-1. OVERVIEW ____________________________________________________III-25 6-2. MDI MODE INDICATION __________________________________________III-25 6-3. MDI OPERATIONS ______________________________________________III-25 7. JOG MODE _______________________________________________________III-25 7-1. OVERVIEW ____________________________________________________III-25 7-2. CONTENTS ON THE SCREEN_____________________________________III-26 7-3. JOG OPERATING METHOD _______________________________________III-26 7-4. SETTING THE SECOND REFERENCE POINT ________________________III-26 7-5. CLEARING THE CURRENT POSITION INDICATION ___________________III-26

IVEXTENDED FUNCTIONS ____________________________________ IV-1

1. OVERVIEW_________________________________________________________IV-3 2. EXTERNAL WORK NUMBER SET FUNCTION ____________________________IV-4 2-1. EXTERNAL WORK NUMBER SET FUNCTION _________________________IV-4 2-2. AUTO MODE SELECTION AT POWER ON ____________________________IV-5 2-3. AUTOMATIC CALLING OF A WORK NUMBER AND BLOCK NUMBER ______IV-5 3. EXTERNAL RETURN TO A REFERENCE POINT INPUT FUNCTION __________IV-6 4. EXTERNAL STOP INPUT FUNCTIONS __________________________________IV-7 4-1. STOP INPUT SIGNAL _____________________________________________IV-7 4-2. INTERLOCK INPUT SIGNAL _______________________________________IV-8 5. MACHINE ORIGINAL POSITION OUTPUT FUNCTIONS ____________________IV-9 6. MACHINE POSITION CONTROL FUNCTIONS ___________________________IV-10

6-1. SOFT LIMIT ____________________________________________________IV-10 6-2. OVERTRAVEL __________________________________________________ IV-11 7. EXTERNAL STORAGE OF PROGRAMS ________________________________IV-12 7-1. OVERVIEW ____________________________________________________IV-12 7-2. PROCEDURE __________________________________________________IV-12 7-2-1. READING PROGRAMS ________________________________________IV-12 7-2-2. PROGRAM OUTPUT __________________________________________IV-13 7-2-3. INPUT AND OUTPUT OF PARAMETERS. _________________________IV-13 7-3. ALARM________________________________________________________IV-14 7-4. PARAMETERS _________________________________________________IV-15 7-5. PAPER TAPE I/O FORMAT ________________________________________IV-16 7-5-1. TAPE FORMAT _______________________________________________IV-16 7-5-2. INTERFACE _________________________________________________IV-18 7-6. PRINTING TPC-JR PROGRAM LISTS _______________________________IV-20 7-6-1. PROCEDURE ________________________________________________IV-20 7-6-2. PARAMETERS _______________________________________________IV-20 7-6-3. SAMPLE LISTS ______________________________________________IV-20 8. REMOTE MODE + M ________________________________________________IV-21 8-1. GENERAL DESCRIPTION ________________________________________IV-21 8-2. PROCEDURE __________________________________________________IV-21 8-3. COMMAND METHOD ____________________________________________IV-21 8-3-1. SAMPLE MACHINING CENTER PROGRAM _______________________IV-22 8-3-2. NOTES _____________________________________________________IV-22 8-4. COMMAND FORMAT ____________________________________________IV-23 8-4-1. COMMAND ABBREVIATION ____________________________________IV-23 8-4-2. DATA DETAILS _______________________________________________IV-23 8-4-3. COMMAND DETAILS __________________________________________IV-24 8-5. PROCEDURE __________________________________________________IV-27 8-6. REMOTE MODE PARAMETER_____________________________________IV-28 8-7. ALARMS ______________________________________________________IV-29 8-8. CABLE CONNECTION ___________________________________________IV-29 8-8-1. CABLE CONNECTION _________________________________________IV-29 8-8-2. INTERLOCKING CABLE _______________________________________IV-30 8-9. NOTES________________________________________________________IV-30

V. PARAMETERS _____________________________________________ V-1

1. SETTING PARAMETERS _____________________________________________ V-2 1-1. PREPARATION FOR SETTING PARAMETERS _________________________ V-2 1-2. PARAMETER SETTING METHOD ___________________________________ V-2 1-3. COMPLETING PARAMETER SETTING _______________________________ V-3

2. PARAMETERS ______________________________________________________ V-3 2-1. PARAMETER ASSIGNMENT _______________________________________ V-3 2-2. PARAMETERS __________________________________________________ V-4 2-3. DETAILS OF PARAMETERS________________________________________ V-6 SYSTEM PARAMETERS 000019 __________________________________ V-7 I/O PARAMETERS 020039 ______________________________________ V-10 SERIAL CHANNEL PARAMETERS 040059 _________________________ V-13 STANDARD SERVO PARAMETERS 110149 ________________________ V-16 SPECIAL SERVO PARAMETERS 150199 __________________________ V-26 2-4. CONVERTING UNITS ____________________________________________ V-32 2-5. SETTING POSITION OF 1ST REFERENCE POINT ____________________ V-32

VIMAINTENANCE____________________________________________ VI-1
1. OUTLINE _________________________________________________________ VI-3 1-1. OUTLINE ______________________________________________________ VI-3 1-2. SAFETY REMARKS ON MAINTENANCE_____________________________ VI-3 1-3. CHECK AT OCCURRENCE OF A FAILURE ___________________________ VI-4 2. ROUTINE CHECK __________________________________________________ VI-4 3. ALARMS__________________________________________________________ VI-5 3-1. ALARM DISPLAY________________________________________________ VI-5 3-2. RESETTING AN ALARM __________________________________________ VI-5 3-3. ALARM OUTPUT SIGNALS _______________________________________ VI-5 3-4. ALARMS ______________________________________________________ VI-6 3-5. DETAILS OF ALARMS____________________________________________ VI-9 3-5-1. PROGRAM ALARMS __________________________________________ VI-9 3-5-2. SERIAL CHANNEL ALARM ____________________________________ VI-12 3-5-3. STROKE END ALARM ________________________________________ VI-12 3-5-4. SERVO ALARMS ____________________________________________ VI-13 3-5-5. OTHER ALARMS ____________________________________________ VI-17 4. SELF-DIAGNOSIS (DGN) ___________________________________________ VI-18 4-1. CHECKING INPUT & OUTPUT SIGNALS AND SERVO STATUS _________ VI-18 4-1-1. PROCEDURE _______________________________________________ VI-18 4-1-2. DETAILS ON INPUT & OUTPUT SIGNAL AND SERVO STATUS CHECK ADDRESS LIST _____________________________________________ VI-18 4-2. OUTPUT SIGNAL CHECK________________________________________ VI-20 4-2-1. PROCEDURE _______________________________________________ VI-20 4-2-2. OUTPUT SIGNAL CHECK ADDRESSES _________________________ VI-20 4-3. STATUS INDICATED BY LAMPS __________________________________ VI-21

5. CABLE CONNECTION _____________________________________________ VI-22 5-1. CABLE LIST___________________________________________________ VI-22 5-2. ACCESSORY CABLES __________________________________________ VI-23 5-3. OPTIONAL CABLES ____________________________________________ VI-23 5-4. CONNECTOR PIN ASSIGNMENT _________________________________ VI-23 5-5. CONNECTING THE INTERLOCKING CABLE ________________________ VI-24 5-5-1. CONNECTING THE INTERLOCKING CABLE______________________ VI-24 5-5-2. INTERLOCKING SIGNAL TIMING _______________________________ VI-26 5-5-3. INPUT SIGNAL USED WITH THE EXTENDED FUNCTIONS __________ VI-27 5-5-4. OUTPUT SIGNALS USED WITH THE EXTENDED FUNCTIONS_______ VI-27 5-5-5. EXTERNAL WORK NUMBER SET FUNCTION_____________________ VI-29 5-6. INPUT SIGNAL EQUIVALENT CIRCUITS____________________________ VI-30 5-7. OUTPUT SIGNAL EQUIVALENT CIRCUITS__________________________ VI-31 6. CIRCUIT DIAGRAMS_______________________________________________ VI-32 6-1. WIRING IN THE TPC-JR CONTROL UNIT ___________________________ VI-32 6-2. TABLE FOR WIRING IN THE TPC-JR CONTROL UNIT ________________ VI-33 6-4. PART LAYOUT IN TPC-JR _______________________________________ VI-37 6-5. PART LIST OF TPC-JR __________________________________________ VI-37 7. ABSOLUTE ENCODER _____________________________________________ VI-38 7-1. ABSOLUTE ENCODER EXPLANATION _____________________________ VI-38 7-2. CHECK ______________________________________________________ VI-38 7-3. REPLACEMENT _______________________________________________ VI-38 7-4. SETUP OF THE ABSOLUTE ENCODER AND THE FIRST REFERENCE POINT____________________________________________ VI-39 7-4-1. SETUP OF THE ABSOLUTE ENCODER___________________________ VI-39 7-4-2. SETTING THE FIRST REFERENCE POINT ________________________ VI-40 8. MAINTENANCE ___________________________________________________ VI-41 8-1. OPENING & CLOSING THE TOP COVER OF THE TPC-JR _____________ VI-41 8-2. REPLACING THE MAIN BOARD ASSEMBLY ________________________ VI-42 8-3. REPLACING THE SERVO UNIT ___________________________________ VI-43

APPENDIX_____________________________________________ Appendix-1
OPERATION PANEL _________________________________________ APPENDIX-2 DISPLAY INDICATION EXAMPLE ______________________________ APPENDIX-2 TPC-JR OPERATION ________________________________________ APPENDIX-3 PROGRAM CODES _________________________________________ APPENDIX-5 PARAMETERS _____________________________________________ APPENDIX-7 ALARMS _________________________________________________ APPENDIX-10 DGN ADDRESSES _________________________________________ APPENDIX-12

I. OVERVIEW
1. SYMBOLS REGARDING SAFETY _______________________________________ I-2 2. OUTLINE OF THIS MANUAL ___________________________________________ I-2 3. SAFETY INSTRUCTIONS ______________________________________________ I-3 4. SPECIFICATIONS ____________________________________________________ I-5
4-1. Standard Specification List _________________________________________________ I-5 4-2. Options ________________________________________________________________ I-9

5. CONFIGULATIONS AND EXTERNAL DIAGRAMS _________________________ I-10

5-1. Standard Configuration of the TPC-Jr ________________________________________ I-10 5-2. External Diagrams of Control Units __________________________________________ I-11

I-1

1. SYMBOLS REGARDING SAFETY

This manual uses the symbols below safety. Be sure to follow the instructions with the symbols regarding safety because they describe important matters.

WARNING CAUTION NOTE

If you do not follow the instruction, you may face a danger and you may be killed or seriously injured. If you do not follow the instruction, you may face a danger and you may get a slight injury. This is a referential instruction for optimum performance of our products.

2. OUTLINE OF THIS MANUAL

This manual consists of the chapters below for users of the TPC series. I. OVERVIEW This chapter explains the specifications, the equipment construction, and the appearance. II. PROGRAMMING The programming method for the TPC-Jr is explained. III. OPERATION The operating method for each mode of the TPC-Jr is explained. IV. EXTENDED FUNCTIONS The functions available with the optional component or by setting a parameter are explained. V. PARAMETER The setting method and the description of parameters are explained. VI. MAINTENANCE Information and the alarm descriptions required for maintenance are explained. For a rotary table, please refer to the instruction manuals for the rotary table packed with the device. General Remarks This manual describes details as minute as possible. However, it can not explain about all the specifications. Therefore, please consider any functions that are not explained in this manual as IMPOSSIBLE functions. Do NOT do anything specifically described in this manual. Figures in this manual sometimes are drawn without safety parts like covers to show details of the device. However, when you operate this machine, attach all the covers and other parts and follow the instructions in this manual. Figures in this manual is a typical sample of the machine. Your machine may be different from the figure in this manual. This manual is subject to change because of machine improvements, specification change, and improvements of the manual.
Copyright () 2001 TSUDAKOMA Corp. Machine Tool Dept. All rights reserved. Any part or all the parts of this manual are not allowed to be copied or reproduced.

I-2

3. SAFETY INSTRUCTIONS
Use the TPC-Jr control unit and the rotary table in the specified

CAUTION

combination. Otherwise, a fire or malfunction occurs.

NEVER use the TPC-Jr control unit in a corrosive atmosphere

CAUTION

or near inflammable gas, or flammable materials. Otherwise, a fire, an electrical shock, or malfunction occurs. Use the power supply voltage within the specified range.

CAUTION

Otherwise, a fire or malfunction may occur.

Be sure to ground the grounding terminal (PE) of the TPC-Jr.

WARNING

Otherwise, malfunctions, an electrical shock or a fire may occur.

Use the TPC-Jr control unit in the installing environment in the

NOTE

range below: 1. Use only indoors. 2. Ambient temperature: 040C 3. Relative humidity: 2080% (Without dew) 4. Vibration: 0.3G or less Otherwise, malfunction may occur.

The TPC-Jr has a sealed structure.

NOTE

Therefore, the case may be hot during operation. This is not abnormal. The power plug attached is for checking the functions.

NOTE

Please change the plug according to the installation conditions when installing the TPC-Jr.

Do NOT touch the movable parts of the rotary table during

WARNING

operation. Otherwise, you may get injured.

I-3

 Do NOT touch inside the TPC-Jr controller.

WARNING

Do NOT open the cover while the power is being supplied. Otherwise, you may receive an electrical shock. NEVER touch the inner terminals of the TPC-Jr controller within five minutes after the power is turned off. Otherwise, you may receive an electrical shock. Any maintenance should be done by a qualified electrician. Otherwise, you may receive an electrical shock.

Do NOT disassemble or modify the TPC-Jr control unit or

CAUTION

the MDI unit. Otherwise, malfunction occurs.

I-4

4. SPECIFICATIONS
4-1. Standard Specification List Item Number of controllable axis Commands Standard specifications 1 1. Angle commands 0.001 degrees 2. Indexing point number commands 1) Direct indexing point number (on a circle of 360 degrees) 2) Arc indexing point number (on a required angle) 1. Combination of incremental and absolute values 2. Incremental values 3. Absolute values 4. Smaller absolute values When inputting an MDI program W 4 digits 00009999 (Work number) N 3 digits 000999 (Block number) G 1 digit 09 (Work commands) F 1 digit 09 (Feedrate commands) R 3 digits 000999 (Repetition counts and arc indexing ) 7 digits 000.000999.999 W N G F R (Direct angular position commands, decimal) div (Indexing commands) 1000 blocks 100 AUTO SINGLE CHECK PROG MDI JOG Begins automatic operation with an external signal. Begins single operation. Checks the contents of programs. Edits TPC-Jr programs Begins single operation of a TPC-Jr program only once. Begins the jog operation mode.

Types of commands

Maximum command values

Block formats

Program size Registered work number Operation mode

I-5

Item Display

Current position indication Remaining amount indication Alarm indication

Specifications Status indication line TPC status RDY/ALM Work number W (displayed by key operation) Subprogram number S (displayed by key operation) Program indication line: Program indication N, G, F, R, Current position/remaining amount POS/REM Control indication: Overtravel OT Machine lock OVR%/MLK Return to reference point ZRN Available in the AUTO, SINGLE, MDI, and JOG modes. Available in the AUTO, SINGLE, and MDI mode Program syntax error, program memory capacity over Communication errors Soft limit alarms, overtravel alarms Servo alarms Enables an angle for movement to be input directly. Enables up to 999,999 equally spaced parts to be input on a 360-degree circle. If the indexing number generates fractions, it is equally divided to avoid gathering the error. Enables up to 999 equally spaced parts to be input directly on a given arc angle. Enables the number of repetitions for the specified movement to be commanded in the range from 1 to 999. Allows operation in conjunction with an axis of the machining center in the open loop status. Allows return to the first, second, or third reference point. Commands the fast feedrate or one of nine other feedrates. A subprogram can be read from a main program. Subprograms can be called up to 999 times. Allows nesting at up to eight levels. Allows a work coordinate to be set at any point. Allows output of a positioning completion signal to be delayed after the rotary table has been positioned within the range from 0.01 s to 9.99 s. Positions the rotary table by controlling the clamp function automatically, Clamping can be disabled by a program. Allows indexing point numbers to be set over several blocks. Allows positioning in one direction even when the rotation direction is opposite. Either positioning completion signal 1, 2 can be selected to output with a program.

Direct angular position command Direct indexing point number command Arc-indexing point number command Repetition function Lead cutting command Reference point return command Feedrate command Subprogram function Work coordinate set function Dwell function Automatic Clamp ON/OFF function Indexing group control function One-direction positioning Completion signal control commands

I-6

Item Backlash compensation Auto setting function at power on Program edit function

Specifications Backlash is compensated. Mode selection AUTO/CHECK Work number setting Block number setting Return to the work number before the power was turned off. Block insert Block delete Program copy Program clear Directory indication JOG feed is possible with the +JOG and the JOG keys. The feedrate can be selected between the programmed F0 ~ F9. Step feeding at the desirable angle is also possible. The second reference point can be changed to any desired point with the JOG mode. Input and output signals and the servo status can be checked. The rotating area of the rotary table can be restricted by limit switches. Note: An overtravel specification is required for the rotary table. A soft limit from the first reference point can be set. An absolute position detector is used for a motor detector. Returning to the reference point when turning on the power is not required. Start: Being connected to an M signal of the machining center, conducts continuous operation. Stop: Connected to an emergency stop signal. Be sure to connect them with the contact signals. [Signal voltage 24Vdc, 10mA] Positioning completion 1: Given when positioning is completed. This is a relay contact signal. Use with a circuit of 24Vdc. TPC-Jr program syntax error Program memory capacity overflow Soft limit Overtravel Servo motor Communication errors

JOG feed function Second reference point change function Input and output signal check function Overtravel function Soft limit function Absolute encoder External input signal

External output signal Alarm indication

I-7

Item Model

Specifications The following two models are available depending on the motor capacity. Model TPC-Jr G2 TPC-Jr G3 Motor capacity 400W 750W Applicable rotary table class *note 150 or less 200 or more

Power supply and capacity

Note) Applicable rotary table class differs depending on reducing ratio and specifications of the rotary table. Single phase 200/220Vac10%, 50/60Hz Power supply Circuit breaker capacity *note capacity TPC-Jr G2 1.2KVA 8A TPC-Jr G3 2.2KVA 15A Note: The value applies to the rated output. Usable only indoors. There should be no cutting liquid splash, corrosive gas or exploding gas. Ambient temperature range: 040C Relative humidity: 2080 (without dew) Vibration: 0.3G or less Main body G2: Width 285 mm x height 128 mm x depth 260 mm (Protrudes are not included.) G3: Width 285 mm x height 128 mm x depth 310 mm (Protrudes are not included.) Weight G2: about 7.2 kg Weight: G3: about 8.1 kg (Each weight does not include cables.) Paint color Munsell 2.5Y8/1.5 (Cream) Power cord (For CN1) 5m 4P (with a ground wire) with plug
The attached power plug is for checking the functions. Please change the plug position according to your installation conditions when installing the TPC-Jr. Be sure to ground before use.

Model

Environmental conditions

External dimensions

Accessory cable

Interlocking cable (14-core cable) (For CN2) to be connected with the M/C 5m Motor power cable (For CN3) between the TPC-Jr ~ the Rotary Table 5m

I-8

4-2. Options Item External input signal Specifications Starts positioning. A work number can be called by an external component. 1) Selecting 16 kinds of work numbers with a parallel signal (4 bit) 2) Selecting 5 kinds of work numbers with the five M signals. The signals can be assigned to any work number. Return to reference point Stop External output signal Completion signal 1 This is a completion signal for positioning. It is also issued when other operations like external work number set are completed. [For standard setting] Completion signal 2 When an operation like work number set or return to the reference point is completed, this signal can be issued. The signal can also be issued by a program. It can also be used as a signal to show that AUTO mode is being selected. Positioning Alarm Serial channel This signal is given during positioning. It can also be used as a signal for the original position signal. This signal is given when an alarm is detected. A program can be stored in an external component. A parameter can be stored in an external component. * A special cable for the RS-232C is required. Remote mode Cable length The TPC-Jr can be directly controlled using a serial channel. * An optional RS-232C cable is required. The cables below are available in addition to the standard 5m-long cable. (Except for RZ specifications) Power cord Interlocking cable Motor cable Cable blade specification (For CN1) (For CN2) (For CN3) [7m10m15m20m] The rotary table can be returned to the first reference point by an external component. An emergency stop signal can be received.

Start
Work number set

The standard motor cable for CN3 is covered with resin flexible tube. However, a wire-blade flexible tube cover is available as an option. (Except for RZ specifications)

I-9

5. CONFIGURATIONS AND EXTERNAL DIAGRAMS

5-1. Standard Configuration of the TPC-Jr The standard configuration of the TPC-Jr is shown below:

TPC-Jr control unit

Power cord (standard 5 m-long) with a 4P-plug*

Interlocking cable (standard 5m-long) with a 2m-long lead wire

Motor cable (standard 5 m-long)

RS232C connection cable (optional)

Rotary Table

I/O components for general-purpose program Prepared by user

The provided power plug is for checking the functions. Please change the plug position according to the installation conditions when installing the TPC-Jr.

I-10

5-2. External Diagrams of Control Units

I-11

MEMO

I-12

IIPROGRAM
1. PROGRAM CONFIGURATION __________________________________________II-2
1-1. Program Number (Work Number) ____________________________________________ II-2 1-2. Program Code ___________________________________________________________ II-2 1-3. TPC-Jr Program Storage Structure ___________________________________________ II-3 1-4. Main Program and Subprograms ____________________________________________ II-5 1-5. Incremental Commands and Absolute Commands _______________________________ II-6 1-6. Unit for Angle Setting______________________________________________________ II-7

2. G codes ____________________________________________________________II-8
2-1. G0: Direct Angular Position Command _______________________________________ II-10 2-2. G1: Direct Indexing Point Number Command __________________________________ II-12 2-3. G2: Arc-indexing Point Number Command ____________________________________ II-13 2-4. G3: Lead Cutting Command _______________________________________________ II-13 2-5. G4: Origin Return Command_______________________________________________ II-16 2-6. G5: Subprogram Call Command ____________________________________________ II-17 2-7. G6: Subprogram Return Command__________________________________________ II-17 2-8. G7: Work Coordinate End Command ________________________________________ II-17 2-9. G8: Work Coordinate Set Command _________________________________________ II-18 2-10. G9: Declaration Command _______________________________________________ II-19

3. F CODES FOR FEED FUNCTIONS______________________________________II-22

3-1. Fast Feed (0) _________________________________________________________ II-22 3-2. Cutting Feed ___________________________________________________________ II-22 3-3. Upper Limit of the Cutting Feedrate _________________________________________ II-22 3-4. Setting a Cutting Feedrate_________________________________________________ II-22 3-5. Dwell _________________________________________________________________ II-23

II-1

1. PROGRAM CONFIGURATION
1-1. Program Number (Work Number) TPC-Jr programs are managed and stored using program numbers starting with W followed by four digits. Up to 100 program numbers can be set with the range from W0000 to W9999 The work numbers are not always displayed. By pressing the 2ndF + N keys, the present work number (program number) being selected is displayed. Example for switching the program display to the work number display

Program display

R000

Switching with the 2ndF + N Work number display

keys

The display automatically returns to the program display after about 1 second while it is in the AUTO or the SINGLE mode.

1-2. Program Code TPC-Jr program codes are represented in the following program formats: F R (A square () indicates a digit.) 1) N code An N code commands a program block address. N codes from N000 to N999 can be entered. Usually, use N000 as the first N code and enter subsequent N codes one by one in ascending order for each block. 2) G code A G code commands a specific operation of the TPC-Jr. G codes are roughly classified into G0 to G4 that command rotary table operations and G5 to G9 that command internal processing of the TPC-Jr. 3) F code An F code commands a feedrate. Up to 10 feedrate can be commanded by F0 to F9. F0 is used for the fast feed positioning rate. F1 to F9 are used for cutting feedrates. For details, refer to 3. F CODES FOR FEED FUNCTION. 4) R code R codes provided as auxiliary codes of G codes command repetition counts, indexing point numbers, rotational speed, selection of items, etc. according to G codes.

II-2

5) (theta) code codes provided as auxiliary codes of G codes mainly command angles and indexing point numbers.

1-3. TPC-Jr Program Storage Structure 1) Program buffer structure The program storage area in the TPC-Jr is roughly divided into the directory and the edit RAM. The directory contains program numbers while the edit RAM contains programs.
Directory Program number W1000 W2000 W3000 Edit RAM addresses G F 0 0 0 0 0 0 0 0 Edit RAM R 0000 0000 0000 0000 +015.000 +020.000 +030.000 +090.000 1000 blocks 0 0 0 0 0 0 0000 0000 0000 +060.000 +115.000 +270.000

100 entries

(1) The directory contains program numbers and edit RAM addresses of these programs. It can hold up top 100 entries. (2) Edit RAM contains one-digit data in the G field, one-digit data in the F field, four-digit data in the R field, and eight-digit data in the field in the R field in the block format. Edit RAM contains up to 1000 blocks. 2) Program file structure The program buffer described in item 1) above is configured in RAM. When the TPC-Jr is turned off, therefore, the contents of the program buffer are lost. To prevent this, the buffer needs to be filled in nonvolatile memory (EEPROM). The program buffer is automatically filed when the or key is pressed to switch from the PROG mode to the CHECKor MDI mode. When the program is changed in the PROG mode, the message FILE appears on line 4 on the display screen to notify that the program has been changed.
Edit RAM G F R File 5 blocks

224 pieces

II-3

Programs in edit RAM are stored in the file in units of five blocks. The file has more blocks than edit RAM. When programs are often divided into non-seven blocks (such as 6 or 11 blocks), however, the error message File Full rarely appears. 3) Programming notes To enter multiple programs, use different work numbers (program numbers) for them. If these programs are separated by block addresses (N codes) under the same work number, it is assumed that the block addresses between programs contain another program. This reduces the memory usage efficiency. a) Bad example 1000 N000 G0 N001 G1 First program 29 blocks N028 G7 000 N029 to N049 are not used. In edit RAM, however, 0 is stored in each of these codes and they are processed, assuming that they contain a program. (21 blocks) N050 G0 N051 G1 Second program 16 blocks N065 G7 050 The number of blocks use by the programs is 66. b) Good example 1000 N000 G0 N001 G1 First program 29 blocks N028 G7 000 N015 G7 000 2000 N000 G0 N001 G1 Second program 16 blocks

The number of clocks used by the programs is 45. Use different program numbers like b) above for these two programs. If there are programs after G7 (block end), delete them with the delete function.

II-4

1-4. Main Program and Subprograms 1) Main program Programs are classified into the main program and subprograms. Usually, the TPC-Jr operates as commanded by the main program. When a subprogram calling command (G5) is coded in the main program, the TPC-Jr is controlled by the called subprogram. When a subprogram return command (G6) is encountered in a subprogram, the TPC-Jr returns to the main program and operates again as commanded by the main program.

Main program W1000 N000G0 N002G0

Subprogram W2000 N000G1 N009G6

N009G5R0012000 W3000 N000G2 N023G5R0013000 N015G6 N035G70000

The main program and subprogram can be edited in the same way in terms of program numbers (work numbers). During program editing, the user can use program numbers without any restrictions. Subprogram: Main program: 2) Subprogram When the same positioning pattern is used repeatedly in a program, it should be coded as a subprogram, making the entire program simple.
Main program Subprogram Subprogram Subprogram

Called by a G5 command and returns control to the main program with a G6 command. Reaches the program end with a G7 command.

G0 G5 G

G0 G5 G6
Nesting at one level

G0 G5 G6
Nesting at two levels

G0 G5 G6
Nesting at eight levels

II-5

1-5. Incremental Commands and Absolute Commands 1) Differences between incremental commands and absolute commands There are two methods for commanding an amount by which the rotary table is moved: incremental commands and absolute commands. Incremental commands are used to program angles themselves for movement while the absolute commands are used to program a coordinate from the reference point. Only the direct angular position command (G0) can direct a coordinate as an absolute command. Direct indexing point number commands such as G1 and G2 and the lead cutting command (G3) function as incremental commands even if they are selected as absolute commands. The positioning shown below can be coded with incremental commands and absolute commands as follows:
[incremental commands] N000 G0 F0 R003 +030.000 N001 G0 F0 R002 +045.000 N002 G0 F0 R002 +090.000 N003 G7 000 [absolute commands] N000 G0 F0 R000 +030.000 N001 G0 F0 R000 +060.000 N002 G0 F0 R000 +090.000 N003 G0 F0 R000 +135.000 N004 G0 F0 R000 +180.000 N005 G0 F0 R000 +270.000 N006 G0 F0 R000 +360.000 N007 G7 000 Moves to the 30 Moves to the 60 Moves to the 90 Moves to the 135 Moves to the 180 Moves to the 270 Moves to the 360 Returns to program end N000 Moves 30 3 times Moves 45 2 times Moves 90 2 times Returns to program end N000

30 90 30 30

45 90 45

Switching between incremental commands and absolute commands can be performed by setting a parameter. Parameter 001: bit 0 For standard specifications, both incremental commands and absolute commands are used mixed. For details, please refer to 3) Use of both incremental commands and absolute commands) 2) Reference point for absolute commands The reference point (0 point) for absolute commands is the point when return to the first, second, or third reference point is completed. When a work coordinate is set by a work coordinate set command (G8), the position obtained as the result of execution of G8 is the reference point (0 point). The positioning shown below can be coded with an absolute command to make a return to the second reference point and a work coordinate set command to set work coordinate, as shown below.

II-6

 N000 G4 R000 Returns to the first reference point N001 G0 F0 R000 +030.000 Moves to the 30 position. N002 G4 R001 Returns to the second reference point. (Setting at the 90 position is assumed.) N003 G0 F0 R000 +030.000 Moves to the 30 position.

30 30
Set work coordinate

Second
reference point

(The reference point is the second reference point.) (270) N004 G8 +270.00 Sets a work coordinate. (The reference point changes to the 270 position.) N005 G0 F0 R000 +030.000 Moves to the 30 position. N007 G7 000 Returns to program end N000. (The reference point is the set work coordinate.)

90 30

3) Use of both incremental commands and absolute commands For the standard specifications, both incremental commands and absolute commands can be used in a program. The R code is used to determine whether the command is an absolute or incremental command. When the R code is all 0s (000), the command functions as an absolute command. When the R code is a repetition count between 001 and 999, the command functions as an incremental command. Example

30 90 30 30

N000 G0 F0 R003 +030.000 Incremental command N001 G0 F0 R000 +135.000 Absolute command N002 G0 F0 R000 +180.000 Absolute command N003 G0 F0 R001 +090.000 Incremental command N004 G0 F0 R000 +360.000 Absolute command N005 G7 000 Returns to Program end N000.

In this example, absolute and incremental commands are

45 90 45

selectively used more frequently than necessity. In actual coding, pay attention so that these commands are correctly coded.

Only direct angular position commands (G0) are allowed for use of both incremental commands and absolute commands. Direct indexing point number commands such as G1 and G2 and the lead cutting command (G3) function as incremental commands.

1-6. Unit for Angle Setting The unit of an angle to be set in a is in the decimal system in the form of . using integral numbers and decimals.

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2. G codes G codes command operations of the TPC-Jr. Ten G codes, G0 to G9, are available.

They are roughly classified into two groups: G0 to G4 that command operations of the rotary table and G5 to G9 that command internal operations of the TPC-Jr. The following table indicates the functions of G0 to G4 and combination of G codes, R codes, and codes.

G code G0: Direct angular position command G1: Direct indexing point number command G2: Arc-indexing point number command G3: Lead cutting command

R code Switching ABS/INC 000 : ABS command 001999: INC commands Number of repetition Number of repetition 001999 Indexing point number and number of repetition 001999 Number of rotary table revolutions 000045 (360R) 000: Return to the first reference point 001: Return to the second reference point 002: Return to the third reference point

code Angle commanded 000.000360.000 ABS command 000.001999.999 INC command Indexing point number on a circle (360) 000001999999div Split angle 000.001360.000 Angle commanded 000.000360.000 (The total amount of movement is 360R +)

G4: Reference point return command

Not required.

G0 to G4 can be executed by entering a start signal in the AUTO mode or pressing the ST key in the SINGLE mode.

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The following table indicates the functions of G5 to G9 and combination of G codes, R codes and codes.
G code G5: Subprogram call command G6: Subprogram return command G7: Program end command G8: Declaration command G9: Declaration command 000: 001: 002: 003: 004: No operations Clamp OFF Clamp ON Dwell OFF Dwell ON Not required Not required Branch destination 000999 Reference coordinate 000.000360.000 Not required Not required Not required Not required Dwell time 001999 (10ms) 005: 006: 007: 008: 009: 010: 011: 012: Indexing group control OFF Indexing group control ON One-directional positioning OFF One-directional positioning ON Completion signal control OFF Completion signal control ON Program display switch Not required Not required Not required Not required Not required
Completion signal selection 011

R code Number of repetitions 000(001)999 Not required

code Subprogram number 000(001)999 Not required

FIN1 FIN2 Not required Current position display switch command Not required Current position reset command 013: Remaining angle display command Not required

 G5 to G9 are executed automatically after the operation of the previous block completes rather

than by the start signal or the ST key. When G5 to G9 are place at the beginning of the program, they are executed automatically when the AUTO or SINGLE mode is selected. They wait in a block containing G0, G1, G2, G3, and/or G4. Only up to consecutive 20 blocks can be executed for G5 to G9 to prevent the program from entering an endless loop.

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2-1. G0: Direct Angular Position Command 1) Incremental command Set an angle by which the rotary table moves in the code. When a number of repetitions is set in the R code, the rotary table moves repeatedly by the angle set in the code for each movement. The codes and R codes can be set in the following ranges: codes: 000.001999.999 R codes: Example 001 999

45 45

30 30 30

N000 G0 F0 R003 +030.000 Moves 30 3 times N001 G0 F0 R001 +090.000 Moves 90 once. N002 G0 F0 R006 +015.000 Moves 15 six times N003 G0 F0 R002 +045.000 Moves 45 twice. N004 G7 000 Return to the program end N000.

15
2Absolute commands

90

Set a coordinate measured from the reference position in the code. Since the number of repetitions in the R code has no effect, set 000 in the R code. Thecode can be specified in the range: 000.000360.000 Example

360 30 60 315 270 225 240 225 180 210 195 90

N000 G0 F0 R000 +030.000 Moves to the 30 position. N001 G0 F0 R000 +060.000 Moves to the 60 position N002 G0 F0 R000 +090.000 Moves to the 90 position N003 G0 F0 R000 +180.000 Moves to the 190 position N004 G0 F0 R000 +195.000 Moves to the 195 position N005 G0 F0 R000 +210.000 Moves to the 210 position N006 G0 F0 R000 +225.000 Moves to the 225 position N007 G0 F0 R000 +240.000 Moves to the 240 position N008 G0 F0 R000 +255.000 Moves to the 255 position N009 G0 F0 R000 +270.000 Moves to the 270 position N010 G0 F0 R000 +315.000 Moves to the 315 position N011 G0 F0 R000 +360.000 Moves to the 360 position N012 G7 000 Return to the program end N000

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3) Reference point for absolute commands The reference point (0 point) for absolute commands is the point when return to the first, second, or third reference point is completed. Example
First reference point

30
Second reference

N000 G4 R000 N001 G0 F0 R000 +030.000 N002 G4 R001 N003 G0 F0 R000 +030.000 N004 G7 000

Return to the first reference point Moves to the 0 position Return to the second reference point. Moves to the 30 position Return to the program end N000.

30

When a work coordinate is set by a work coordinate set command (G8), the position obtained as the result of execution of G8 is the reference point (0 point). (For more information, see the item of G8.) The 0,+360, and -360 positions specified in absolute commands are placed at the same coordinate. These commands are:

360 360 360

N000 G0 F0 R000 +360.000 Moves to the +360 position (The rotary table rotates one turn in the normal direction.) N001 G0 F0 R000 +000.000 0= +360(The rotary table does not rotate.) N002 G0 F0 R000 -360.000 Moves to the -360 position. (The rotary table rotates one turn in the reverse direction.) N003 G0 F0 R000 +360.000 Moves to the +360 position. (The rotary table rotates one turn in the normal direction.)

To specify an angle of 360 or more in a lead cutting command (G3) in the absolute mode and to use G0 to position the rotary table after it moves, code these commands as follows:

N000 G3 F0 R003 +180.000 Moves to the +180 position after three turns. N001 G0 F0 R000 +000.000 Moves to the 0 position. (The rotary table does not rotate three turns.)

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2-2. G1: Direct Indexing Point Number Command When 1 is set in the G code, the code changes to 000000. Set the number of indexing points on a circle in the code. Set the number of repetitions in the R code. The and R codes can be set in the following ranges: code: 000000div 999999div R code: 001 999 In the case of code designations that are indivisible numbers such as 7 parts or 11 parts, conduct positioning by proportionally dividing these indivisible numbers so that they do not collect in one place. Example [Incremental commands]
N000 G1 F0 R003 +000012 div Divides 360 by 12 and performs positioning three times.

45 45

30 30

N001 G0 F0 R001 +090.000Moves to the 90 position once. N002 G1 F0 R006 +000024 div Divides 360 by 24 and performs positioning six times. N003 G1 F0 R002 +000008 div Divides 360 by 8 and performs positioning twice. N004 G7 000 Return to the program end N000.

30 [Absolute commands] 90

N000 G1 F0 R003 +000012 div Divides 360 by 12 and performs positioning three times. N001 G0 F0 R000 +180.000Moves to the 90 position once.

15

N002 G1 F0 R006 +000024 div Divides 360 by 24 and performs positioning six times. N003 G1 F0 R002 +000008 div Divides 360 by 8 and performs positioning twice. N004 G7 000 Return to the program end N000.

Note G1: Direct indexing point number (G1) commands in the absolute mode operate in the incremental mode. When the number of indexing points in the R code exceeds the maximum number of repetitions (999), use indexing group control implemented by G9 R006. Example To equally divide the circle by 1234

N000 G9 R006 Enables indexing group control N001 G1 F0 R500 +001234 div Moves to a position equally space at an interval obtained by dividing 360 by 1234 500 times. N002 G1 F0 R734 +001234 div Moves to a position equally spaced at an interval obtained by dividing 360 by 1234 734 times. N003 G9 R005 Disables indexing group control.

When 360 is divided by 1234, the number of repetition exceeds 999. So, indexing group control is used. First, positioning at a position equally spaced at an interval obtained by dividing 360 by 1234 is performed 500 times. Then, positioning is performed the remaining number of times (734), totaling 1234 times in steps and

When indexing group control is commanded like this, proportional computation continues even if G1 commands are specified over multiple blocks. Be sure to code G9 R005 at the end of the program to disable indexing group control.

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2-3. G2: Arc-indexing Point Number Command Enter the angle of an arc to be divided in the code. Enter in the R code the number of divisions to be made for the arc specified in the code as well as the number of repetitions. The and R codes can be set in the following ranges: code: R code: 000.000360.000 001 999

When the angle of an arc to be divided and the number of repetitions specified in the code are indivisible, conduct positioning by proportionally dividing these indivisible numbers so that they do not collect in one place. Example [Incremental command]
N000 G2 F0 R003 +090.000 Divides 90 by 3 and performs positioning three times.

45 45

30 30

N001 G0 F0 R001 +090.000 Move to the 90 position once. N002 G2 F0 R006 +090.000 Divides 90 by 6 and performs positioning six times. N003 G2 F0 R002 +090.000 Divides 90 by 2 and performs positions twice. N004 G7 000 Returns to program end N000.

30 [Absolute commands]
N000 G2 F0 R003 +090.000 Divides 90 by 3 and performs positioning three times. N001 G0 F0 R000 +180.000 Moves to the 180 position once.

15

90

N002 G2 F0 R006 +090.000 Divides 90 by 6 and performs positioning six times. N003 G2 F0 R002 +090.000 Divides 90 by 2 and performs positioning twice. N004 G7 000 Return to program end N000.

2-4. G3: Lead Cutting Command 1) Programming When lead cutting is performed, the rotary table sometimes must rotate at least one turn (360). To set an amount of movement, therefore, enter the number of turns in the R code and the remaining angle after the specified turns in the code. The total amount is represented by the following formula: (R code 360) code () The and R codes can be set in the following ranges: code: R code: 000.000360.000 000 045 (Number of rotary table revolutions)

The G3 command in the absolute mode is handled as an incremental command. 2) Lead cutting Since the TPC-Jr is an NC system that controls only one axis, only one axis such as the axis of the rotary table can be controlled at one time. This means that precise lead cutting is not possible. However, use of the G3 command apparently enables two axes (the axis of the rotary table and one axis of the machining center) to be rotated simultaneously. When performing this operation, be sure to start the rotary table and the machining center at the same time and match the feedrate (moving time) of the rotary table with that of the machining center.

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3) Operation timing of the TPC-Jr Usually, the TPC-Jr performs positioning in the following sequence after it receives a start (M) signal: Unclamping Motor rotation Clamping Output of positioning completion signal When G3 commands are used, the TPC-Jr operates as follows: <1> Receives a start (M) signal. <2> Unclamps the rotary table. <3> Outputs a positioning completion signal. <4> Runs the motor after M signal is turned off. (The rotary table starts to rotate.) <5> The machining center also operates after the M signal is turned off.

Start signal (M)

Unclamps the rotary table Positioning completion output

TPC motor

A
M/C motor

B
Lead cutting is performed according to this timing chart. In the timing chart shown above, the letter A is the times, whose length is about 10 msec., beginning when the positioning completion signal (M) is turned off and ending when the TPC-Jr motor starts. The letter B is the time beginning when the M signal on the machining center side is turned off and ending when the machine center starts. The smaller the difference between A and B, the better the leading cutting. 4) Calculating the feedrate of the TPC-Jr Example Lead angle: A = 32. 142 Lead : L = D/tanA = 100 Feedrate for the X axis: Fx = 200.0[mm/min]

D=20

Lx = 220

Note When FANUC NC machine is used, errors of the X-axis feedrate is 2%.

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(1) Calculating the TPC-Jr movement angle

TPC-Jr movement angle

792 is two turns (720) plus 72.

working length () on X axis Lead () 360 220 792 100

360

Therefore, enter R002 in the R code and +072. 000 in the code. (2) Calculating the TPC-Jr feedrate Working time (time during which the TPC-Jr moves) is obtained by feedrate Fx on the X axis and movement amount Lx on the X-axis.

Feedrate of X axis () 220 1.1 [min] t 200 Therefore, the TPC-Jr should move over the movement angle of 792 obtained in item (1) above in 1. 1 minutes. When setting a TPC-Jr feedrate, use cmd/sec (command unit/second) that allows data to be entered down to the decimal point. Parameter 001: bit 2: Change it to 1. Convert the value obtained in item (1) above to the one in the minimum command unit as follows: When the minimum command unit is 0.001 (decimal) cmd angle 1000 cmd 792 1000 792000 Therefore, the TPC-Jr feedrate is:

Work time (TPC-Jr moving time)

Amount of movement of X axis ()

Amount of movement cmd Working time (TPC-Jr moving time) t

792000 1.1

720000 [cmd/min]

Since the F code is set to cmd/sec.

F code

720000 60

12000 [cmd/sec]
(Round off fractions to an integral number.)

Sample program On the TPC-Jr side: N000 G3 F2 R002 072. 000 (Use F2 as an example.) Feedrate setting: Feedrate F2 F012000 cmd/sec On the machining center side M70 G01 X220 F200 Note that there is an error of about 2% between the calculated feedrate and the settable feedrate. Set the optimum feedrate while measuring it. Strictly speaking, the difference in characteristics between the TPC-Jr servomotor and the machining center motor and other factors make it impossible to obtain a complete match.

II-15

2-5. G4: Origin Return Command The reference point return command can specify return to the first, second, or third reference point when combined with an R code. When the R code is 000: Return the first reference point When the R code is 001: Return to the second reference point When the R code is 002: Return to the third reference point When return to an reference point is in progress or is completed, MZRN is displayed on line 2 on the display screen, for return to the first reference point, WZRN for return to the second reference point, or TZRN for return to the third reference point. Return to the first reference point has the same effect as when the Return to the second reference point has the same effect as absolute commands. 1) Return to the first reference point The servomotor uses an absolute encoder. Therefore, return to the first reference point is performed at high-speed like positioning. 2) Return to the second reference point There are two ways to set the second reference point. It can be set by the coordinate in the parameter beforehand, or it can be set in the JOG mode. Usually, the second reference point is positioned to the coordinate set by the Parameter 128. However, the second reference point set by the JOG overrides the second reference point set by the Parameter 128. To set the desirable position to the second reference point with the JOG mode, please refer to III. OPERATION, 7. JOG MODE. NoteThe second reference point set to the desirable position with the JOG mode can be changed repeatedly. Use when the reference position is changed because of the workpiece shapes and chucking. 3) Return to the third reference point When a return to the third reference point is made, the reference point is set at the coordinate set in Parameter 129. 4) Operation when soft limits are in effect When return to the first, second, or third reference point is commanded with the soft limits in effect (by which an operation range is set), a return to the reference point is mad in a direction in which the shorter way is selected so that interference with the soft limits does not occur.
M ZRN

key switch is pressed. key switch is pressed.

W when the ZRN

The point as the result of return to the first, second, or third reference point is the reference point for

II-16

2-6. G5: Subprogram Call Command The subprogram call command calls a subprogram. Enter the program number (work number) in the code. To call the subprogram repeatedly, enter the number of repetitions in the R code. The and R codes can be set in the following ranges: code: 0000 ~ 9999 R code: 000 ~ 999 (When calling the subprogram only once, specify R000 or R001. ) It can also be possible to call another subprogram from the subprogram. The maximum allowable nesting level is 8. For more information, see 1-4 Main Program and Subprograms. The start (M) signal is not required to execute G5. After positioning is completed in the previous block, G5 is automatically executed. Example
incremental commands

90

10 20 10div 10div 10

20

W1000 (Main program) N000 G5 R0029000 N001 G0 F0 R001+030.000 N002 G0 F0 R001+090.000 N003 G5 R0029000 Calls subprogram W9000 twice. Moves +30. Moves +90. Calls subprogram W9000 twice. Moves +30. Moves +90. Return to program end N000.

30 N004 G0 F0 R001+030.000
N005 G0 F0 R001+090.000

30 10 10div 10div 20 10 20 90

N006 G7 000 W9000 (subprogram) N000 G2 F0 R010 +020.000 N001 G0 F0 R001 +010.000 N002 G6

Divides +20 by 10. Moves +10. Subprogram return.

2-7. G6: Subprogram Return Command The G6 command must be placed at the end of a subprogram. When G6 is executed, control is returned to the main program The start (M) signal is not required to execute G6. After positioning is completed in the previous block, F6 is automatically executed. 2-8. G7: Work Coordinate End Command The G7 command must be place at the end of the main program. In practice, consider that the G7 command is a jump command to return to the beginning of the program. Set a branch destination which is required to execute G7. After positioning is completed in the previous block, G7 is automatically executed. The start (M) signal is not required to execute G7. After positioning is completed in the previous block, G7 is automatically executed. By setting the parameter, the FIN2 completion signal can also be issued at the same time when the completion signal FIN1 is issued when G7 (program end) is executed. Parameter 023: bit 0

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2-9. G8: Work Coordinate Set Command The G8 command can be used to change the reference point in the absolute mode. The G8 command functions in the same way as for return to the second or third reference point. G8, however, is not accompanied with movement of the rotary table. The G8 command also provides a useful method when the work reference is changed each time the work or tool is changed. Enter in the code an angle measured from the first reference point to the point to be set as the new reference point. The code can be set in the following range: Code: 000.000 360.000 In the following example, a subprogram is shared by absolute commands. Example
Q1001 (Main program) N000 G5 R000 9001 N001 G8 +090.000 Calls subprogram W9001. Set the work coordinate at 90. Calls subprogram W9001. Set the work coordinate at 180. Calls subprogram W9001. Set the work coordinate at 270. Calls subprogram W9001. Set the work coordinate at 0. Returns to program end N000.

5 15 20 20 15 5

N002 G5 R000 9001 N003 G8 +180.000 N004 G5 R000 9001 N005 G8 +270.000 N006 G5 R000 9001 N007 G8 +000.000 N008 G7 000 W9000 (Subprogram) N000 G0 F0 R000 +000.000 N001 G0 F0 R000 +005.000 N002 G0 F0 R000 +020.000 N003 G0 F0 R000 +040.000 N004 G6

5 15 20 20 15 5

Moves to 0 position. Moves to 5 position. Moves to 20 position. Moves to 40 position. Subprogram return

The reference point return (G4) command and the work coordinate set (G8) command have the following priorities: The reference point return command for return to the first reference point has the top priority because the first reference point is the reference point for all operations. The reference point return commands for return to the second and third reference points and the work coordinate set command have the same-level priority. For example, when a work coordinate is set after a return to the second reference point is made, the work coordinate is the new reference point. Conversely, when an reference point return command for return to the second reference point is executed after a work coordinate is se, the second reference point is the new reference point. The start (M) signal is not required to execute G8. After positioning is completed in the previous block, G8 is automatically executed.

II-18

2-10. G9: Declaration Command The declaration command enables or disables individual functions according to the setting of the R code. 1) G9 R000: No operation This command does not have a special function. The program automatically steps. 2) G9 R001R002: Clamp OFF and ON commands When a G9 R001 command is executed in the AUTO or SINGLE mode, the clamp function of the rotary table is no longer enabled. The clamp unction also remains disabled when e operation mode is changed. The clamp function also remains disabled when the operation mode is changed. When power is turned on, the clamp function is initially enabled. 3) G9 R003R004: Dwell OFF and ON commands When a G9 R004 command is executed in the AUTO or SINGLE mode, output of the subsequent positioning completion signals is delayed by the time specified in the code. The specifiable dwell time is from 001 to 999 [10msec]. Once a dwell ON command is executed, the dwell function remains enabled until a G9 R003 (dwell OFF) command is executed. When power is turned on, the dwell function is initially disabled. 4) G9 R005R006: Indexing group control OFF and ON commands These commands can be used to code G1 and G2 indexing commands over multiple blocks or to output another completion signal during execution of an indexing command with a G9 R010 (completion signal control signal). Proportional computation for indexing continues from when a G9 R006 is executed in the AUTO or SINGLE mode to when indexing group control is disabled by a G9 R005. When power is tuned on, the indexing group control is initially disabled. ExampleWhen too large a repetition count is specified in an indexing command 1To equally divide 360 by 1234
N000 G9 R006 N001 G1 F0 R500 +001234 div N002 G1 F0 R734 +001234 div N003 G9 R005 Enables indexing group control Divides 360 by 1234 equally and performs positioning 500 times. Divides 360 by 1234 equally and performs positioning 734 times. Disables indexing group control.

2To equally divide 360 by 7 and output completion signal FIN2 at the end
N000 G9 R006 N001 G1 F0 R006 +000007 div N002 G9 F0 R010 010 N003 G1 F0 R001 +000007 div N004 G9 F0 R009 N005 G9 R005 Enables indexing group control. Equally divide 360 by 7 and performs positioning six times. (The completion signal is FIN 1. ) Enables completion signal control (FIN2 is selected.) Equally divide 360 by 7 and performs positioning once. (The completion signal is FIN 2. ) Disables completion signal control. Disables indexing group control.

II-19

5) G9 R007R008: One-directional positioning OFF and ON commands When a G9 R008 is executed in the AUTO, or SINGLE mode, the subsequent positioning is performed in the approach direction specified by a parameter. To disable one-directional positioning, execute a G9 R007 command. When power is turned on, one-directional positioning is initially disabled.

command

Specify an amout of overrun and an approach direction in parameter address N132.

command

To implement one-directional positioning, set an amount of overrun and an approach direction in Parameter 132. An appropriate overrun amount is approximately 2. NoteReturn to the reference point is not handled as one-directional positioning by G9R008 command. Set the one-directional positioning OFF or ON with Parameter 152: bit 3 6) G9 R009R010: Completion signal control OFF and ON commands The FIN1 positioning completion signal is usually output. However, FIN2 can also be output. When a G9 R010 command is executed in the AUTO or SINGLE mode, the positioning completion signal specified in the is output as subsequent positioning completion code. G9 R010 0 (Enter 0 or 1 in a square ().) When 1 is set, FIN 1 is output. When 1 is set, FIN 2 is output.

To return to the original FIN1 positioning completion signal, execute a G9 R009 command. When power is turned on, positioning completion signal control is initially disabled. Note A positioning completion signal can also be selected by a parameter when a G7 (program end) command is executed. Parameter 023: bit 0

II-20

7) G9 R011R012R013: Display change commands These commands display the following contents on line 2 on the display screen in the AUTO or SINGLE mode: G9 R012: Displays or resets the current position. G9 R013: Displays the remaining angle. G9 R011: Displays the contents of a program. While the current position is displayed, POS is displayed at the beginning of line 2 on the display screen. While the remaining angle is displayed, REM is displayed instead. These display modes can also be changed by keys.

2ndF F 2ndF R 2ndF G

The current position is displayed. The remaining angle is displayed. The contents of a program are displayed.

Sample for display of current position

Sample for display of remaining angle

Notes on G9: declaration commands G9 R001: The clamp function is disabled. G9 R004: Dwell ON G9 R006: Indexing group control ONG9 R008: One-directional positioning ON

G9 R010: Completion signal control ON The commands above are disabled when: Their corresponding OFF commands are executed. The AUTO or SINGLE mode is changed to another mode. The program used for work number set is changed to another program.

II-21

3. F CODES FOR FEED FUNCTIONS

3-1. Fast Feed (F0)

When an F0 code is specified together with a G0, G1, G2, or G3 command, positioning is performed at a fast feed mode. The feedrate is determined by the value set in the Parameter 122.
3-2. Cutting Feed

When an F code from F1 to F9 is specified together with, G0, G1, G2, or G3, positioning is performed at the cutting feedrate. The feedrate for F1 to F9 can be set on a feed screen in the PROG mode.
3-3. Upper Limit of the Cutting Feedrate The upper limit of the cutting feedrate is the value set on the Fmax feed screen in the PROG mode. When a value exceeding the limit set on the Fmax screen is set for the cutting feedrate (F2 to F9), the possible feedrate is up to the feedrate set on the Fmax screen. For F1, however, a value up to the fast feedrate can be set. When the override function is executed, the positioning speed is limited to the upper limit except for F1. 3-4. Setting a Cutting Feedrate A cutting feedrate can be set on a feed screen in the PROG mode. To bring up a feed screen, press the 2ndF and keys in the PROG mode. Usually, the unit of feedrate is mm/min with respect to the radius. It can be changed to the minimum command unit/min (cmd/min) with a parameter Parameter 001: bit 2 1) Feed screen1 (to set a feedrate with respect to the radius) One of F1 to F9 and Fmax is displayed on the right of line 1 on the screen. F1 to F9 correspond to F1 to F9 in the program. Fmax indicates the maximum cutting feedrate.

Feed screen 1

On line 2 on the screen, Fmm/min Rmm(a square () indicates a digit) are displayed. Set a feedrate in this field. When radius R (mm) and feedrate F (mm/min) on the circumference are set, the TPC-Jr automatically calculates the feedrate. The specifiable ranges for F and R are: F: 1999999mm/min R: 1999mm

R mm

II-22

2) Feed screen 2 (cmd/sec) Usually, a feedrate is set with respect to a radius as described in item 1) above. When a G3 (lead cutting) command is used to specify a feedrate, however, an amount of movement per second (minimum command unit) must be set for more accurate calculation. To switch the screen to the feed screen 2, change the parameter Parameter 001: bit 2 ExampleTo set a feedrate of 12. 6 (12 3600)/min Decimal: 0.001 12. 6 1000 60 = 210 [cmd/sec] For details about calculating the speed, please refer to 2-4. G3: Lead Cutting Command.

Feed screen 2

3-5. Dwell After positioning is completed, output of a positioning completion signal can be delayed by a time set in a G9 R004 command. For more information, please refer to 2-10G9: Declaration Command 3) Dwell.

II-23

MEMO

II-24

III.OPERATIONS
1. CONTROL UNIT _______________________________________________ III-3
1-1. Power Supply On/Off _____________________________________________________ III-3

2. Details of Operation Panel _____________________________________ III-4

2-1. LCD Screen ____________________________________________________________ III-4 2-2. LED Indicators __________________________________________________________ III-6 2-3. Operation Mode Display and Switching _______________________________________ III-6 2-4. Program Editing Keys ____________________________________________________ III-6 2-4-1. Keys used for program editing mainly in the PROG or CHECK mode. ______ III-7 2-4-2. Keys used for other than program editing mainly in the SINGLE or AUTO mode _____________________________________ III-8 2-5. Operation Keys _________________________________________________________ III-9

3. OVERVIEW OF OPERATION MODES ____________________________ III-10

3-1. AUTO Mode ___________________________________________________________ III-10 3-2. SINGLE MODE ________________________________________________________ III-10 3-3. PROG Mode __________________________________________________________ III-10 3-4. CHECK Mode _________________________________________________________ III-10 3-5. MDI Mode ____________________________________________________________ III-10 3-6. JOG Mode ____________________________________________________________ III-10

4. AUTO AND SINGLE MODES____________________________________ III-11

4-1. Overview _____________________________________________________________ III-11 4-2. Start Input Signal 4-3. Start Key 4-4. Reference Point Return Keys 4-5. Stop Key 4-6. Machine Locking 4-7. Display Switching [valid in the AUTO mode] ______________________ III-12 [Valid in the SINGLE mode] _____________________ III-12 [valid in the SINGLE mode] _____________________ III-12 [valid in both the AUTO and SINGLE modes] _______ III-12 [valid in both AUTO and SINGLE modes] __________ III-12 [valid in both AUTO and SINGLE modes ___________ III-13

4-8. DGN_________________________________________________________________ III-13

5. PROGRAM / CHECK MODES ___________________________________ III-14

5-1. Overview _____________________________________________________________ III-14 5-2. Entering a Program _____________________________________________________ III-15 5-2-1. Procedure for Entering a Program ______________________________________ III-15 III-1

5-2-2. Entering Data for the field (Entering decimal numbers and signs) ___________ III-16 5-2-3. Scrolling a Program__________________________________________________ III-16 5-2-4. Sample G code display _______________________________________________ III-16 5-3. Setting and Selecting a Work Number_______________________________________ III-17 5-4. Inserting a Block _______________________________________________________ III-18 5-5. Deleting a Block________________________________________________________ III-18 5-6. Displaying the Directory__________________________________________________ III-19 5-7. Copying a Program _____________________________________________________ III-19 5-8. Deleting a Program _____________________________________________________ III-19 5-9. Deleting All Programs in Edit RAM and the File________________________________ III-20 5-10. Setting a Feedrate _____________________________________________________ III-20 5-11. Input/Output & Storage of Programs to the external components._________________ III-21 5-12. Setting Parameters ____________________________________________________ III-21 5-13. Inputting and Outputting Parameter Data to and from the External Components _____ III-22 5-14. Self-diagnosis ________________________________________________________ III-22 5-15. Adjusting Contrast on the LCD Display _____________________________________ III-24

6. MDI Mode ___________________________________________________ III-25

6-1. Overview _____________________________________________________________ III-25 6-2. MDI Mode Indication ____________________________________________________ III-25 6-3. MDI Operations ________________________________________________________ III-25

7. JOG MODE__________________________________________________ III-25

7-1. Overview _____________________________________________________________ III-25 7-2. Contents on the screen __________________________________________________ III-26 7-3. JOG operating method __________________________________________________ III-26 7-4. Setting the Second Reference Point ________________________________________ III-26 7-5. Clearing the current position indication ______________________________________ III-26

III-2

1. CONTROL UNIT
LED indication section Power breaker

2nd F

RUN

STOP

TPC -Jr
R REM
PRM

LCD

No W DGN 2nd F
M W ZRN ZRN JOG JOG

PRG

F POS FEED CLR DEL

USER

COPY

SCH

MODE AUTO SINGLE CHECK PROG MDI JOG

I O

ST

SP

C ALM +/MLK

INS

DIR CR

Operation keys

Program edit keys

Operation mode indication LED/ Switch

1-1. Power Supply On/Off

1) Power on Turn on the breaker (to the I side) on the right side of the TPC-Jr. When no abnormality is found, RDY (ready) is shown on the LCD display. 2) Power off Confirm that the machine is stopped. Turn off the breaker (to the O side) on the right side of the TPC-Jr. Note Usually, use this breaker to turn on or off the power for the TPC-Jr. However, if you use a transformer to adjust the voltage, use the primary side of the transformer to turn on or off the power as much as possible. The TPC-Jr has a sealed structure. Therefore, it may become hot during operation. This is not abnormal. The power plug attached is for checking the functions. Please change the plug according to the installation condition when installing the TPC-Jr. Be sure to ground it before use.

III-3

2. Details of Operation Panel

2-1. LCD Screen
On the LCD screen, the operation status of the TPC-Jr and information on the program are displayed. The normal display is shown below:

On the following screen, all information items are displayed. The meaning of each information item is explained below: 1) TPC-Jr status display RDY/ALM

The status of the TPC-Jr is displayed. Usually, RDY (ready) is displayed. When an alarm is given, ALM is displayed.

2)

Program display line Part of a TPC-Jr program is displayed on two lines. 1 Operation Code G, Feedrate F, Auxiliary Code R, Angle Code are displayed. 2
1 The program is sometimes displayed on one line depending on G codes. 2 F codes, R codes, or codes are not required depending on G codes. They are not displayed.

Current position or remaining amount display When the current position or the remaining amount is displayed in the field, POS or REM appears at the beginning of the line. (This is displayed only in the AUTO, SINGLE, MDI, or JOG mode.)

3)

Control display line File alarm display FILE This display is indicated when a program is overwritten with the program mode. Overtravel display OT This display indicates that overtravel is in process. When the TPC-Jr restores from the overtravel status, the display disappears. (This is displayed only in the AUTO, SINGLE, MDI, or JOG mode.) This display is valid only when the overtravel limit switch is installed on the rotary table being controlled.

III-4

Machine lock display MLK This display appears when the machine lock operation is in progress. (This is displayed only in the AUTO, SINGLE, MDI, or JOG mode.) Origin return display This display appears when return to a reference point is in progress or after it has been finished. This display disappears when movement of even one pulse is commanded after return to the reference point has been finished. MZRN shows a return to the first reference point. WZRN shows a return to the second reference point. TZRN shows a return to the third reference point. (This is displayed only in the AUTO, SINGLE, MDI, or JOG mode.) 4) Work number display

This display is not always displayed. When the 2ndF + N keys are pressed, the work number (program number) currently selected is displayed. Subprogram number display

When a subprogram is called by a G5 command, the subprogram number is automatically displayed. (This is displayed only in the AUTO, SINGLE, MDI, or JOG mode.) 5) Alarm display If an alarm is given, the alarm number and simple message are shown. An asterisk (*) blinks at the left of the alarm number to draw the operators attention while an alarm is being displayed. A sample display is given below:
Alarm number Alarm message

Current position indication when the power is turned on.

The current position is indicated in a plus value when the power is turned off and on between the absolute position of 0 ~ 180 degrees. When the power is turned off and on between the absolute position of 180 ~ 360 degrees, the current position is indicated in a minus value. For example, When the power is turned on at +90 degrees, the value +90 is shown. When the power is turned on at +270 degrees, the value -90 is shown. When the power is turned on at -90 degrees, the value -90 is shown. When the power is turned on at -270 degrees, the value +90 is shown.
The area shown in minus value when the power is turned on. The area shown in plus value when the power is turned on. First reference point

180

When the multi-turn limit Parameter 119 is set to 65535, the sign before the power is turned off is shown.

III-5

2-2. LED Indicators

1) RUN [Indicators] When positioning is in progress, this lamp is on. When the TPC-Jr waits for the machine being controlled to be clamped or unclamped completely, the lamp blinks. 2) STOP [indicates that stop or interlock is in progress.] When an external stop signal is input, this lamp lights. When an interlock signal is input, the lamp blinks. (The interlock signal is exclusive of the stop signal.) This lamp also lights when positioning is stopped by the SP key in the middle. 3) 2ndF [indicates that the second functions are enabled.] When the 2ndF key is pressed, this lamp lights, indicating that the second functions whose names are written at the lower right corners of individual key are enabled.

2-3. Operation Mode Display and Switching

The mode currently selected is indicated by LED lamps. Names for each mode are as below. For details, refer to 3. OVERVIEW OF OPERATION MODES. AUTO automatic mode SINGLE single mode CHECK check mode PROG program mode MDI MDI mode JOG jog mode To change the mode, press the or mode switching key. Each time the key is pressed, the mode changes as shown below. AUTO SINGLE CHECK PROG MDI JOG Similarly, each time the key is pressed, the mode changes as shown below. AUTO SINGLE CHECK PROG MDI JOG

2-4. Program Editing Keys

Program editing keys are used mainly for input or editing of programs. To enable second functions implemented by keys, on which INS, DEL, or another name is written at the lower right corner, press the 2ndF key then a desired key such as INS or DEL. Use the PRG, POS, REM, DGN, ALM, and MLK blue keys for second function operations during other than program editing. For more information, see individual operation methods.

III-6

2-4-1. Keys used for program editing mainly in the PROG or CHECK mode. Key Explanation
G F R Numeric keys Use these keys to enter numeric data for programs. Program code keys Use one of these keys to select a code when entering a program. When the key is pressed, for example, the N field on the program display line blinks. Then, any data can be entered with numeric keys. Decimal point key Use this key to decimally set the data in the code when entering a program. When the key then the key are pressed sequentially, the decimal point is displayed and data can be entered decimally. +/Sign key Use this key to set a sign in the code when entering a program. First press the key. Then, the sign following changes like each time the +/- key is pressed. CR key Press this key to store a program. Work number key (2ndF + WNo.) Use these keys to change a work number (program number). 2ndF After pressing the 2ndF and keys, enter a new work number then press the CR key. Then, the program identified by the work number is called. 2ndF 2ndF Insert key (2ndF + INS) Use these keys to insert one block in a program. Delete key (2ndF + DEL) Use these keys to delete one block from a program. Directory key (2ndF + DIR) Use these keys to see the usage status of program memory. The number for clocks used and the remaining free blocks in memory are displayed for a work number. Copy key (2ndF + COPY) Use these keys to copy a program identified by a work number. Clear key. (2ndF + CLR) Use these keys to delete a program identified by a work number.

CR

2ndF

2ndF

2ndF

III-7

Keys used to edit a program (continued)

Key 2ndF

Explanation Serial channel key (2ndF + SCH) Use these keys to input or output a program to or from the general-purpose paper tape puncher or reader over the serial channel. Parameter key (2ndF + USER) For future extension. Feed key (2ndF + FEED) Use these keys to set a feedrate from F1 to F9. Parameter key (2ndF + PRM) Use these keys to set a parameter. Clear key Use these keys to restore the TPC-Jr from a second operation such as a copy or clear operation. These keys can also be used to reset an alarm.

2ndF 2ndF 2ndF

2-4-2. Keys used for other than program editing mainly in the SINGLE or AUTO mode
Key Explanation Current position display (2ndF + POS) Use these keys to switch the display in the field on the program/current position display line to the current position. This switching can also be commanded by a <G9 R012> command in a program. Remaining angle display key (2ndF + REM) Use these keys to switch the display in the field on the program/current position display line to the remaining angle. This switching can also be commanded by a <G9 R013> command in a program. Program display key (2ndF + PRG) When these keys are pressed with the current position or remaining angle displayed, the field returns to the program display mode. Diagnose (2ndF + DGN) Use these keys to monitor the status of external input/output signals or the servo status. To return to the previous display, press the C key. Alarm key (2ndF + ALM) Use these keys to display the nature of an alarm on the control display line. To delete this display, press the C key. (Except when a servo alarm is being given.) Machine lock key switch (2ndF + MLK) Use these keys to make the machine lock function effective. By pressing the 2ndF & +/- keys, the machine lock becomes effective. To release the machine lock, press the 2ndF & +/- keys again.

2ndF

2ndF

2ndF

2ndF

2ndF

2ndF +/-

III-8

2-5. Operation Keys

The following operation keys can be used to command operations such as start and stop. Key switch ST Explanation Start key Use this key to execute one block in a program. The key is valid in the SINGLE, or MDI mode. Stop key Use this key to stop positioning. To resume positioning, press the ST key in the SINGLE, or MDI mode. Then, the rotary table moves by the remaining angle. First reference point return key Use this key to return to the first reference point. The key provides the same operation as the G4 R000 command. It is valid in the SINGLE, or MDI mode. The same operation as the G4 R000 command. Second reference point return key Use this key to return to the second reference point. The key provides the same operation as the G4 R001 command. It is valid in the SINGLE, or MDI mode. The same operation as the G4 R001 command. +JOG operation key Use this key to proceed +JOG feeding. It is valid in the JOG mode. When this key is pressed in the CHECK or PROGRAM mode, the program display can be scrolled. -JOG operation key Use this key to proceed -JOG feeding. It is valid in the JOG mode. When this key is pressed in the CHECK or PROGRAM mode, the program display can be scrolled.

SP

M ZRN

W ZRN

JOG

JOG

III-9

3. OVERVIEW OF OPERATION MODES

3-1. AUTO Mode
1) In the AUTO mode, a start input signal such as an M signal from the machining center is received to conduct auto operation. 2) When plural M signals are prepared as an extended function, external reference point return, and the external work number set function can be used.

3-2. SINGLE MODE

1) In the SINGLE mode, the contents of a program can be checked manually before automatic operation starts. When the ST key is pressed, positioning is performed once. M W 2) The ZRN and ZRN keys can be used for returning to the reference point.

3-3. PROG Mode

1) In the PROG mode, programs are input. Up to 1000 program blocks can be input. Up to 100 work numbers (program numbers) can be registered. 2) The program entered in the PROG mode must always be filed. The program is filed when the PROG mode is switched to the CHECK or MDI mode with the or key. 3) The filed program is memorized even the power is turned off No backup power supply like a battery is required because a reliable special memory is used.

3-4. CHECK Mode

In the CHECK mode, programs are checked in the same way as in the PROG mode. The contents of programs are not rewritten, enabling you to check programs safely.

3-5. MDI Mode

1) In the MDI mode, a program can be entered as in the PROG mode and manual operation is allowed as in the SINGLE mode. 2) Use the MDI mode to run test programs or perform setup. 3) Up to 10 program blocks can be used. Usable G codes are restricted to G0 to G4 and G7. Note Once the power is turned off, the entered program is deleted.

3-6. JOG Mode

1)
Jog feeding and step feeding are possible by using the JOG and the The feedrate can be selected from the ten rates, F0 ~F9. W ZRN JOG

keys.

2)

By pressing the 2ndF + reference point.

keys at the desired position, the position can be set to the second

III-10

4. AUTO AND SINGLE MODES

4-1. Overview
1) The AUTO or SINGLE mode is used for the program which is selected in advance in the PROG mode. Before selecting the AUTO or SINGLE mode, select a program to be run in he PROG or CHECK mode. When he AUTO or SINGLE mode is selected, the TPC-Jr waits for a start input signal to be entered or for the start key to be pressed. When the first block of a program contains commands such as G5 to G9 which are not involved in movement, the program is automatically executed. (To implement automatic advance by G5 to G9, up to 20 consecutive blocks can be coded.) The program advances until one of G0 to G4 which command movement is encountered. Then, the program waits for a start input signal to be entered or for a similar event to occur. The AUTO and SINGLE modes provide the same effect except that the AUTO mode is entered by an external input signal while the SINGLE mode is entered when a key on the MDI unit is pressed. AUTO mode SINGLE mode Start input (M signal, etc.) Start ST key External reference point return input (M signal, etc.) Return to a reference point M W Work number set (B signal, etc.) ZRN ZRN key switch

2)

3)

Common functions Stop SP key Stop signal / Interlock signal input Machine lock Display switching (Current position/remaining angle) Machine reference point output Soft limit Overtravel DGN

Note

For the functions marked with , Refer to IV. EXTENDED FUNCTIONS.

III-11

4-2. Start Input Signal

[valid in the AUTO mode]

1) When receiving a start input signal, the TPC-Jr performs positioning once according to the contents of a program block in the wait state. 2) Upon completion of positioning, the TPC-Jr advances to the next block. When the number of repetitions, is specified in an indexing command or incremental command, the value of the R field is decreased one by one. When it reaches 0, the TPC-Jr advances to the next block. 3) When positioning is completed, positioning completion signal 1 (FIN1) is output.

4-3. Start Key

[Valid in the SINGLE mode]

1) When the ST key is pressed in the SINGLE mode, positioning is performed in the same way as when a start input signal is entered in the AUTO mode. 2) Positioning completion signal 1 (FIN1) is also output as in the AUTO mode.

4-4. Reference Point Return Keys

[valid in the SINGLE mode]

M W 1) When the ZRN or ZRN key is pressed, the TPC-Jr starts return to a reference point. 2) While the TPC-Jr is returning to a reference point or after it has returned to it, MZRN or WZRN is displayed on line 4 on the display screen. 3) MZRN means return to the first reference point, providing the same effect as the G4 R000 command. WZRN means return to the second reference point, providing the same effect as the G4 R001 command. 4) Upon completion of return to a reference point, positioning completion signal 1 (FIN1) is output.

The completion signal by a reference point return key can be assigned to FIN1 and FIN2 by setting a parameter. Parameter 023: bit 4

4-5. Stop Key

[valid in both the AUTO and SINGLE modes]

1) When the SP key is pressed during positioning or return to a reference point, the rotary table lowers its speed and finally stops. 2) When the rotary table, the stop lamp lights. 3) To restart the rotary table, enter a start input signal (M signal, etc.) again in the AUTO mode or change the AUTO mode to the SINGLE mode then press the key, The rotary table ST moves by the remaining angle.

4-6. Machine Locking

[valid in both AUTO and SINGLE modes]

1) When the 2ndF and +/- keys are pressed, the machine lock function is enabled. In this stares, MLK is displayed on line 2 on the MDI unit screen. 2) When the machine lock function is executed, the rotary table does not move but the current position is displayed as if the rotary table were moving. 3) To disable the machine lock function, press the 2ndF and +/- keys again or change the SINGLE or AUTO mode to another mode with the Note or key.

The feedrate during machine locking is not the actual speed. Machine is locked immediately.

III-12

4-7. Display Switching

1) The 2ndF and current position. F

[valid in both AUTO and SINGLE modes

keys can be used to switch the display on line 2 on the display to the

2) The 2ndF and R keys can be used to switch the display on line to the remaining angle. 3) To return to the original program display from the current position or remaining angle splay, press the 2ndF and G keys. 4) The current position display can be reset by the press the 2ndF and C key. To change the display to the coordinate for the current position from the first reference point,

keys.

Current position indication when the power is turned on. The current position is indicated in a plus value when the power is turned off and on between the absolute position of 0 ~ 180 degrees. When the power is turned off and on between the absolute position of 180 ~ 360 degrees, the current position is indicated in a minus value. For example, First reference point When the power is turned on at +90 degrees, the value +90 is shown. When the power is turned on at +270 degrees, the value -90 is shown. When the power is turned on at -90 degrees, The area shown The area shown the value -90 is shown. in minus value in plus value When the power is turned on at -270 degrees, when the power when the power is turned on. is turned on. the value +90 is shown. 180 When the multi-turn limit Parameter 119 is set to 65535, the sign before the power is turned off is shown.

4-8. DGN
1) The 2ndF and keys can be used to the self-diagnosis screen. 2) In the AUTO or SINGLE mode, only the input signal is checked during self-diagnosis --output signals can not be forcibly set or reset. 3) Select the address of a block to be checked with the and numeric keys or the CR key. 4) To exit from the self-diagnosis screen, press the C key. 5) The start input signal and the ST key are valid during self-diagnosis. 6) For more information, see MAINTENANCE.

III-13

5. PROGRAM / CHECK MODES

5-1. Overview
In the program (PROG) mode, a program is entered or edited. In the CHECK mode, the program entered in the PROG mode is checked. 1) Filing a program The program entered in the PROG mode needs to be filed, this is automatically done when the PROG mode is switched to another mode with the or key. Please note if the power is turned off before this operation is completed, the program is not filed and the entered program will be lost. When the program is entered with the program mode, FILE is displayed on line 2 on the display screen to draw the operators attention. It takes about six seconds to file 1000 blocks. 2) Program editing and RAM structure RAM in which programs are entered and edited consists of a directory and edit RAM. The directory contains memory address of programs. Edit RAM contains programs. For more information, see II. PROGRAMMING. The directory can contain up to 100 entries and edit RAM can contain up to 1000 blocks. If usage of them is unbalanced as shown below, the available memory capacity is reduced. a) When many work numbers are used for shot programs. Example One hundred work numbers are used and the length of each program is several blocks: Edit RAM contains only several hundreds of blocks but the directory is full. As a result, the edit RAM can be contain no more programs. Solution: Do not split programs into too small of segments. Use large programs to some extent. b) When less work numbers are used but individual programs are long: Example Ten programs are used, each of which consists of about 100 blocks: The directory contains only 10 entries but edit RAM is full and cannot contain more programs. SolutionCode a program shared as a subprogram. 3) Program file structure The program file stores programs contained in edit RAM in units of five blocks. Its capacity is 1120 blocks (224 x 5 blocks), which is slightly larger than that of edit RAM. When many programs are divided into non-seven blocks (such as six or eleven blocks), the error message File Full rarely appears. For more information, see II. PROGRAMMING.

III-14

4) Programming notes To enter multiple programs, use different program numbers (work numbers) for them. If these programs are separated by N addresses under the same work number, it is assumed that the blocks between programs contain another program. This reduces the memory usage efficiency. For more information, see II. PROGRAMMING. 5) Write-protected programs Programs can be write-protected by a parameter. Parameter 000: bit 7 6) The following operations can be done in the PROG or CHECK mode. Operation Entering a program Setting/changing a work number Inserting a block Deleting a block Displaying the directory Copying a program Deleting a program Deleting all programs in edit RAM and the file Setting a feedrate Transmitting a program to and from the external components. Setting a system parameter. Adjusting contrast on the LCD screen. Self-diagnosis Wno INS DEL DIR COPY CLR CLR FEED SCH PRM MLK DGN F key PROG mode CHECK mode
(Checking is possible)

(Checking is possible)

(Checking is possible)

5-2. Entering a Program 5-2-1. Procedure for Entering a Program 1) On the screen on which no program is displayed, address N000 is displayed but nothing is displayed in the G,F,R, fields.
2) Press the G key. The cursor appears in the G field and a zero is displayed in each column.

3)

Enter a G code with numeric keys. Press the F them in the same way.

R , and keys and enter data for

4) 5)

When all data is entered, press the CR key. This block is stored and the next block (N0001) is displayed. Repeat Steps 2) to 4) above for each block to enter the entire program.

III-15

5-2-2. Entering Data for the field (Entering decimal numbers and signs) To enter decimal numbers for the field, use the decimal key . To change the sign, use the +/- key.
The example below shows how to enter the data with the decimal system. To enter 123.340 ( indicates the position of the cursor. )

Press the key to make the field 0. The first digit of thefield is a sign. (rotating direction.) Press the +/key to change the sign to -.

. . .

Press the numeral keys , and to enter the integral numbers. Press the decimal point key and the decimal point appears at the end of the field. Press the numeral key numbers. , to enter the decimal

Press the CR

key to register the program.

When the last digit of the decimal number is zero, it is not necessary to enter a zero. It is automatically entered.

5-2-3. Scrolling a Program An N address can be scrolled in an ascending or descending order by pressing the jog keys. 5-2-4. Sample G code display Some G codes do not have an F field or do not require an R field. The samples are shown below:

III-16

Direct angular position command

Direct indexing point number command

G2Arc-indexing point number command

Lead cutting command

Origin return command

Subprogram return command

Subprogram return command

Program end command

Work coordinate setting command

R0004 declaration command (dwell ON)

R010 declaration command (completion signal control ON)

Another declaration command

5-3. Setting and Selecting a Work Number

1) 2) Press the 2ndF , and keys. The work number field is set at all 0s and the cursor appears. Enter a work number with numeric keys then press the CR key. This completes work number setting. The program having the new work number at address N000 is displayed. Work numbers can be set in the range from 0000 to 9999. 3)

To display the previous work number after the new work number is displayed in Item 2) above, press the C key. III-17

5-4. Inserting a Block

1) 2) Use this function to insert a block in a program. Select an N address where a block is to be inserted,. Then, press the 2ndF and keys. The question Insert? appears on line 2 on the screen.

3) Press CR. The new block is inserted in the N address. Nothing is shown in the G, F, R, and fields.

4) Enter the program to be inserted and press the CR key. To exit from the insertion screen in Item 2) above, press the C key. Example 122 0 0 0001 +045.000 123 0 0 0000 +000.000 124 0 0 0001 +090.000 125 0 0 0001 +180.000

122 0 0 0001 +045.000 123 0 0 0001 +090.000 124 0 0 0001 +180.000

Insert the new program to N123.

Note

A block cannot be inserted in the branch destination specified in a G7 command. When the N address of the branch destination is changed, modify the program involved in G7.

5-5. Deleting a Block

1) 2) Use this function to delete a block from a program. Select an N address from which a block is to be deleted, Then, press the 2ndF and keys. The question Delete? appears on line 2 on the screen. 3)

To delete the block, press the CR key. 4) To exit from the deletion screen in Item 2) above, press the C key. Note A block cannot be deleted from the branch destination specified in a G7 command. When the N address of the branch destination is changed, modify the program involved in G7.

III-18

5-6. Displaying the Directory

1) 2) 3) The work numbers of the programs stored and the number of blocks in the programs can be displayed. Press the 2ndF and keys. The directory display screen is displayed. When there are too many work numbers to find on the screen, press the CR key. The screen changes each time the key is pressed. 4) The number of remaining blocks is given at the end of the display. Note Work numbers are displayed not in ascending order but in the order in which they were input
o o o

5-7. Copying a Program

1) 2) 3) The program having a particular work number can be copied. Press the 2ndF and keys. The copy screen is displayed.

The cursor appears at the position indicated by in the figure on the right. Enter the work number of the program to be copied then press the CR key. The cursor moves to the position indicated by . Enter the work number of the destination program, then, press the CR . The question mark (?) appears at the position indicated by for confirmation. When you are sure, press the ST key to start the copy operation. To go back to initial screen in Item 2) above, press the C key.

To exit from the copy screen, press the C key one more time. While the program is being copied, an asterisk (*) and the cursor are displayed at the position indicated by . 4) When the destination work number is already present, the error message Copy err 2 appears.

5-8. Deleting a Program

1) The program having a particular work number can be deleted. Press the 2ndF and keys. The clear screen is displayed.

2) 3)

The cursor appears at the position indicated by in the figure on the right. Enter the work number of a program to be deleted then press the CR key. The W0000 Clear? appears at the position indicated by for confirmation. When you are sure, press the ST key to start deletion. To go back to initial screen in Item 2) above, press the To exit from the clear screen, press the C where the ? was indicated. III-19 C key.

key one more time.

While the program is being deleted, an asterisk (*) and the cursor are displayed at the position

Note

This program delete function deletes only a program in edit RAM --- the program in the file is not deleted. To delete the program in the file, switch the PROG mode to another mode then manipulate the file (see 5.1). If a program is deleted by mistake, turn power off before file operation is performed. The program is not deleted from the file and it can be read again.

5-9. Deleting All Programs in Edit RAM and the File

1) All programs in edit RAM and the file can be deleted at one time. 2) Press the 2ndF and clear screen. 3) Press the ST key. Deletion of all programs in the edit RAM and the file starts. Execute appears on Line 2 during deletion. To go back to the program clear screen in 5.8, press the C key.

key on the program clear

screen in 5.8 above. The screen changes to the all

Note This All-program delete function deletes both the program in the edit RAM and the program in the file. Because all the programs are deleted, be careful when using this function.

5-10. Setting a Feedrate

1) 2) Set an F code (F1 to F9) in a TPC-Jr program. Press the 2ndF and keys. The feedrate screen is displayed. On the feedrate screen, a feedrate can be set by either of the following two methods Parameter 001: bit 2: specification of a radius (mm) and a rate on its circumference (mm/min) and specification of a command unit per minute.
R mm

Specification of a radius and a rate on its circumference Radius R: 1999 [mm] Rate F on circumference: 1999999 [mm/min]

F mm/min

In the field indicated by in the figure at right, F1 to F9 and Fmax are displayed. F1 to F9 correspond to F codes F1 to F9. Fmax indicates the maximum rate of F2 to F9. Select the item with the key and the numeric keys or with the CR key. Enter a rate [mm/min] at the circumference into the F filed indicated by . After pressing the key, enter the rate with the numeric keys. Enter a radius [mm] in the R field indicated by . After pressing the R key, enter the radius with the numeric keys. After entering the data for each digit, press the CR key to

III-20

memorize the data. [valid only in the PROG mode] To exit from the feedrate setting screen, press the C key. By pressing the JOG key, the display for the F field of can be scrolled. b Specification of a command unit per second A feedrate is usually represented by a radius and the rate in 1) above. However, when setting the feedrate for the G3 (lead cutting command), the feedrate is entered by an amount of movement per second (command unit/second) to attain an accurate setting value.

The command unit (cmd) changes depending on the minimum setting unit. For the TPC-Jr, it is 0.001. Example The feedrate for 12.6/minute is: Setting unit: 0.001 12.6 1000 60 = 210 [cmd/sec]

5-11. Input/Output & Storage of Programs to the external components.

Programs can be input and output using external components like a general paper tape reader and a punching machine. For details, refer to IV EXTENDED FUNCTIONS 7. EXTERNAL STORAGE OF PROGRAMS.

5-12. Setting Parameters

1) 2) 3) 4) Set individual parameters of the TPC-Jr as follows: To bring up the parameter setting screen, press the 2ndF and keys. Line 2 on the screen indicates a parameter address from N000 to N199 and a parameter data field. The parameter data can be checked on this screen but new parameters cannot be set. To set new parameters, use the following procedure [Only in the PROG mode]: Select the PROG mode and change the screen to the parameter setting screen. Press the , , ., , , and keys in that order.

Press the CR key. The PROG mode lamp blinks, indicating that new parameters can be set. Enter new parameters in the same procedure as when usually entering program. After pressing the key, enter a parameter address with numeric keys. After pressing the key, enter parameter data with numeric keys. To store the entered data, press the key for CR each data. C To exit from the parameter setting screen, press the key. By pressing the JOG key, the display for the parameter address can be scrolled.

III-21

Note 1 Parameters are not checked. When a too large of a value is set in a servo parameter at an address from N100 to N199, however, an error message SV Data may be displayed. Note 2 Some parameter data is substituted immediately when it is entered. However, other parameter data is substituted after power is turned off once, then on again.

5-13. Inputting and Outputting Parameter Data to and from the External Components
As with input/output of programs, parameter data can be input and output. For more information, see 10. STORING PROGRAMS IN EXTERNAL MEMROY in IV. EXTENDED FUNCTONS.

5-14. Self-diagnosis
1) Input signals can be checked in the same way as in the SINGEL and AUTO modes. In addition, output signals can be set and reset.

2)

To bring up the self-diagnosis screen, press the 2ndF and 1. Input signals and the servo can be checked. 2. Compulsory ON/OFF of output signals are checked. Select either mode with the or keys.

keys.

3)

When check of an input signal is selected: Select the address of an item to be checked with the key and numeric keys or the CR key. To return to the initial screen described in Item 2), press the C key. When check of an output signal is selected: Select the address of a signal to be output with the key and numeric keys or the CR key.

4)

Set the signal to be output in thecode with the , , and Press the ST

keys.

key. The bits of the specified output signal are turned on or off. At the same

time, an asterisk (*) blinks on line 2 on the screen. When the SP key is pressed, the output signal returns to the original status and the asterisk disappears. To return to the initial screen described in Item 2), press the C key.

III-22

DGN input check items Contents Address bit N36 N37 N38 N39 N40 N41 N42 External input signal Internal input signal Internal input signal External output signal Control output signal LED output
B Clamp SOL
Overcurrent

bit 6
(*Emergency stop)

bit 5
Work number set B Main circuits power SV-FWD PROGRAM

Bit 4
B1 Unclamp LS Clamp SOL

bit 3
Return to reference point Clamp LS

bit 2
Stop Servo COIN

bit 1
Start *Servo alarm

bit 0
Servo ready

B External output
overcurrent

LED 2ndF

Input power switch SV-REV MDI

ALM

LEVEL

JOG

CHECK

SINGLE

SV-AUTO AUTO

SV-PCON STOP

SV-ON RUN

Servo deviation counter Commanded servo rate Current servo rate Commanded servo torque Commanded servo pulse rate Accumulated servo load Regenerative servo load Regenerative servo resistance consumption power Identical servo inertia ratio Positioning time Servo alarm trace back Servo alarm trace back Servo motor type Servo motor capacity Servo encoder type Servo special specifications Servo software version Servo encoder software version Servo type Servo rotating angle 1 Servo rotating angle 2 Servo input port monitor Servo output monitor Servo command pulse counter Servo feedback pulse counter Servo type main boat software version When a signal is on, the N00N09 indicates 1 and when a signal is off, the N00N09 indicates 0. The signals marked with an asterisk (*) show whether it is on or off by inversion.

III-23

DGN output check items

Address

Contents bit bit 6 bit 5 bit 4 bit 3

ALM

bit 2
LEVEL

bit 1
FIN2

bit 0
FIN1

External Input Main Clamp power circuit LED 2ndF output SOL switch power signal Control SV-REV SV-FWD output signal All the LEDs light up. The LCD is displayed.

SV-AUTO

SV-PCON

SV-ON

When 1 is set to N00 or N01, the current conditions of the output signals are indicated inversely. For N02, all the LED except for the [2ndF] LED light up for about five seconds.

5-15. Adjusting Contrast on the LCD Display

1) The contrast on the LCD display varies according to the temperature and angle at which the operator views the screen. However, the contrast can be adjusted with ease. 2) To bring up the contrast adjustment screen, press the 2ndF and the +/- keys with the CHECK mode. The message for contrast adjustment appears on line 2 of the screen. 3) To increase the value , press the +/- key. The LCD display becomes brighter. 4) When the value reaches 15, next pressing the +/- key changes the value to 00. The display becomes darkest. 5) After the desired contrast is reached, press the contrast. Contrast can be adjusted at 16 levels from 00 to 15. The contrast adjusting data is saved in the parameter area. It is also possible to adjust the contrast by directly changing a parameter. Parameter 039 CR key. This completes adjustment of

III-24

6. MDI Mode
6-1. Overview
1) In the MDI mode, programs can be entered as in the PROG mode and manual operation is possible as in the SINGLE mode. 2) The MDI mode can be used to perform setup using programs. 3) The number of usable program blocks is 10. The usable G codes are only G0~G4 and G7. Note Once the power is turned off, the entered program is deleted.

6-2. MDI Mode Indication

1) The MDI mode indication is basically the same as the usual program display. However, the number following N on line 1 changes to a one-digit number. The program capacity becomes 10 blocks. N0~N9

6-3. MDI Operations

Operations in the MDI mode can be done in the same way as in the PROG and SINGLE mode. Therefore, description of MDI operations is omitted. 1) Entering programs Programs can be entered in the same way as in the PROG mode. However, usable G codes are only G0~G4 and G7. The second reaction operations, such as inserting, deleting are not supported. While the program is being entered, the MDI mode LED blinks. When operation becomes ready after entering the program, the MDI mode LED light remains on. 2) Manual start As in the SINGLE mode, the following functions can be implemented: Manual start of a program with the ST Return to the reference point with the key.
M ZRN

or the

W ZRN

key.

Stop with the SP key External stop and interlock input signals can be used. 3) Other functions a) The display switching, and self-diagnosis are supported as in the SINGLE mode. b) Machine locking is not supported.

7. JOG MODE
7-1. Overview
Continuous jog feeding and jog step feeding are possible with the JOG key.

III-25

7-2. Contents on the screen

JOG-1 on Line 1 on the screen indicates the JOG feedrate. Any desirable feedrate can be selected between 0 ~ 9 with the numeral keys. JOG-0 applies to the fast feedrate, and JOG-1 ~ 9 to the indexing feedrate of F1 ~ F9 respectively. Moving angle of JOG step feeding. Line 2 on the screen indicates the current position. The default for the feedrate and the step feeding angle can be set with a parameter. Parameter 012, 013.

7-3. JOG operating method

1) 2) Continuous JOG feeding The Rotary Table moves in the + or - direction while the JOG or JOG key is pressed. JOG step feeding Pressing the JOG or JOG key conducts the step feeding by the moving angle in . To set the moving angle of the step feeding, enter the desired angle with the numeral keys after pressing the key in the same way as entering a program. The setting range is 0.001 ~ 9.999. Changing the feedrate Select the desired feedrate between 0 ~ 9 with the numeral keys. The numeral keys are valid anytime except for during JOG feeding. However, after changing the step feeding angle with the key, press the F key before pressing the numeral keys.

3)

7-4. Setting the Second Reference Point

Any desirable position can be defined to the second reference point with the JOG mode. Usually, the second reference point is positioned to the coordinate specified by Parameter 128. However, it is possible to define it with the JOG mode. This function is convenient for a workpiece whose reference points are different for each processing because the second reference point can be changed without changing the parameter. How to set the second reference point 1) Move the rotary table to the desirable position with the JOG mode. W 2) Press the 2ndF and ZRN keys, and WZRN Position set ? is indicated on line 4. 3) To set the position to the second reference point, press the CR key. Not to set the position to the second reference point, press the C key in the procedure 2) above and the indication on line 4 disappears. The set reference point can be memorized in a parameter. Parameter 004: bit 5

7-5. Clearing the current position indication

The current position indication during the JOG mode can be cleared with the C key. Returning to the absolute position from the first reference point can be done with the 2ndF and keys.

III-26

8-7. Alarms The alarms generated in the remote mode + M specifications are shows below: If another alarm not described below occurs, refer to VI. MAINTENANCE. To reset an alarm, press the C key.

1) ALM40~42 SCH Rx PE, FE, OR Each alarm means a parity error, framing error, or overrun error in the above order. If the communication parameter does not match between the NC on the machining center and the communication parameter, these alarms are given. Check the parameters for the baud rate and the transmission code. If these alarms occur, though they do not occur usually, noise influence is suspected. In this case, reduce noise around the installed place. In addition, follow the countermeasure to lower the baud rate or shorten the length of the RS-232C cable being used for connection. 2) ALM43 SCH Rx Full AL45 CMD BF Full

These alarms are given when the receiving buffer full error occurs. They are given when the command and the data length are very long. Check that the program on the machining center side does not include unnecessary digits or wrong descriptions. 3) ALM46 SCH CMD Err

This alarm is given when a command error occurs. If the TPC-Jr receives a command that is not defined, check that the program on the machining center for mistakes. 4) ALM47 SCH DATA Err This alarm is given when an data error occurs. Check that the data description of the program on the machining center side is correct. 5) ALM48 SCH NO Cmd

This alarm is given when an M signal is received though no command is given. Check the program on the machining center.

8-8. Cable Connection 8-8-1. Cable connection To connect an M signal, use the TPC-Jr standard interlocking cable. For details of connection of the M signal, refer to VI MAINTENANCE, 5. CABLE CONNECTION. An RS-232C connection cable is used for remote commands. For details of the cables, refer to 7. EXTERNAL STORAGE OF PROGRAMS, 7-5-2. Interface. Note The length of the RS-232C cable is restricted to 5m or less only for the remote mode + M specifications.

IV-30

8-8-2. Interlocking cable For details of the connection of the interlocking cable, refer to VI. MAINTENANCE, 5. CONNECTION OF CABLES. The interlocking signals usable in the remote mode + M specifications are shown below: Standard interlocking cable Start (AT71) Stop (AT72 An M input signal to give a start to the TPC-Jr. Usually, an emergency stop signal is connected. A completion signal against the M signal.

Positioning completion 1 output (AT85)

Signals available with the extended functions The signals provided with the extended function can also be used in the remote mode + M specifications. However, not all the signals can be used. The usable signals are as follows: Input signal Start (AT71) Stop (AT72) Output signal Positioning completion 1 output signal (AT85) A completion signal against the M signal Level (AT88) Alarm (AT89) 8-9. Notes The RS-232C signal is different from an M signal. It is a small and fast signal. Therefore, if there is any noise around the machine, the remote mode may malfunction. Install a surge killer on the electric control box of the machining center to reduce noise. The longest acceptable length of the RS-232C cable is 5 m. If the above countermeasure against noise does not improve the environment and an alarm is given, using an RS-422, RS-485, or an optical communication cable that receives less influence of noise is recommended. When using one of these cables, use a level converter in market to convert the RS-232C signal for them. Indicates that the rotary table is in positioning. Given if an alarm occurs. An M input signal to give a start to the TPC-Jr. Usually, an emergency stop signal is connected.

IV-31

IV. EXTENDED FUNCTIONS

1. OVERVIEW _________________________________________________________ IV-3 2. EXTERNAL WORK NUMBER SET FUNCTION (AVAILABLE IN THE AUTO MODE)_________ IV-4
2-1. External Work Number Set Function _________________________________________ IV-4 2-2. AUTO Mode Selection at Power On _________________________________________ IV-5 2-3. Automatic Calling of a Work Number and Block Number _________________________ IV-5

3. EXTERNAL RETURN TO A REFERENCE POINT INPUT FUNCTION (AVAILABLE IN THE AUTO MODE) ________________________________________________________ IV-6 4. EXTERNAL STOP INPUT FUNCTIONS ___________________________________ IV-7
4-1. Stop Input Signal ________________________________________________________ IV-7 4-2. Interlock Input signal _____________________________________________________ IV-8

5. MACHINE ORIGINAL POSITION OUTPUT FUNCTIONS _____________________ IV-9 6. MACHINE POSITION CONTROL FUNCTIONS ____________________________ IV-10
6-1. Soft Limit _____________________________________________________________ IV-10 6-2. Overtravel ____________________________________________________________ IV-11

7. EXTERNAL STORAGE OF PROGRAMS_________________________________ IV-12

7-1. Overview _____________________________________________________________ IV-12 7-2. Procedure ____________________________________________________________ IV-12
7-2-1. Reading programs ___________________________________________________________ IV-12 7-2-2. Program output______________________________________________________________ IV-13 7-2-3. Input and output of parameters. _________________________________________________ IV-13

7-3. Alarm ________________________________________________________________ IV-14 7-4. Parameters ___________________________________________________________ IV-15 7-5. Paper Tape I/O Format __________________________________________________ IV-16
7-5-1. Tape Format________________________________________________________________ IV-16 7-5-2. Interface ___________________________________________________________________ IV-18

7-6. Printing TPC-Jr Program Lists _____________________________________________ IV-20

7-6-1. Procedure__________________________________________________________________ IV-20 7-6-2. Parameters_________________________________________________________________ IV-20 7-6-3. Sample lists ________________________________________________________________ IV-20

8. REMOTE MODE + M_________________________________________________ IV-21

8-1. General Description _____________________________________________________ IV-21 8-2. Procedure ____________________________________________________________ IV-21 IV-1

8-3. Command Method ______________________________________________________ IV-21

8-3-1. Sample machining center program ______________________________________________ IV-22 8-3-2. Notes _____________________________________________________________________ IV-22

8-4. Command Format ______________________________________________________ IV-23

8-4-1. Command abbreviation _______________________________________________________ IV-23 8-4-2. Data details ________________________________________________________________ IV-23 8-4-3. Command details ____________________________________________________________ IV-24

8-5. Procedure ____________________________________________________________ IV-27 8-6. Remote Mode Parameter_________________________________________________ IV-28 8-7. Alarms _______________________________________________________________ IV-29 8-8. Cable Connection ______________________________________________________ IV-29
8-8-1. Cable connection ____________________________________________________________ IV-29 8-8-2. Interlocking cable ____________________________________________________________ IV-30

8-9. Notes ________________________________________________________________ IV-30

IV-2

1. OVERVIEW
In addition to the functions described in [II. PROGRAM,] and [III. OPERATION,] various TPC-Jr functions can be used by adding options and setting parameters. 1) External work number set function External work numbers (program numbers) can be set from the external component. 2) External return to a reference point function Return to a reference point is conducted by an external input signal. 3) External stop input signal Stop input Interlock input 4) Machine original position output function When the predetermined range or position is reached during positioning, a signal can be output. 5) Machine position control functions Soft limit function When positioning beyond the predetermined range is commanded, an alarm is output. Overtravel function (Only for rotary tables with overtravel specifications) Limit switches can be installed on the machine to determine a positioning range. 6) External storage to retain programs Programs and parameters can be stored by external components using a general-purpose program input and output devices. The optional RS-232C connection cable is required. 7) Remote mode + M (optional) A machining center can directly send commands using a general-purpose serial channel (CN4). The optional RS-232C connection cable is required.

IV-3

2. External Work Number Set Function (Available in the AUTO mode)

2-1. External Work Number Set Function 1) General description The M signal and the B signal provided as an NC auxiliary function can be used to directly call or change a work number (program number) on the TPC-Jr. When a workpiece is changed, the external work number set function still enables all programs to be managed at the machining center without requiring operation at the TPC-Jr. This function is roughly classified in the two kinds: a) Selecting the maximum 16 kinds of work numbers by using the 4-bit parallel signal (B signal, etc.). b) Selecting the five kinds of work numbers by preparing the maximum five M signals. Please select a method to be used with a parameter beforehand. 2) Operation a) Operation by 4-bit parallel signal Enter the desirable work number with the 4-bit parallel signal (B signal, etc.), and then, give a strobe signal. The TPC-Jr calls the set work number. b) Operation by plural M signals Enter the desirable work number with the 4-bit parallel signal (B signal, etc.), and then, give a strobe signal. The TPC-Jr calls the set work number. The N address when the work number is called will be 000. Either completion signal FIN1 or FIN2 can be issued depending on the parameter. Parameter 023 bit 2 3) Parameter to set the work number Set the work number corresponding to each input signal to Parameter 060 ~ 075 beforehand. a) The work number parameters corresponding to the 4-bit parallel signal (B signal, etc.) are as follows:
Input signal B1
OFF Parameter address to set the desirable work number Standard set value (Reference)

Parameter 020 bit 2

B2
OFF OFF

B4
OFF OFF OFF OFF

B8
OFF OFF OFF OFF OFF OFF OFF OFF

BF

ON
OFF

ON
OFF

ON ON
OFF OFF

ON
OFF

ON
OFF

ON ON
OFF OFF

ON ON ON ON
OFF OFF OFF OFF

ON
OFF

ON
OFF

ON ON
OFF OFF

ON
OFF

ON

ON ON

ON ON ON ON

ON ON ON ON ON ON ON ON

060 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075

0000 0100 0200 0300 0400 0500 0600 0700 0800 0900 1000 1100 1200 1300 1400 1500

IV-4

b) The work number parameters corresponding to the plural M signals are as follows: BF ON
OFF OFF OFF OFF

Input signal B1 B2 B4
OFF OFF OFF OFF OFF OFF

B8
OFF OFF OFF OFF

Parameter address to set the desirable work number

Standard set value (Reference)

ON
OFF OFF OFF

ON
OFF OFF

ON
OFF

ON

060 061 062 063 064

0000 0100 0200 0300 0400

Note For the connections of each signal cable, refer to VI. MAINTENANCE, 5-5. Connection of Interlocking Cable.

2-2. AUTO Mode Selection at Power On 1) General description The TPC-Jr usually selects the CHECK mode when the power is turned on. However, the AUTO mode is selected by the following parameter: 2) Parameter To have the auto mode selected when the power is turned on: Parameter 000: bit 0 To make the auto mode selection at power on. For details, refer to V. PARAMETERS.

2-3. Automatic Calling of a Work Number and Block Number 1) General description A work number and block number set in advance can be called by the following parameters: 2) Parameter The automatic calling of a work number and block number function is enabled by the following parameters. Parameter 000: bit3 Parameter 000: bit4 Parameter 010: Parameter 011: To make the automatic calling of the last work number on. To make the automatic calling of the work number on. To select the work number to be called when the power is on. To select the block number to be called when the power is on.

For details, refer to V. PARAMETERS. 3) Notes When the parameters are not set, W0000 and N000 are called.

IV-5

3. EXTERNAL RETURN TO A REFERENCE POINT INPUT FUNCTION (Available in the AUTO mode)
1) General description Return to the first reference point can be commanded by an external input signal. 2) Operation An M signal in addition to the start signal is prepared for the return to the reference point. Either a pulse signal (The level width must be 10 msec or wider.) or a level signal can be accepted. When the return to the reference point signal is entered, the TPC-Jr begins to return to the first reference point. When return to the reference point is completed, a completion signal is given. Either completion signal FIN1, 2 can be selected. 3) Parameter These functions are enabled by the following parameters: Parameter 020: bit0 Parameter 023: bit4 To make the external return to the reference point function on and to select the description. To select the completion signal for the external return to the reference point. For details, refer to V. PARAMETERS.

IV-6

4. EXTERNAL STOP INPUT FUNCTIONS

Stop or interlocking can be commanded by an external input signal. The stop/interlock signals use the same input signal. Therefore, select the specifications to which the signal is applied with a parameter beforehand.

4-1. Stop Input Signal 1) General description An emergency stop signal is connected. When receiving a stop input signal during positioning, the TPC-Jr immediately stops the rotary table. When this happens, the STOP lamp lights. Either a b contact signal for open command or an a contact signal for close signal can be accepted as a stop input signal. While a stop signal is being entered, the TPC-Jr does not start positioning for any start command. Note The specification to keep the remaining amount during stop can be selected by setting a parameter. At this time, when the stop input signal is turned off and the start signal (M signal) is entered again, the rotary table positions by the remaining amount. In the SINGLE or MDI mode, positioning is done by pressing the ST key. To reset the remaining amount, press the C 2) Operation key.

Positioning Start Stop This start signal is ignored.

3) Parameter The external stop input function is enabled by the following parameters: Parameter 021: bit0 Parameter 021: bit5 To make the external stop input function on and to select the description. To keep the remaining amount at the stop by the external stop signal. For details, refer to V. PARAMETERS.

IV-7

4-2. Interlock Input signal 1) General description When an interlock signal is received during positioning, the TPC-Jr immediately stops. The STOP lamp blinks at this time. Either a b contact signal for open command or an a contact signal for close command can be accepted. While the stop input signal is being entered, The TPC-Jr does not start positioning for any start command. When the interlock signal is turned off, positioning is resumed and the rotary table moves by the remaining amount. 2) Operation

Positioning Start Interlock This start signal is ignored.

3) Parameter The interlock input function is enabled by the following parameter: Parameter 021: bit2 To make the external interlock input on, to select the description. For details, refer to the V. PARAMETER.

IV-8

5. MACHINE ORIGINAL POSITION OUTPUT FUNCTIONS

1) General description When the predetermined range or position is reached during positioning, the machine original position signal is given. The machine original position output signal is assigned to the positioning output signal (LVL). 2) Operation In the following example, the machine original position output range is set between <6090>: Example 1 When the rotary table passes through the machine original position:

Positioning position Machine original position output signal

(FIN4)

60

90

110

When the rotary table is passing through the original position output range, the output signal is on only during passing When the range is small and positioning is quickly done, the signal might not be given.

Example 2 When the rotary table is positioned in the original position range:

Positioning position Machine original position output signal

(FIN4)

80 60

80

90

110

While the rotary table is stopped, the output signal remains on. When positioning is resumed and the rotary table exists from the set range, the output signal is turned off.

3) Parameter The machine original position output function is enabled by the following parameters: Parameter 023: bit1 Parameter 034: Parameter 035: To make the machine original position output function on. Original position output range 1. Original position output range 2.

The output range is between the positions set by Parameter 034 and 035. The reference point is the first reference point (MSRN). Example 1
Parameter N034=350 N035= 10

Example 2

Parameter N034= 10 N035=350

When Parameters N034 and N035 are set at the same value, the machine original output range is a point. IV-9

6. MACHINE POSITION CONTROL FUNCTIONS

6-1. Soft Limit 1) General description When positioning beyond the predetermined range is commanded by a parameter, an alarm is output. 2) Operation During operation in the AUTO, SINGLE, MDI mode One of the following alarm messages is given when an attempt is made to command positioning beyond the soft limit range: ALM50 + SL ALM51 - SL A soft limit is detected when the positive direction movement is commanded. A soft limit is detected when the negative direction movement is commanded. How to reset Clear the alarm with the C key. Correct the program so that it does not enter the soft limit range. During operation in the JOG mode When an attempt is made to feed the rotary table beyond the soft limit with the handle feeding or the jog feeding, one of the following alarm messages is given and the rotary table stops at the soft limit. ALM50 + SL ALM51 - SL A soft limit is detected when the positive direction movement is commanded. A soft limit is detected when the negative direction movement is commanded. How to reset Clear the alarm with the C key. Rotate the rotary table with the JOG mode in the opposite direction of the direction the alarm was given direction to escape from the soft limit. 3) Parameter The soft limit function is enabled by the following parameters. Parameter 101: bit0 Parameter 130: Parameter 131: To make the soft limit function on. Soft limit position in the positive side Soft limit position in the negative side.

For details, refer to V. PARAMETERS.

IV-10

6-2. Overtravel 1) General description The TPC-Jr detects an attempt to move beyond a stroke end with an overtravel limit switch attached to the rotary table. When TPC-Jr detects such an attempt, it issues an alarm and stops positioning. This function is available only when the rotary table is equipped with the overtravel limit switches. 2) Operation Usually, one overtravel limit switch is attached in each direction, positive and negative. The alarm messages when overtravel is detected during operation in the AUTO, SINGLE, MDI, JOG modes are as follows: ALM55 + OT 1 ALM56 - OT 1 your attention. 3) Restoration from overtravel Clear the alarm with the C key. Rotate the rotary table in the opposite direction of the alarm with the JOG mode to escape from the overtravel area. When the overtravel limit switch is off, the alarm is cleared. At the same time, the ALM lamp and the OT indication on the display screen disappear. 4) Parameter The soft limit function is enabled by the following parameters: Parameter 101: bit7 Parameter 150: bit1 To make Overtravel on. To stop overtravel. +over-travel 1 is detected. -over-travel 1 is detected.

While the overtravel is being detected, Line 2 on the display screen indicates OT to draw

For details, refer to V. PARAMETERS. 5) Notes The overtravel function can be used only when limit switches are attached to the inclined rotary table.

IV-11

7. EXTERNAL STORAGE OF PROGRAMS

7-1. Overview Programs and parameters can be entered or given using a general-purpose tape reader or puncher. For connection, use optional RS232C cables. If the baud rate of the Parameter 050 is not set, programs or parameters can not be entered or given. (A general-purpose tape reader/puncher shall be prepared by a user.) 7-2. Procedure The following serial channel display screen appears when the 2ndF pressed. 1. In means reading from a general-purpose tape reader/puncher. 2. Out means writing to a general-purpose tape keys. To exit from the serial channel display screen, press the C 7-2-1. Reading programs 1) When 1. In is selected, the reading display screen appears. When 1. All is selected, all the programs are read. When 2. WNo is selected, the specified work number is read. Select either one with the or key. To exit from the initial display screen press the C key 2) When 1. All is selected (All the programs are read.) Line 2 indicates All input? To start reading all the programs, press the ST key. The ? on line 2 changes to an asterisk * and blinks while the programs are being read. To stop reading the programs, press the SP key. 3) When 2. WNo is selected (The specified work number is read.) Line 2 indicates W0000. Enter the work number to be read with the numeric keys. When the CR key is pressed, W input (a square is a digit.) is indicated. When the ST key is pressed, the specified work number program begins to be read. The ? on line 2 changes to an asterisk * and blinks while the programs are being read. To stop reading the program, press the SP key. 4) Completion Upon completion of reading, the screen returns to the program display screen.

and

keys are

reader/puncher. Select either one with the

or

key.

IV-12

After reading completion, change the mode from the PROG mode to the CHECK or the MDI mode with the or key to save the program.

If the same work number has been in the TPC-Jr when the program is read from the external components, an alarm ALM16 Copy err 2 is indicated. At this time delete the unnecessary program. 7-2-2. Program output 1) When 1. Out is selected, the output display screen appears. When 1. All is selected, all the programs in the TPC-Jr are issued to the external components. When 2. WNo is selected, only the specified work number is issued. Select either one with the or key. key. To exit from the initial display screen in 1), press the C 2) When 1. All is selected (All the programs are issued.) Line 2 indicates All output? To start issuing all the programs, press the ST key. The ? on line 2 changes to an asterisk * and blinks while the programs are being issued. To stop issuing, press the SP key. 3) 2. WNo is selected (the specified work number is issued.) Line 2 indicates W0000. Enter the work number to read with the numeric keys. When the CR key is pressed, W output? (A square means a digit) is displayed. When the ST key is pressed, the specified work number program is issued. The ? on line 2 changes to an asterisk * and blinks while the programs are being issued. To stop issuing the program, press the SP key. 4) Completion Upon completion of issuing, the screen returns to the program display screen. 7-2-3. Input and output of parameters. 1) Make the TPC-Jr parameter changeable status (the program lamp blinks) with the parameter display screen. 2) Press the 2ndF and keys to change the display

to the parameter serial channel display screen. 1. In means parameter input. 2. Out means parameter output. Select either one with the or key. C key. To exit from the parameter display screen, press the IV-13

3) When 1. In is selected (Parameter input) Line 2 indicates Input? To start reading parameters or users parameters, press the ST key. The ? on line 2 changes to an asterisk * and blinks while the programs are being read. Upon completion of reading, the display returns to the parameter display screen. To stop reading the parameters, press the SP key. Note After reading the parameters, it is necessary to initialize the TPC-Jr with a new parameter. Therefore, turn off the power and then, turn it on again. 4) When 2. Out is selected (Parameter output) Line 2 indicates Output? To start output of parameters and users parameters, press the ST key. The ? on line 2 changes to an asterisk * and blinks while the programs are being issued. Upon completion of output, the display returns to the parameter display screen. To stop issuing the parameters, press the SP key. 7-3. Alarm Alarms to be given for input/output of programs or parameters as follows: Message ALM15 Copy err 1 Nature of alarm A work number was specified to write a program but the specified program could not be found. ALM16 Copy err 2 A work number was specified to read a program but the specified work number is present in the TPC-Jr. ALM20 Format err The format of a program being read is invalid. ALM40 SCH Rx PE ALM41 SCH Rx FE ALM42 SCH Rx OR ALM43 SCH Rx FULL Receive parity error Receive framing error Overrun error at reception The receive buffer is full. Check the program/parameter file is valid for the TPC-Jr. Check that the serial channel parameter matches to the external input/output components and solve the problem. Check that the program to be read is correct, and delete the program in the TPC-Jr. Countermeasure Enter a correct work number.

IV-14

7-4. Parameters The parameters regarding serial channels are shown below: The TPC-Jr standard set value is Character length: 7 bits / Parity EVN / Stop bit: 1bit. To change the set value, enter 1 into Parameter 040: bit2 and change Parameter 043. 1) Serial channel baud rate Set the same baud rate as the paper tape reader/puncher to be used. If this parameter is not set, input or output operation of programs or parameters is not possible. The TPC-Jr standard set value is 4800 baud. 2) Feed space output When issuing programs or parameters, a feed space is issued at the first and the last part. Select when using a paper tape. 3) XON/XOFF control on The soft XON/OFF control with a device control code is made effective. Use this function according to the paper tape reader/puncher specifications. Parameter 040: bit 4 4) RAM operation only. The file is not replaced. The received program is stored only in the program edit RAM in the TPC-Jr. The file (nonvolatile store) is not changed. Parameter 042: bit 0 5) RAM is completely deleted and the new programs are registered when all the programs are read. All the contents of the program edit RAM stored in the TPC-Jr are deleted, and the received programs are stored. It is also possible to use this function with a combination of the function in 5) above. Parameter 042: bit1 6) The feedrate data is also issued when all the programs are issued. The feedrate data F1F9, Fmax is issued immediately after program data. Note that feedrate alone cannot be issued. Parameter 042: bit 2 7) FANUC PPR specifications The software XON/XOFF control in 4) above is not available for the FANUC PPR. Therefore, the program/parameter output results in an alarm. To avoid the alarm, insert a waiting time between each block when issuing programs and parameters from the TPC-Jr. Parameter 040: bit 6 Set about 300 msec waiting time. Parameter 051 Parameter 040: bit5 Parameter 050

IV-15

7-5. Paper Tape I/O Format The paper tape I/O format can be used by setting a parameter. The I/O code is ISO code. The program format of the TPC-Jr G series is interchangeable with the programs made with the TPC2, 3 and the TPC-Jr E series. However, the parameter or feedrate data is not interchangeable. For the TPC2 and 3, the interchangeable program is restricted to the data using the decimal system in units of 0.001 for a command unit. 7-5-1. Tape Format 1) Program format

W1234 G0F0R0001Q180
Reader (ignored)

Work number

Beginning of tape

Beginning of a program

Block delimiter

Program

G0F0R0001Q270000 G0F0R0001Q090 %
Program Program Tape end

Block delimiter

Block delimiter

Block delimiter

Beginning of tape Assign this code at the beginning of tape. Use the %. Reader The reader field extends after the beginning of tape % and continues until the first LF is encountered. This field is ignored regardless of the program. This part is dispensable. Beginning of a program The data after the first LF after the beginning of tape (%) is handled as a program. Work number field Set a work number W (a square () is a digit) at the beginning of the program field. A frame between two LFs must be 18 characters long. therefore, 13 SPs (spaces) must be added. Program field A program is input or output with N codes omitted. One block in the TPC-Jr block format is handled as one frame. (18 characters) When F and/or codes are omitted in G4 to G9, add SPs until one frame contains 18 characters. The units of degrees, minutes, and seconds ( ' " ) in the code are omitted. Use the letter Q instead of the letter . Block delimiter Delimit blocks with an LF. IV-16 When a work number is set,

 End of tape Assign this code at the end of tape to indicate the end of the tape. Use the % mark as this code. 2) When two or more programs are coded: To input or output two or more programs, specify a work number W (a square () is a digit.) in the next frame after the end of a program.

% W1234

G0 G70 W2345
Program W1234

G0

G1 W3456
Program W2345

G0 G0 G7 %
Program W3456

3) Feedrate data format Feedrate data can be output after the program field by setting a parameter.

S0F12345R100 S1F54321R100 S2 S9F54321R100 %

Fmax data F1 data F2 data

F9 data

S0 to S9 can be output. S0 is the maximum cutting feedrate. S1 to S9 indicate the feedrates of F1 to F9. When a feedrate is set with a feedrate (F) and a radius (R), a 6-digit feedrate and a 3-digit radius are output. When a feedrate is set in the form of [cmd/sec], a 6-digit feedrate is output after F (a decimal point is omitted). 3) Parameter format Parameter addressed N000 to P199 can be input and output. The 8-digit data for the D field is a parameter data.

% P000D01000010 P001D01000010 P199D10000010 %

Parameter N000 Parameter N001

Parameter N199

IV-17

7-5-2. Interface CN4 is used for the serial channel interface 1) Connector pin assignment D-sub 9-pin Pin 1 6 2 RxD 7 3 TxD 8 4 DTR 9 5 SG

2) Connection to the external I/O unit (for RS-232C specifications)

Connection cable (9-pin 25-pin cable) FG 2 3 5 RxD TxD SG 1 3 2 7 4 5 20 6 8 TPC-Jr CN4 side FG RD SD SG RS CS ER DR CD TPC-Jr CN4 side 2 3 5 Connection cable (9-pin 9-pin cable) FG RxD TxD SG 2 3 5 7 8 4 6 1 FG RD SD SG RS CS ER DR CD

D-Sub 9 pin (Socket type)

D-Sub 25 pin (Pin type)

D-Sub 9 pin (Socket type)

D-Sub 9 pin (Socket type)

There are two kinds of optional connection cables, one is 9-pin 25-pin and the other is 9-pin 9-pin. The 9-pin 25-pin cable is designed so that it can be directly connected to the D-sub 25-pin socket on an external I/O unit to be connected. The 9-pin 9-pin cable is designed so that it is connected to a personal computer, etc. When fabricating these cables, refer to the above drawings. Note that the total length of the cables does not exceed 5 m to conform to the RS-232C interface standard. Note When the external I/O unit is unnecessary, remove the RS-232C cable. If they are connected, noise will influence the operation and malfunctions may be caused.

IV-18

3) Transmission modes The specifications of applicable transmission modes are as follows Synchronous transmission Start bits Data length Stop bits Codes Transmission rate Start-stop transmission 1 bit 8 bits (Including the parity bit) 2 bits ISO code or EIA code
(Whether to enable or disable control code DC1~DC4 can be determined by a parameter.)

50~9600 bps
(The standard transmission rate is 4800bps.)

4) Control codes XON/XOFF control is possible with a control code by setting a parameter. DC1 DC2 DC3 DC4 Tape reader start Tape punch selection Tape reader stop Tape punch deselection (11H) (12H) (13H) (14H)

5) When the TPC-Jr sends data to an external I/O unit: (XON/XOFF control is enabled.)
On the TPC-Jr side Within 10 characters

DC2

DC4

TxD
DC3 DC1

RxD
6) When TPC-Jr receives data from an external I/O unit: (XON/XOFF control is enabled.)

On the TPC-Jr side

DC3

DC3 (DC2)

DC1 (DC4)

TxD RxD
It is not important whether DC2 and DC4 are present
Within 10 characters

7) Transmission time Standard time of program transmission is calculated by the following equation: Program transmission time (sec) Number of program blocks 256 baud rate [When XON/XOFF control is enabled, the program transmission time is prolonged by the transmission relay time.] Example When 1000 blocks are transferred at 4800 baud, the program transmission time is approximately 54s.

IV-19

7-6. Printing TPC-Jr Program Lists TPC-Jr program lists can be printed on a commercially available printer. For connection with the printer, use an RC-232C serial channel interface for CN4. Note The printer to be connected must have an RS-232C interface. 7-6-1. Procedure The procedure for printing a list is the same as that for parameter output. 7-6-2. Parameters To print a list on a printer, set 1 in parameter 040bit1. The baud rate in Parameter 050 must be the same as that set in the printer. When 1 is set in Parameter 042: bit2, the feedrate data is also given when all the programs are issued. 7-6-3. Sample lists 1) Program list TPC-Jr PROGRAM LIST PAGE 1 2) Feedrate data list TPC-Jr F1 F2 F3 F4 F5 F6 F7 F8 F9 FEED DATA LIST

PROGRAM NO. W0000 N000 GO F0 R004 A+090.000 N001 G1 F0 R999 A+009999div N002 G2 F0 R007 A-090.000 N003 G3 F0 R010 A+000.000 N004 G4 R000 N005 G5 R001 A1000 N006 G6 N007 G7 A000 N008 G8 A+000.000 N009 G9 R000

Fmax F05000mm/min R100mm F05000mm/min R100mm F02000mm/min R100mm F01000mm/min R100mm F00500mm/min R100mm F00200mm/min R100mm F00100mm/min R100mm F00050mm/min R100mm F00020mm/min R100mm F00010mm/min R100mm

3) Parameter data list TPC-Jr PARAMETER LIST PAGE 1 P002 D00000000 P006 D00000000 P010 D00000000 P014 D00000001 P018 D00000000 P022 D00000000 P026 D00000000 P029 D00000000 P003 D00000000 P007 D00000000 P011 D00000000 P015 D00000010 P019 D00000000 P023 D00000000 P027 D00000000 P030 D00000050

P000 D00000000 P004 D00000000 P008 D00000000 P012 D00000050 P016 D00000100 P020 D00000000 P024 D00000000 P028 D00000000

P001 D00000000 P005 D00000000 P009 D00000000 P013 D00000001 P017 D00000005 P021 D00000000 P025 D00000000 P028 D00000000

IV-20

8. REMOTE MODE + M
8-1. General Description The TPC-Jr remote mode + M specification is to realize more flexible control using R-232C serial communication. The TPC-Jr can be directly controlled by the machining center. Therefore, the processing programs that have been controlled separately by the machining center and the TPC-Jr can be controlled by the machining center only. 8-2. Procedure The commanded angle or other data is sent to the TPC-Jr using a RS-232C port on the machining center for input and output of NC program. An M signal is used as a start signal as usual. The diagram below shows the connection image.

TPC-Jr

CN4 CN2 FIN

command M signal

RS-232C M signal

Procedure 1) The angle data to move is sent using a DPRNT text to the TPC-Jr from the RS-232C port of the machining center. 2) An M signal is sent to the TPC-Jr. 3) The TPC-Jr positions according to the angle data to move sent in 1) and sends a completion signal to the machining center. Notes The RS-232C signal is different from an M signal. It is a small and fast signal. Therefore, if there is any noise around the machine, the remote mode may malfunction. Install a surge killer on the electric control box of the machining center to reduce noise. The longest acceptable length of the RS-232C cable is 5 m. Necessary environment An RS-232C connection cable is required. For details of a cable, refer to, 7. EXTERNAL STORAGE OF PROGRAMS, 7-5-2. Interface. It is also required that the NC of the machining center is provided with an RS-232C connector and the custom macro B option (for the FANUC machine). For details, please consult a machining center manufacturer. 8-3. Command Method The machining center sends the angle data to move using a DPRINT text as an RS-232C signal. For positioning start of the TPC-Jr, an M signal is used as usual. IV-21

8-3-1. Sample machining center program

POPEN G00 X100. Y200. DPRNT[/MOVA90.]; M70; G01 Z100. F200.; DPRNT[/MOVA180.]; M70; G01 Z100. F200.; RS-232C port opens. M/C operates +90 degrees absolute positioning command is sent to the TPC-Jr TPC-Jr begins positioning M/C operates +180 degrees absolute positioning command is sent to the TPC-Jr TPC-Jr begins positioning M/C operates

PCLOS; M02;

RS-232C port closes. The program ends.

Explanation for the POPEN text, DPRNT text, and PCLOS text For FANUC For details, refer to the instruction manuals for each NC. POPEN text This is a command to make the RS-232C port effective. Command before the DRRNT text. DPRNT text Letters described in [ ] are issued from the RS-232C port. Write the angle data to move the TPC-Jr here. PCLOS text This is the command to close the RS-232C port. Use the POPEN text and the PCLOS text in a pair. It is not necessary to write a POPEN text and a PCLOS text every time a DPRNT is used. Usually, it is efficient fully to write a POPEN text at the top of the program and at the end of the program. 8-3-2. Notes A DPRNT text buffer works even when an M code is contained in the text with some NC specifications. Usually, the DPRNT text is not used in such a way, however, if commands continue to be given for test purpose, enter axis operation or a dwell between the commands. Bad sample
DPRNT[/MOVA90.]; M70; DPRNT[/MOVA180.]; M70;

Before this M70 is executed, DPRNT [/MOVA180.]; is read, and /MOVA180. is sent at the same time the /MOVA90 is sent.

Correction
DPRNT[/MOVA90.]; M70; G00 X100.; DPRNT[/MOVA180.]; M70;

Enter other axiss movement, and DPRNT[/MOVA180.]; is not read before M70. A dwell data is also efficient.

IV-22

A new command sent while the TPC-Jr is in movement started by an M signal (during positioning) is ignored. M70 is used as an M signal to start the TPC-Jr in the sample. Actually, make a program using an applicable M signal to be used for NC.

8-4. Command Format The communication format sent by a DPRNT text to the TPC-Jr consists of a command filed and a data field. DPRNT text sample DPRNT[/MOVA+123.456]; Command field The usable commands are shown below
Command
Abbreviation

Data field

Date field (note)

Description

/MOVA /MOVI /DIV /MZRN /WZRN /TZRN /SET /FEED

/A or /B /I or /N /D /Z /W /T /S /F

XXX.XXX XXX.XXX XXXXXX (Not provided) (Not provided) (Not provided) XXX.XXX 09 or XXXXXX.

Absolute positioning command Incremental positioning command 360 degrees indexing command Return to the first reference point command Return to the second reference point command Return to the third reference point command Absolute coordinate setting command Feedrate command

8-4-1. Command abbreviation Usually, the command field is expressed in 3 ~ 4 letters like /MOVA, however, only one-letter commands can be used. Select either method with a parameter. Parameter 041: bit2 Be sure to enter / preceding the command letters. Sample) /MOVA+90. /A+90. or /B+90. is also accepted. 8-4-2. Data details 1) Angle data /MOVAXXX.XXX (/MOVI or /SET is the same.) The data field can be abbreviated as follows. However, the decimal point is indispensable. +360.000 -12.800 +0.150 +1.5 +360. -12.8 +.15 1.5

When the sign is +, it can be omitted.

IV-23

2) Indexing point number data /DIVXXXXXX Command in up to 6 digits. The sign + can also be omitted as for the angle data. The decimal point is not necessary. 3) Feedrate data /FEEDX or /FEEDXXXXXX. There are two methods to command the feedrate, one-digit mode that commands the feedrate in one digit and multi-digit mode using six digits. When the one-digit mode is selected, the feedrate stored in the TPC-Jr is used. To command a desirable feedrate, select the multi mode. At this time, use numeric data consisting of 2 ~ 6 digits. The unit for the feedrate is [deg/min]. The two modes are distinguished by the digits number for the data field. To clarify the command more, enter a decimal point to the data end. 8-4-3. Command details 1) MOV command This is a positioning command. The /MOVA command is an absolute command and the /MOVI command is an incremental command. Sample NC program
POPEN; DPRNT[/MOVA+90.]; M70; G00 X100.; M/C operates. DPRNT[/MOVI+45.]; M70; G00 X200.; M/C operates. M70; G00 X300.; M/C operates. DPRNT[/MOVA+270.]; M70; G00 X400.; M/C operates M70; PCLOS;
0

270 180

90

When the MOV command is commanded beforehand, the same positioning can be repeated by an M signal. [, above] However, when the absolute command is used, the rotary table is positioned to the same point [, above]

IV-24

2) DIV command This is a command to divide a circle. Enter the indexing point number for 360 degrees into the data field. The indexing point number should be 2~6 digits. Sample NC program
POPEN; DPRNT[/DIV+4]; M70; G00 X100.; M/C operates. M70; G00 X200.; M/C operates. M70; G00 X300.; M/C operates. M70; PCLOS;
180 270 90 0

When the commanded indexing point number generates a fraction (such as 7 equal divisions or 11 equal divisions), positioning is conducted not to gather the fraction in one area. If another command like MOV is entered during indexing positioning, the calculation for equal division is cleared. 3) ZRN command This is a command to return to a reference point. /MZRN means the first reference point, /WZRN means the second, and /TZRN means the third. These ZRN commands do not require a data field. To begin returning to the reference point, an M signal is required as the MOV command is required. Sample NC program
POPEN; DPRNT[/MZRN]; M70; Return to the first reference point is started. PCLOS;

The second and the third reference points are determined in the TPC-Jr parameter mode. For details, refer to V. PARAMETERS. 4) SET command This is a command to change the standard point of the absolute coordinate ( 0 degree point). Enter the angle from the first reference point. For this command, an M signal is not required. Sample NC program
POPEN; DPRNT[/SET+270.]; DPRNT[/MOVA+90.]; M70; PCLOS;
180 SET 90 0

IV-25

5) FEED command This is a command for feedrate. There are two modes depending on the data field digit number. FEED 1-digit mode Ten kinds of feedrate can be commanded by entering 0~9 into the first digit of the data field. 0 means a fast feedrate. 1~9 commands the feedrate predetermined by the TPC-Jr. (Feedrate for the set value of 1~9 is determined in the PROGRAM mode. For details, refer to III. OPERATION, 5-10 Setting Feedrate.) FEED multi-mode Any desirable feedrate can be commanded by entering a 6-digit number into the data field. The unit for the feedrate is [deg/min]. The two modes are distinguished by the digit number entered into the data field. To clarify the command mode more with [deg/min], enter a decimal point to the last digit of the field. If the feedrate exceeding the fast feedrate is commanded, actual feedrate is restricted to the fast feedrate. The fast feedrate (F0) is automatically selected after the TPC-Jrs power is turned on provided that no feedrate command is given. When the FEED command is given, the feedrate commanded by the FEED command does not change before the next FEED command is given. For the FEED command, the relative order to an MOV command is not important provided that the FEED command is given before an M signal. Sample NC program
POPEN; DPRNT[/MOVI+10.]; M70; Moves by 10 degrees with F0 feedrate. G00 X100.; M/C operates. M70; Moves by 10 degrees with F0 feedrate. G00 X200.; M/C operates. DPRNT[/FEED5]; M70; Moves by 10 degrees with F5 feedrate. G00 X300.; M/C operates DPRNT[/MOVI+20.]; M70; Moves by 20 degrees with F5 feedrate. G00 X400.; M/C operates. DPRNT[/FEED1000.]; DPRNT[/MOVA+30.]; M70; Moves by 30 degrees with 1000 [deg/min]. PCLOS;

Notes The FEED command can not be written in the same line of an MOV command or other commands in the same DPRNT text. Use a single DPRNT text.
Wrong Right DPRNT[/MOVI+10. /FEED1000.]; DPRNT[/MOVI+10.]; DPRNT[/FEED1000.];

IV-26

8-5. Procedure Select the AUTO mode to use the remote mode +M specification. When the power is turned on, the AUTO mode is automatically selected. The display screen (initial indication) for the remote mode +M specification is shown at right. Line 1 indicates Remote and the following No Cmd shows no command has been received. Line 2 shows the feedrate. The default is F0 fast feedrate. 1) When a command is received, the display becomes as in the figure at right. This example shows that /MOVA+180.000 was received. 2) When a FEED command is received, the feedrate description (data section) is indicated. For a 1-digit mode, either F0 ~ F9 is indicated. In the F multi-mode, the specified feedrate [deg/min] is indicated as in Fxxxxxx. (x means a numeral.) When the power is turned on, F0 (fast feedrate) is selected. 3) The ZRN command disappears when the applicable movement is completed, However, the MOVA, MOVI, or DIV command does not disappear before the next command is given. If the received command contains a mistake, the received text is indicated as much as possible. 4) Key operations for switching the current set value/remaining amount, etc. are possible as in the AUTO, or SINGLE mode

IV-27

8-6. Remote Mode Parameter The parameters relative to the remote mode + M specifications is as follows. For setting, refer to V. PARAMETERS. Parameter 041:bit0 [REM] To use the remote mode, enter 1 into this parameter. Parameter 041:bit1 [M] To use an M signal as a start signal for the remote mode, enter 1 into this parameter. (Be sure to enter 1.) Parameter 041:bit2 [ELL] To use an abbreviated commands (See 8-4-1.), enter 1 into this parameter. Parameter 041:bit3 [FXD] If the NC specifications do not allow use of a decimal number in the data, set this parameter to 1. Fixed data input example (The decimal data is eliminated.) +360 360000 -128 +015 Parameter 050 -12800 +150 [BPS] This is for serial channel baud rate. Set the baud rate according to the baud rate of the NC. (Usually, it is used at about 4800bps.) Parameter 043 This is for serial channel transmission parameter. Set according to the NC specifications. To make Parameter 043 effective, it is necessary to enter 1 into Parameter 040:bit2. When the NC is a product of FANUC, this parameter (043) is not required to be changed, by using the parameter like below: Sample setting of the NC on the machining center side. (For FANUC Series 16) The example below shows when the RS-232C port is used by the I/O channel 0. For details, contact an NC manufacturer. Parameter address 0000 Parameter address 0101 Parameter address 0101 Parameter address 0101 Parameter address 0102 Parameter address 0103 Notes The letter code to be used for the TPC-Jr remote mode + M specifications is ISO (ASCII) code only. The EIA code can not be used. ISO SB2 ASI NFD 1Data input/output code = ISO 0Stop bit = 1bit 0Data input code = ISO/EIA 0Feed space (Not for output)

(automatically distinguished) Specification number of the I/O component = 0RS232-C Baud rate = 4800

IV-28

8-7. Alarms The alarms generated in the remote mode + M specifications are shows below: If another alarm not described below occurs, refer to VI. MAINTENANCE. To reset an alarm, press the C key.

1) ALM40~42 SCH Rx PE, FE, OR Each alarm means a parity error, framing error, or overrun error in the above order. If the communication parameter does not match between the NC on the machining center and the communication parameter, these alarms are given. Check the parameters for the baud rate and the transmission code. If these alarms occur, though they do not occur usually, noise influence is suspected. In this case, reduce noise around the installed place. In addition, follow the countermeasure to lower the baud rate or shorten the length of the RS-232C cable being used for connection. 2) ALM43 SCH Rx Full AL45 CMD BF Full

These alarms are given when the receiving buffer full error occurs. They are given when the command and the data length are very long. Check that the program on the machining center side does not include unnecessary digits or wrong descriptions. 3) ALM46 SCH CMD Err

This alarm is given when a command error occurs. If the TPC-Jr receives a command that is not defined, check that the program on the machining center for mistakes. 4) ALM47 SCH DATA Err This alarm is given when an data error occurs. Check that the data description of the program on the machining center side is correct. 5) ALM48 SCH NO Cmd

This alarm is given when an M signal is received though no command is given. Check the program on the machining center.

8-8. Cable Connection 8-8-1. Cable connection To connect an M signal, use the TPC-Jr standard interlocking cable. For details of connection of the M signal, refer to VI MAINTENANCE, 5. CABLE CONNECTION. An RS-232C connection cable is used for remote commands. For details of the cables, refer to 7. EXTERNAL STORAGE OF PROGRAMS, 7-5-2. Interface. Note The length of the RS-232C cable is restricted to 5m or less only for the remote mode + M specifications.

IV-29

8-8-2. Interlocking cable For details of the connection of the interlocking cable, refer to VI. MAINTENANCE, 5. CONNECTION OF CABLES. The interlocking signals usable in the remote mode + M specifications are shown below: Standard interlocking cable Start (AT71) Stop (AT72 An M input signal to give a start to the TPC-Jr. Usually, an emergency stop signal is connected. A completion signal against the M signal.

Positioning completion 1 output (AT85)

Signals available with the extended functions The signals provided with the extended function can also be used in the remote mode + M specifications. However, not all the signals can be used. The usable signals are as follows: Input signal Start (AT71) Stop (AT72) Output signal Positioning completion 1 output signal (AT85) A completion signal against the M signal Level (AT88) Alarm (AT89) Indicates that the rotary table is in positioning. Given if an alarm occurs. An M input signal to give a start to the TPC-Jr. Usually, an emergency stop signal is connected.

8-9. Notes The RS-232C signal is different from an M signal. It is a small and fast signal. Therefore, if there is any noise around the machine, the remote mode may malfunction. Install a surge killer on the electric control box of the machining center to reduce noise. The longest acceptable length of the RS-232C cable is 5 m. If the above countermeasure against noise does not improve the environment and an alarm is given, using an RS-422, RS-485, or an optical communication cable that receives less influence of noise is recommended. When using one of these cables, use a level converter in market to convert the RS-232C signal for them.

IV-30

V. PARAMETERS
1. SETTING PARAMETERS _____________________________________________ V-2
1-1. Preparation for Setting Parameters ___________________________________________ V-2 1-2. Parameter Setting Method__________________________________________________ V-2 1-3. Completing Parameter Setting ______________________________________________ V-3

2. PARAMETERS ______________________________________________________ V-3

2-1. Parameter Assignment ____________________________________________________ V-3 2-2. Parameters _____________________________________________________________ V-4 2-3. Details of Parameters _____________________________________________________ V-6 SYSTEM PARAMETERS 000019 __________________________________________ V-7 I/O PARAMETERS 020039 ______________________________________________ V-10 SERIAL CHANNEL PARAMETERS 040059 _________________________________ V-13 STANDARD SERVO PARAMETERS 110149 ________________________________ V-16 SPECIAL SERVO PARAMETERS 150199 __________________________________ V-26 2-4. Converting Units ________________________________________________________ V-32 2-5. Setting Position of 1st Reference Point _______________________________________ V-32

V-1

1. SETTING PARAMETERS
When using the TPC-Jr Controller together with the Rotary Table, it is necessary to set parameters so that the optimum performance and functions of the combined equipment is obtained.

1-1. Preparation for Setting Parameters

To prevent parameters from being modified by mistake, follow the procedure described below before setting parameters. 1) Mode selection Press or key to select the PROG (program) mode. Then press 2ndF and 9 . The display screen changes to show the parameter.

The 1st line shows the parameter mode is currently selected. The N field of the 2nd line shows a parameter address, and the field of the 2nd line shows parameter data.

It is possible to confirm parameters under this condition. When the CR key is pressed to enter a parameter, however, an alarm message of ALM1 PS N is given and parameters cannot be entered. Then, the following operations are required in order to prepare for a parameter to be entered. 2) Preparing for parameters to be entered Select the PROG mode and shift to the parameter display screen. Press the 9 9 9 1 keys sequentially.

Press the CR key. The program mode lamp blinks, and the screen is ready for parameter entry.

1-2. Parameter Setting Method

Enter parameters in the same manner as when entering a program. Press the key. Then, select a parameter address with numeric keys. Press the key. Then, enter parameter data with numeric keys. Press the CR key to store the entered data.

V-2

1-3. Completing Parameter Setting

Upon completion of parameter setting, turn off the power of the TPC-Jr or press the C exit from the parameter screen. There are two types of parameters: online parameters that can be changed without having to turn the power off and offline parameters that can be changed only after the power is turned off once. Those online and offline parameters are respectively specified with the marks of ON and OFF in the detailed description of parameters. key to

2. PARAMETERS
2-1. Parameter Assignment
The TPC-Jr parameters are assigned as shown below. Item System I/O 060075 Serial channel Work number set Standard Special Parameter Address 000009 010019 020029 030039 040049 050059 060075 100109 110149 150159 160199 Parameter Type Bit type Data type Bit type Data type Bit type Data type Data type Bit type Data type Bit type Data type

Servo parameters

1) Bit-type parameters 7 6 5 4 3 2 1 0 Data of 0 to 9 are set for each bit of b0 to b7. Some parameters are set in a simple bit unit. The other parameters are set in a combination of multiple bits. Note Be sure to set 0 in a bit for which usage is not specified clearly. 2) Data-type parameters

Set decimal data in data-type parameters. Note 1 Parameter data are not subject to any special data checking. When a large value is set in some servo parameters, however, an error message of ALM36 SV Data may be given. Note 2 Be sure to set 0 in a bit for which usage is not specified clearly. V-3

2-2. Parameters
Parameter address

Parameter System parameter function selection 1 System parameter function selection 2 System parameter function selection 3 Reserved System parameter function selection 5 Reserved Work number called at power ON Block number called at power ON. Default feeding speed by jog operation Default feeding amount by jog step operation Selection of extended functions Selection of stop/interlock input functions
Selection of a/b contacts for external output signal

Change ON OFF OFF ON ON ON ON ON OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON

Standard value

Factory-set value

000 001 002 003 004 005 010 011 012 013 020 021 022 023 030 031 034 035 036 037 038 039 040 041 042 043 050 051 052 060 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075

Selection of external output signal Pulse width for output signal 1 (FIN1) Pulse width for output signal 2 (FIN2) Original position signal output range 1 Original position signal output range 2 Reserved Reserved Delayed time for reading B signal input Contrast data Selection of serial channel code Selection of serial channel remote mode Selection of serial channel control Selection of serial channel operation Serial channel baud rate Waiting time for using FANUC PPR Reserved Work number for B signal data 0 Work number for B signal data 1 Work number for B signal data 2 Work number for B signal data 3 Work number for B signal data 4 Work number for B signal data 5 Work number for B signal data 6 Work number for B signal data 7 Work number for B signal data 8 Work number for B signal data 9 Work number for B signal data 10 Work number for B signal data 11 Work number for B signal data 12 Work number for B signal data 13 Work number for B signal data 14 Work number for B signal data 15

00000000 00000000 00000000 00000000 00000000 00000000 0 0 1 1 00000000 00000000 00000000 00000000 50 50 0 0 0 0 0 8 00000000 00000000 00000000 00000000 4800 0 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

V-4

Parameter address

Parameter Servo specification selection 1 Servo specification selection 2 Servo specification selection 3 Servo specification selection 4 Servo specification selection 5 Reserved Reserved Position loop gain Speed loop gain Speed loop integral time constant Load inertia ratio Speed bias Speed bias summing width Total reduction ratio Numerator of electronic gear ratio Denominator of electronic gear ratio Multi-turn limit Positioning completion range Over-flow level for positioning deviation counter Maximum motor feedrate Acceleration/deceleration time Reserved Reserved Reserved Backlash compensation amount 2nd reference point 3rd reference point Soft limit in the positive direction Soft limit in the negative direction Over-travelling amount during one-directional positioning Waiting time for clamping Waiting time for unclamping P operation timing P operation torque level Clamping/unclamping completion time-out Reserved Reserved Servo specification selection 6 Servo specification selection 7 Servo specification selection 8

Change OFF OFF OFF OFF OFF ON ON ON ON ON ON OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF

Standard value

Factory-set value

100 101 102 103 104 105 106 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 150 151 152

00000010 00000000 00000000 00000002 00000110 00000000 00000000 60 60 1000 0 0 7 60 1500 16384 59 10 40 3000 200 0 0 0 0 0 0 0 0 -2000 200 100 1000 70 20 0 0 00000000 00000004 00000000

V-5

Parameter address

Parameter 2nd position loop gain 2nd speed loop gain 2nd speed loop integral time constant Feed forward gain Feed forward filter time constant Mode switch operation level: Torque command Mode switch operation level: Speed command Mode switch operation level: Acceleration Mode switch operation level: Deviation pulse Speed feedback compensation Torque command filter Torque limit in forward operation Torque limit in reverse operation Emergency stop torque Operation retaining time at instantaneous power failure Regenerative resistance capacity Notch filter switch Notch filter frequency Reserved Reserved Offset amount for an absolute encoder ABSRN) Offset amount for an absolute encoder ABSPS)

Change ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON ON OFF OFF

Standard value

Factory-set value

160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 200 201

40 40 2000 0 0 200 3000 0 0 100 100 800 800 800 20 0 0 2000 0 0 (auto-set) (auto-set)

2-3. Details of Parameters

For a parameter displayed in a solid field For a parameter displayed in a segmented field bit of b0 to b7. , set a value with a decimal number. , set a value of 0 to 9 for each

Be sure to set 0 for a parameter for which usage is not specified clearly. Parameters marked with (ON) designate online parameters. Parameters marked with (OFF) designate offline parameters. The value of each parameter remains unchanged until the power is turned off. The value in brackets is a related parameter address.

V-6

SYSTEM PARAMETERS 000019

Parameter address

Parameter PWP 7 AUT NOW 6 0: 1: WME 0: 1: WNS 0: 1: BNS 0: 1: NOW PWP 0: 1: 0: 1: BNS 5 WNS 4 WME 3 2 1 AUT 0 bit No.

Related parameters

0 0 0 ON

CHECK mode is selected at power ON. AUTO mode is selected at power ON. Work number call at power OFF is disabled. Work number call at power OFF is enabled. The specified work number (W) is not called at power ON. The specified work number (W) is called at power ON. The specified block number (N) is not called at power ON. The specified block number (N) is called at power ON Work number is automatically displayed. Work number is not automatically displayed. Programs are write-protected. Programs are not write-protected. Standard setting:00000000 [011] [010]

0 0 1 OFF 7 6 5 4 3

CPS 2 1

ABS 0 bit No.

ABS: Command type selection 0: Mixture of absolute type and incremental type 1: Incremental 2: Absolute 3: Short-cut absolute CPS: Feedrate setting 0: Specify radius Rmm) and speed Fmm/min). 1: Specify command unit/second cmd/min). Standard setting: 00000000

V-7

Parameter address

Parameter CLR 7 NCL 6 5 JPC 4 PCN 3 2 NLSC 1 NCL 0 bit No.

Related parameters

0 0 2 OFF

0: The clamp function is enabled. 1: The clamp function is disabled.

NLSC 0: The LS signal is checked when clamping/unclamping. 1: The LS signal is checked only when clamping. 2: The LS signal is not checked either when clamping or unclamping. NLSU 0: The LS signal is checked when unclamping. 1: The LS signal is not checked when unclamping. PCN: P operation change when clamping 0: Auto-switching 2: No switching JPC 1: Switching is possible at any time. 3: Servo-OFF is possible at any time. [135[136
Level setting when P operation/gain is switched.

Gain while stopping in jog mode operation 0: Nothing 1: Follow PCN.

CLR

0: Exciting the clamp solenoid valve when ON-clamping 1: Exciting the clamp solenoid valve when OFF-clamping Standard setting:00000000

0 0 4 ON

MLK 7 6

WPM 5

AZS 4

NAG 3 2 1 0 bit No.

NAG 0: When executing G9R0000, programming goes forward automatically. 1: When executing G9R0000, programming does not go forward automatically. AZS 0: When executing G9R0000, the 2nd reference point is not automatically set. 1: When executing G9R0000, the 2nd reference point is automatically set. WPM 0: When setting the 2nd reference point in jog mode operation by the 2ndF + WZRN keys, parameter 128 is not rewritten. 1: When setting the 2nd reference point in jog mode operation by the 2ndF + WZRN keys, parameter 128 is rewritten. MLK 0: Machine lock operation is possible. 1: Machine lock operation is not possible. Standard setting: 00000000 V-8

Parameter address

Parameter W N O

Related parameters

0 1 0 ON

WNO Work number called at power ON. Setting range: 09999 Standard setting: 0

[000]

0 1 1 ON BNO

O [000] Standard setting: 0

Block number called at power ON. Setting range: 0999

0 1 2 ON

JSPD Default feedrate of jog operation. Set the feedrate for the jog mode. Set the feedrate in the range of F1 ~ F9. Setting range: 19 Standard setting: 1

0 1 3 ON

JSTP Default value of feeding amount in jog step feeding. Set the feeding amount for jog mode. Set the feeding amount in the range of 0 ~ 9.999. The actual set value is the feeding amount x 1000. Setting range: 19999 Standard setting: 1

V-9

I/O PARAMETERS 020039

Parameter address

Parameter EWNS 7 6 5 4 3 2 1 EZRN 0 bit No.

Related parameters

0 2 0 OFF

For details of each function, refer to IV EXTENDED FUNCTIONS.

EZRN: External zero return function 0: OFF 1: ON EWNS: External work number setting function 0: OFF 1: ON 2: ON Binary mode M mode Standard setting: 00000000 0 2 1 OFF EXTP 7 STP 6 SPER 5 4 3 2 IL 1 STP 0 bit No.

[038] [060] ~ [075] [060] ~ [075]

External stopping function 0:OFF 1:ONTo enter b-contact.) 2:ONTo enter a-contact.)

The STP and the IL are exclusive mutually. They can not be on at the same time.

IL

External interlocking function 0:OFF 1:ONTo enter b-contact.) 2:ONTo enter a-contact.)

SPER: Remainder when external stopping function is performed. 0:Not to be preserved. 1:To be preserved. EXTP: External input signal power supply switching 0:Internal power supply 1:External power supply Standard setting: 00000000

V-10

Parameter address

Parameter ALM 7 6 5 4 3 LVL 2 FIN2 1 FIN1 0 bit No.

Related parameters

0 2 2 OFF

Selecting external output signal contact 0: a-contact (Normally open contact) 1: b-contact (Normally closed contact) FIN1 Positioning completion output signal 1 FIN2 Positioning completion output signal 2 LVL Output to indicate that positioning is in progress. ALM Alarm output Standard setting: 00000000 0 2 3 ON ATO 7 G7O G3LV 6 G3O 5 EZO 4 3 WSO ORGO G7O 2 1 0 bit No.

If a normally closed contact is selected when TPC-Jr power supply is OFF, the output is off.

Completion output signal for G7program end) 0: No output 1: FIN1 output 2: FIN2 output

When the ATO is used, the FIN2 output for G70, WJO. RSO, or EZO can not be selected. The machine original position output is made by the LVL fixed output signal.

ORGO : The original position output signal 0: OFF 1: ONFIN4 output) WSO Completion output signal for external work number set 0: FIN1 output 1: FIN1 output 2: FIN2 output EZO G3O Completion output signal for external zero returning 0: FIN1 output 1: FIN1 output 2: FIN2 output Completion output form for G3lead cutting command) 0: Output only before positioning begins. 1: Output only after positioning is completed. 2: Output either before or after positioning

G3LV LVL output form to indicate that positioning for G3 lead cutting command) is in progress. 0: Output 1: No output ATO FIN2 output is used as a AUTO mode selecting signal. 0: Used. 1: Not used. Standard setting: 00000000

V-11

Parameter address

Parameter O O OPS P P S S 1 2

Related parameters

0 3 0 ON 0 3 1 ON

Pulse width for positioning completion output signal OPS1: OPS2: Positioning completion output signal FIN1) Positioning completion output signal FIN2) Standard setting: 50

Setting range: 109999 [msec]

0 3 4 ON 0 3 5 ON

O O

R R

G G

1 2
For details about machine original position signal output, refer to IV EXTENDED FUNCTIONS, Section 5.

ORG1, ORG2: Setting the range of the original position signal output. Example 1 ORG1=350 ORG210 Example 2 ORG1= 10 ORG2350

Set coordinate position based on the 1st reference point. Set the value by a command unit. When the same value is assigned to ORG1 and ORG2, a point is set rather than a range. Setting range: 0360000 [command unit] Standard setting: 0 3 8 ON B D L Y 0

For details about an angle to a value in a command unit, refer to Section 2.4 Converting Units.

BDLY Delayed reading time for entering B signal in unit of [msec] when the external work number set function is in use. Setting range: 0500 [msec] Standard setting: 0 [020]

0 3 9 ON

T
For contrast adjustment, refer to III OPERATIONS, Section 5-15.

CONT A contrast value for the display screen The smaller the value is, the darker the display becomes. The bigger the value is, the brighter the display becomes. Setting range: 015 Standard setting: 8

V-12

SERIAL CHANNEL PARAMETERS 040059

Parameter address

Parameter CTLZ 7 PRN PPR 6 FSP 5 XON 4 3 OTR 2 PRN 1 0 bit No.

Related parameters

0 4 0 ON

Listing function 0: OFF 1: ON [043]

OTR

Changing serial channel transfer parameter 0: OFF 1: ON

XON

Serial channel XON/XOFF control function 0: OFF 1: ON

FSP

When output is on paper tape, feed spaces are output at the beginning and end. 0: No feed spaces. 1: Add feed spaces.

PPR

FANUC PPR special specification 0: OFF 1: For PPR

[051]

CTLZ Ctrl-Z code is output at the end of the serial data. 0: No Ctrl-Z code. 1: Add Ctrl-Z code. Standard setting: 00000000 0 4 1 OFF 7 6 5 RED 4 FXD 3 ELL 2 M 1 REM 0 bit No.
For details of remote mode, refer to IV EXTENDED FUNCTIONS Section 8 Remote Mode + M.

For remote mode operation selection. Note Set the parameters only for remote mode specifications. Normally, this setting is not necessary. REM Remote mode specification 0: OFF 1: ON +M +M specification 0: OFF 1: ON ELL Command abbreviation function 0: OFF 1: ON FXD Fixed data entering function 0: OFF 1: ON RED Data handling after operation 0: Not clear 1: Clear Standard setting: 00000000

V-13

Parameter address

Parameter FED 7 6 5 4 3 2 ACL 1 NOF 0 bit No.

Related parameters

0 4 2 ON

For serial channel control selection. NOF Program file 0: The file is rewritten.Normal operation) 1: The file is only for RAM operation, and is not rewritten. ACL Program entered from the serial channel 0: The contents of edit RAM are not deleted. Normal operation) 1: The contents of edit RAM are completely deleted. FED Feedrate data when All output program is selected. 0: The feedrate data is not output. 1: The feedrate data is also output simultaneously. Standard setting: 00000000 0 4 3 ON 7 STP 6 5 PEN 4 3 CAR 2 1 0 bit No. [040]

For serial channel transfer. Note Normally, there is no need to set these parameters. To set this parameter to on, set 1 to PRM040: OTR. CAR Serial channel character length 10: 7bit PEN 11: 8bit

Serial channel parity 00: No parity 10: Odd number parity 11: Even number parity

STP

Serial channel stop bit length 01: 1bit 10: 1.5bit 11: 2bit Standard setting: 00000000

0 5 0 ON BPS

Serial channel baud rate Setting range: 99600 [bps] Standard setting: 4800

0 5 1 ON

Waiting time for using the FANUC PPR. Setting range: 09999 [msec] Standard setting: 0

V-14

Parameter address

Parameter W S 0

Related parameters

0 6 0 ON

0 7 5 ON WS0 WS15

15

The work number corresponding to the B signal input value when the external work number set function is used. Setting range: 09999 For the standard set value, refer to 2-2. Parameters.

V-15

STANDARD SERVO PARAMETERS 110149

Parameter address

Parameter CTL 7 6 5 4 3 2 1 CCW 0 bit No.

Related parameters

1 0 0 OFF

Pn000

CCW 0: The motor turns for (+) direction in response to a (+) command. 1: The motor turns for (-) direction in response to a (+) command. CTL Control system Be sure to enter 1 for this parameter. Standard setting: 00000010 1 0 1 OFF OT 7 SL 6 5 4 3 2 1 SL 0 bit No. [130][131] [119]

0:Soft limit function is disabled. 1:Soft limit function is enabled.

Note To use the soft limit function, set the PRM119: MTL multi-return limit value to 65535. OT 0: Over-travelling function is disabled. 1: Over-travelling function is enabled. Standard setting: 00000000

1 0 2 OFF 7 ENC 6 5 4 3

ENC 2 1 0 bit No.

Pn002

Motor encoder specification 0: Absolute encoder 1: Incremental encoder Standard setting: 00000000

V-16

Parameter address

Parameter ATUN 7 6 5 4 3 2 1 0 bit No.

Related parameters

1 0 3 OFF

Pn110

ATUNServo gain auto-tuning 0Auto-tuning is performed only at an initial operation. 1Auto-tuning is normally performed. 2Auto-tuning is not performed. Standard setting: 00000002

1 0 4 OFF 7 6 5 4 3

CLCN CLPP 2 1 0 bit No.

Pn200

CLPP: Servo amplifier error counter clearing signal 0: H level 1: First transition edge 2: L level 3: Last transition edge CLCN: Servo deviation counter clearing operation 0: An error pulse is cleared when the servo amplifier is turned off. 1: An error pulse is not cleared when the servo amplifier is turned off. Follow the standard setting to use CLPP and CLCN normally. Standard setting: 00000110

V-17

Parameter address

Parameter K KP P

Related parameters

1 1 0 ON

Pn102

Servo position loop gain. This parameter is to determine the response of a position loop. Normally, when a bigger value is entered, a better response is obtained. However, properties and load condition of the Rotary Table may give a limit to the response. Setting range: 1200 [sec1] Standard setting: 60
Pn100

1 1 1 ON KV

Servo speed loop gain. This parameter is to determine the response of a speed loop. Normally, when a larger value is entered, a better response is obtained. However, when the parameter is set at an unreasonably large value, vibration may occur. Setting range: 12000[Hz] Standard setting: 60
Pn101

1 1 2 ON TI

Servo speed loop integral time constant This parameter relates to a speed loop. Normally, when a smaller value is entered, a better response is obtained. However, when the parameter is set at an unreasonably small value, vibration may occur. Setting range: 1551200[0.01 ms] Standard setting: 1000

V-18

Parameter address

Parameter I IN Loaded inertia ratio The motor shaft conversion inertia at the load side is set in proportion to the servo motor rotor inertia, according to the calculation as follows. Loaded inertia ratio Motor shaft conversion inertia Rotor inertia 100[%] N

Related parameters

1 1 3 ON

Pn103

The table below shows servo motor rotor inertia. MODEL TPC-Jr- G2 G3 Rotor Inertia [kgm x 10 ] 0.331 2.10
2 -4

[gfcms2] 0.338 2.14 Standard setting: 0

Setting range: 010000[]

1 1 4 ON BIS

B Speed bias setting

Pn107

Setting range: 0450 [rpm] Standard setting: 1 1 5 ON BSA B S A 0

Pn108

Speed bias summing width Setting range: 0250 [command unit] Standard setting: 7

Speed bias A bias given to a speed command inside the servo makes it possible to reduce a stationary time for the positioning control. When the bias is set at an unreasonably high value, vibration may occur.

V-19

Parameter address

Parameter T R D R

Related parameters

1 1 6 OFF

Pn107

TRDR Total reduction ratio For setting total reduction ratio of the Rotary Table. Set the parameter in accordance with the total reduction ratio of the Rotary Table in use. Setting range: 36360 Standard setting: R A T A

[119]

60
Pn203

1 1 7 OFF 1 1 8 OFF

RATA Numerator of the electronic gear ratio R A T B

[001]
Pn202

RATB Denominator of the electronic gear ratio The value of RATA and RATB changes subject to the reduction ratio of the Rotary Table and a command unit, as listed in the table below.
Reduction ratio

[001]

RAT

RATB

360 250 16384 240 375 16384 180 500 16384 120 750 16384 90 1000 16384 72 1250 16384 60 1500 16384 45 2000 16384 36 2500 16384 The value shown in the columns which correspond to the reduction ratio 120 and decimal 0.001in the above table is for the standard setting. 1 1 9 OFF MTL M T L

Pn205

Multi-turn limit This parameter is set when driving an infinite shaft as is the case of the Rotary Table. It makes an absolute encoder return to 0, when the Rotary Table turns 360. Set the value which equals to the total reduction ratio (TRDR) minus 1.

[116]

[101] Models that use the soft limit or the overtravel function like those with a tilting-axis, etc. do not use the multi-turn limit. For these cases, set 65535. The mode will be the straight axis mode. Setting range: 065535 Standard setting: 59 V-20

This value is for the total reduction ratio of 60.

Parameter address

Parameter C O I N

Related parameters

1 2 0 ON

Pn500

COIN In-position width of the servo position deviation counter. When the current position is set within the range of the target position COIN (the value specified by this parameter), servo positioning is regarded completed. Setting range: 1250 [command unit] Standard setting: O V R L V

10
Pn505

1 2 1 ON

OVRLV: Overflow detection level of the servo position deviation counter Once the servo position deviation counter exceeds this value, an alarm message of ALM92 SV OF is given. The parameter is in units of x256 command unit. OVRLV Reduction ratio 360 240 180 120 90 72 60 45 36 RATA4MXSPD 60KP256 OVRLV 3

[110][117] [122]

MXSPD = 3000 The calculated value when the KP = 60. However, note that the

10 15 20 30 40 40 40 80 100 Standard setting: 40

value for the reduction ratio 1/72 is calculated with MXSPD = 2500, and the reduction ratio 1/60 is with MXSPD = 2000.

1 2 2 ON

Depending on the Rotary Table to be applied, the standard set value changes. Depending on the specifications or the loading conditions of the Rotary Table, the maximum value may not be reached.

MXSPD: Maximum motor feedrate This is the speed when positioning (F0). It is set by the motor shaft revolution. The setting range may vary depending on types of the TPC-Jr. Setting range: 13000[rpm] Standard setting: 2000

V-21

Parameter address

Parameter L LINT I N T

Related parameters

1 2 3 ON

Linear acceleration/deceleration time The linear acceleration/deceleration time is set. If this value is small, the acceleration and deceleration constant will be large. Setting range: 130000 x 0.1 [rpm/ms] Standard setting: 200

Pn30D Motor rotation acceleration per 1 msec. The standard set value is 20 rpm/1 ms = 3000 rpm/150 ms x 10

1 2 7 ON

BRPLS Backlash compensation amount The compensation amount is set in a command unit. Setting range: 01000 [command unit] Standard setting: 0

1 2 8 1 2 9 ON

W T

Z Z

R R

N N

WZRN The position of the 2nd reference point TZRN The position of the 3rd reference point Respectively for the positions of the 2nd and 3rd reference points. Set their coordinate positions assuming that the 1st reference point is regarded as 0. Set the value by a command unit. Setting range: 0360000 [command unit] Standard setting: 0
For converting an angle to a command unit, refer to Section 2.4 converting Units.

V-22

Parameter address

Parameter P N PSL NSL S S L L

Related parameters

1 3 0 1 3 1 ON

Soft limit in the positive direction Soft limit in the negative direction Set their coordinate positions assuming that the 1st reference point is regarded as 0. Set the value by a command unit. Setting range: 0360000 [command unit] Standard setting: 0

[101]

For converting an angle to a command unit, refer to Section 2.4 converting Units.

1 3 2 ON

MOV1 Over-travelling amount during one-directional positioning. Set the value by a command unit. When the prefixed value code is minus(-), positioning is in the positive direction. When it is plus(+), positioning is in the negative direction. Usually, set about 2. Setting range: 050000 [command unit] Standard setting:
When MOV1 is minus. (+) command When MOV1 is plus.
For converting an angle

-2000

MOV1

(+) command

MOV1

to a command unit, refer to Section 2.4 converting Units.

(-) command (-) command

V-23

Parameter address

Parameter C M P W T

Related parameters

1 3 3 ON

CMPWT: Waiting time for clamping The delayed time after the completion of the servo positioning until the clamping output for the Rotary Table. Set a value of 200[ms] for the Rotary Table of air clamping type, and 50[ms] for that of hydraulic clamping type. Setting range: 010000 [ms] Standard setting: 200
This value may vary depending on the type of Rotary Tables.

1 3 4 ON

UCMWT: Waiting time for unclamping The delayed time after the completion of unclamping the Rotary Table until the start of the servo motor. Set a value of 100[ms] for the Rotary Table of air clamping type, and 250[ms] for that of hydraulic clamping type. Setting range: 010000 [ms] Standard setting: 100
This value may vary depending on the type of Rotary Tables.

1 3 5 ON

T [002]

PCWT: P operation timing The delayed time after the completion of clamping the Rotary Table until the start of P operation. When P operation is automatically executed, this parameter is served for sampling time to monitor the torque. Setting range: 010000 [ms] Standard setting: 1000

1 3 6 ON

L [002]

PLVL P operation torque level After the completion of clamping the Rotary Table, torque is monitored at every PCWT timing. When torque is higher than prefixed, P operation starts automatically. Set the value in proportion to the rated torque which is regarded as 100%. Setting range: 0100[] Standard setting: 70

V-24

Parameter address

Parameter

Related parameters

1 3 7 ON

Clamping/unclamping completion time-out The monitoring time to check the completion of clamping or unclamping the Rotary Table. When a completion signal for clamping/unclamping is not returned, an alarm message of ALM18 CL time out is given. When the value is set as 0, time-out checking is not executed. Setting range: 060[s] Standard setting: 20

V-25

SPECIAL SERVO PARAMETERS 150199

address

Parameter OTDB AODB 7 6 5 4 3 2 1 0 bit No.

Related parameters

1 5 0 OFF

Pn001

AODB The method of stopping at Servo OFF/Servo Alarm 0: Dynamic braking 1: Free operation after a stop by dynamic braking 2: Free operation OTDB The method of stopping at Over-travelling 0: Follow AODB. 1: Torque stopping 2: Free operation after torque stopping Standard setting: 00000000 1 5 1 OFF 7 6 5 4 3 2 SLOP MSW 1 0 bit No.
Pn10B

MSW Mode switch 0: Torque level 2: Acceleration level 4: OFF SLOP Speed loop control 0: PI control 1: IP control Standard setting: 00000004 1 5 2 OFF 7 CZR 6 ZPR 5 4 PIZ 3 CZR 2 1 0 bit No. 1: Speed level 3: Deviation level [165][166] [167][168]

Returning direction to the 1st, 2nd and 3rd reference points. 0: Follow the coordinate positions. 1: Take shorter ways to operate. Returning direction to the 1st, 2nd and 3rd reference points. 0: Normal operation 1: One-directional positioning operation This operation is conducted without executing G9R0008 to enable one-directional positioning.) Returning to the 1st reference point at the position of 0. 0: Returning operation is executed. 1: Returning operation is not executed. Only a completion signal is output. Standard setting: 00000000

PIZ

ZPR

V-26

Parameter address

Parameter K KP2 P 2

Related parameters

1 6 0 ON

Pn106

2nd servo position loop gain The position loop gain at stopping. Setting range: 1200[sec1] Standard setting: 40
Pn104

1 6 1 ON KV2

2nd servo speed loop gain The speed loop gain at stopping. Setting range: 12000[Hz] Standard setting: 40
Pn105

1 6 2 ON TI2

2nd servo speed loop integral time constant The speed loop integral time constant at stopping. Setting range: 1551200[0.01 ms] Standard setting: 2000

Usually, the second loop gain is not used.

1 6 3 ON FFG

Pn109

Feed forward gain The feed forward compensation is given to the position control. This parameter is used to shorten positioning time. If it is set at an unreasonably higher value, oscillation may occur. Setting range: 0100[] Standard setting: 0 F F F
Pn10A

1 6 4 ON FFF

Feed forward filter Set this parameter in order to avoid an unstable operation like over-shooting at acceleration or deceleration, which may occur at feed forward operation. Setting range: 06400[0.01ms] Standard setting: 0

V-27

Parameter address

Parameter M M M M S S S S W W W W T S A E

Related parameters

1 6 5 ON 1 6 6 ON 1 6 7 ON 1 6 8 ON

Pn10C

Pn10D

Pn10E

Pn10F

Mode switch operation level Set the mode switch detection level according to the contents of MSW in the parameter 151 Bit No. 0. When the value exceeds the detection level, the servo speed loop shifts from the PI operation to the P operation. MSWT: Torque command Setting range: 0800[] MSWS: Speed command Setting range: 03000 [rpm] MSWA: Acceleration Setting range: 03000[10r/min/s] Standard setting: MSWE: Deviation pulse Setting range: 010000[Pulse] Standard setting: 0 0 Standard setting: 3000 Standard setting: 200

[151]

1 6 9 ON VFC

Pn111

Speed feedback compensation When the speed feedback compensation is applied, the position loop gain and speed loop gain is apparently raised. If it is set at an unreasonably smaller value, oscillation may occur. Setting range: 1500[] Setting range: 100
Pn401

1 7 0 ON TCF

Torque command filter time constant Set this time constant when twisting resonance occurs in the mechanical parts. If it is set at a higher value, the resonance may disappear. Setting range: 065535[0.01 ms] Standard setting: 100

V-28

Parameter address

Parameter address T T L L M M F R

Related parameters

1 7 1 1 7 2 ON

Pn402 Pn403

TLMF Torque limit in forward rotation TLMR Torque limit in reverse rotation Usually set the maximum value. Setting range: 1800[] Standard setting: 800
Pn406

1 7 3 ON

TLME: Emergency stop torque Emergency stop torque can be set. Enter 1 or 2 in OTDB of the parameter 150, and then the stop is executed at this prefixed torque. Usually set the maximum value. Setting range: 1800[] Standard setting: 800
Pn509

1 7 4 ON

PCFT Operation retaining time at instantaneous power failure At an instantaneous power failure of duration within this prefixed time, the servo main circuit retains its operations. However, if too big load is engaged, an alarm message of ALM68 SV UV is given. Further, in case of an instantaneous power failure lasting 1.5 cycles or more, the system checking function does not work under this prefixed value, and an alarm message of Power down. is given. Setting range: 20100[ms] Standard setting: 20

1 7 5 OFF

Pn600

RDBC: Regenerative resistance capacity Set the value when using a regenerative resistance which is externally installed. Set the value at 0, because it is normal to use a built-in regenerative resistance. Setting range: 0(Value depends on types of the TPC-Jr)[W] Standard setting: 0

V-29

Parameter address

Parameter T L S W

Related parameters

1 7 6 ON

Pn408

TLSW: Notch filter switch Standard setting: 0

1 7 7 ON

Pn409

NTFL Notch filter frequency Set the value when vibration occurs in the mechanical parts. When the value is set in accordance with the vibration frequency, the vibration may be eliminated. Enter 1 in TLSW of parameter 176 when a notch filter is applied. Setting range: 502000[Hz] Standard setting: 2000

V-30

Parameter address

Parameter The offset value of the 1st reference point for an absolute encoder. This value is automatically set when operating the return to the 1st reference point. (Refer to Chapter 2-5.) Do not change this value carelessly even though it can be rewritten. Offset amount for total number of the motor shaft rotation. Setting range: 0MTL Offset amount for one motor shaft rotation Setting range: 065535

Related parameters

2 0 0 OFF 2 0 1 OFF

V-31

2-4. Converting Units

Moving amounts such as soft limits are set in parameters by command units. The method of converting command units is as described below. ABC. DEF ABC. DEF x 1000 (Example) For the case of 12.34 12.34 x 100012340[command unit]

2-5. Setting Position of 1st Reference Point

An absolute encoder is applied to the motor detector of the TPC-Jr. The lithium battery is used as a backup power for the encoder. Follow the procedures as follows to set the position of the 1st reference point. 1) 2) For an absolute encoder, refer to VI MAINTENANCE, 7. Absolute Encoder. Turn on the power for the TPC-Jr. Select the HANDLE mode with the or key. Fix the position of the 1st reference point using a dial gauge. Be sure to fix the position in the positive direction. If the position is fixed in the negative direction, backlash compensation is executed to result in incorrect positioning. Some special cases such as operating the Rotary Table with tilting axis are exceptional.) 3) 4) Select the PROG mode with the or key. keys. Then, conduct the key

Switch to the parameter setting screen with the 2ndF + 9 operations of change 9 9 9 1

CR sequentially to enable parameter

5)

Press the 2ndF and display screen.

M ZRN

keys, and then the

position of the 1st reference point is shown on the

6) 7) 8)

Press the

CR key to store the 1st reference point position.

Turn off the power for the TPC-Jr. Turn on the power again to return to the 1st reference point, and check the position. The 1st reference point position is stored in parameters 200 and 201. Parameter 200 stores the offset amount of [0MTL] for the total number of motor shaft rotation which relates to the 1st reference point. Parameter 201 stores the offset amount of [065535] for one motor shaft rotation. Do not change the values carelessly although it is possible to change or rewrite them in parameter mode operation.

V-32

 If the absolute encoder alarm is given: When the motor is mounted for the first time, or the lithium battery is removed for maintenance, the servo encoder backup alarm ALM75 SV ENC BU is given. When the reduction ratio of a parameter and the multi-turn limit value is changed, *ALM91 SV EC MTL is displayed. If any of these alarms relating to the absolute encoder is given, reset the absolute encoder following the procedure below. For the explanation of the absolute encoder, refer to VI. MAINTENANCE, 7. Absolute Encoder. 1) Turn on the power for the TPC-Jr. ALM75 SV ENC BU or another message is indicated. 2) Clear the alarm with the key. or the key. + keys. Then, conduct sequentially, to enable the 3) Select the program mode with the the key operations of parameter change. 5) Press the 2ndF + keys, and the absolute encoder reset is displayed. 6) Press the CR key to reset the absolute encoder. 7) Turn off the power for the TPC-Jr. 8) Turn on the power again to confirm that the alarm is not indicated. 9) Set the first reference point following the procedure in 2-5. Setting Position of 1st Reference Point. Current position indication when the power is turned on. The current position is indicated in a plus value when the power is turned off and on between the absolute position of 0 ~ 180 degrees. When the power is turned off and on between the absolute position of 180 ~ 360 degrees, the current position is indicated in a minus value. For example, When the power is turned on at +90 degrees, the value +90 is shown. When the power is turned on at +270 degrees, the value -90 is shown. When the power is turned on at -90 degrees, the value -90 is shown. When the power is turned on at -270 degrees, the value +90 is shown. First reference When the multi-turn limit Parameter 119 is set to 65535, the sign before the power is turned off is shown.
The area shown in minus value when the power is turned on. The area shown in plus value

4) Switch the display to the parameter setting display with the 2ndF CR

180

when the power is turned on.

V-33

MEMO

V-34

VI. MAINTENANCE
1. OUTLINE _________________________________________________________________ VI-3 1-1. Outline ________________________________________________________________ VI-3 1-2. Safety Remarks on Maintenance ___________________________________________ VI-3 1-3. Check at Occurrence of a Failure ___________________________________________ VI-4 2. ROUTINE CHECK __________________________________________________________ VI-4 3. ALARMS _________________________________________________________________ VI-5 3-1. Alarm Display __________________________________________________________ VI-5 3-2. Resetting an Alarm ______________________________________________________ VI-5 3-3. Alarm Output Signals_____________________________________________________ VI-5 3-4. Alarms ________________________________________________________________ VI-6 3-5. Details of Alarms ________________________________________________________ VI-9 3-5-1. Program alarms _____________________________________________________ VI-9 3-5-2. Serial Channel Alarm ________________________________________________ VI-12 3-5-3. Stroke End Alarm ___________________________________________________ VI-12 3-5-4. Servo Alarms ______________________________________________________ VI-13 3-5-5. Other Alarms_______________________________________________________ VI-17 4. SELF-DIAGNOSIS (DGN) ___________________________________________________ VI-18 4-1. Checking Input & Output Signals and Servo Status ____________________________ VI-18 4-1-1. Procedure _________________________________________________________ VI-18 4-1-2. Details on Input & Output Signal and Servo Status Check Address List__________ VI-18 4-2. Output Signal Check ____________________________________________________ VI-20 4-2-1. Procedure _________________________________________________________ VI-20 4-2-2. Output signal check addresses ________________________________________ VI-20 4-3. Status Indicated by Lamps _______________________________________________ VI-21 5. CABLE CONNECTION _____________________________________________________ VI-22 5-1. Cable List ____________________________________________________________ VI-22 5-2. Accessory Cables ______________________________________________________ VI-23 5-3. Optional Cables ________________________________________________________ VI-23 5-4. Connector Pin Assignment _______________________________________________ VI-23 5-5. Connecting the Interlocking Cable__________________________________________ VI-24 5-5-1. Connecting the interlocking cable_______________________________________ VI-24 5-5-2. Interlocking signal timing _____________________________________________ VI-26

VI-1

5-5-3. Input signal used with the extended functions _____________________________ VI-27 5-5-4. Output signals used with the extended functions ___________________________ VI-27 5-5-5. External work number set function ______________________________________ VI-29 5-6. Input Signal Equivalent Circuits____________________________________________ VI-30 5-7. Output Signal Equivalent Circuits __________________________________________ VI-31 6. CIRCUIT DIAGRAMS ______________________________________________________ VI-32 6-1. Wiring in the TPC-Jr Control Unit __________________________________________ VI-32 6-2. Table for Wiring in the TPC-Jr Control Unit ___________________________________ VI-33 6-4. Part Layout in TPC-Jr ___________________________________________________ VI-37 6-5. Part List of TPC-Jr ______________________________________________________ VI-37 7. ABSOLUTE ENCODER_____________________________________________________ VI-38 7-1. Absolute Encoder Explanation_____________________________________________ VI-38 7-2. Check _______________________________________________________________ VI-38 7-3. Replacement __________________________________________________________ VI-38 7-4. Setup of the Absolute Encoder and the First Reference Point ____________________ VI-39 7-4-1. Setup of the absolute encoder _________________________________________ VI-39 7-4-2. Setting the first reference point_________________________________________ VI-40 8. MAINTENANCE___________________________________________________________ VI-41 8-1. Opening & Closing the Top Cover of the TPC-Jr _______________________________ VI-41 8-2. Replacing the Main Board Assembly________________________________________ VI-42 8-3. Replacing the Servo Unit_________________________________________________ VI-43

VI-2

1. OUTLINE
1-1. Outline
This chapter explains about the standard check items, the descriptions of the alarms, self-diagnosis (DGN), and the cable connections for the TPC-Jr.

1-2. Safety Remarks on Maintenance Only a technician who has the expertise or a fixer should

WARNING

inspect and maintain this device.

Before opening the upper cover for the TPC-Jr control unit,

WARNING

turn off the breaker on the switchboard, turn off the power for the TPC-Jr, and remove the power connector to prevent an operator from receiving an electrical shock. Never touch inside the TPC-Jr controller.

WARNING

Do NOT open the cover while the power is being supplied. If it is necessary to maintain the device with the power supplied, do NOT touch any parts that do not require adjustment. NEVER touch the internal terminals of the TPC-Jr controller within 5 minutes after the power is turned off. Otherwise, you may receive an electrical chock.

Never touch the movable section of the rotary table while it is

WARNING

under maintenance or adjustment. Otherwise, you will get injured because of unexpected movement of the rotary table.

Do NOT disassemble or modify the TPC-Jr controller.

CAUTION

Malfunctions may be caused.

VI-3

1-3. Check at Occurrence of a Failure

If a failure occurs, check the following items before contacting Tsudakoma so that quick action can be taken: If you notice any abnormality like odor or smoke, immediately turn off the breaker on the switchboard that supplies the power to the TPC-Jr and turn off the power of the TPC-Jr. 1) Symptom Alarm number Operation mode Frequency of failure occurrence Does the failure occur at a certain position of the rotary table? Amount of displacement Value of the current position display Ambient environment (hot, cold, dusty, scattered cutting lubricant, etc.) 2) Contents of the program and parameters 3) Type and the machine number of the TPC-Jr (indicated on the nameplate on the rear of the TPC-Jr) Type and the machine number of the rotary table 4) Power supply voltage Check the single phase 200/220 Vac10% with a tester. Check also that a ground wire is connected correctly. 2. ROUTINE CHECK The TPC-Jr is designed in such a way that adjustment is minimized. To use the TPC-Jr under the best conditions for a long time, however, check the following items: Does the fan rotate properly? (Check everyday.) The fan is in the controller. When the power is turned on, the fan makes noise. Check the sound. Is the TPC-Jr controller clean? (Check periodically.) The TPC-Jr controller is drip-proof but not completely drip-proof. When oil or cutting liquid splashes on it, wipe it up with a cloth as soon as possible. Do not lay the controller directly on the floor. Place it on a base that does not vibrate. It should be placed in a place where dust, machining oil, or cutting liquid does not directly splash on it. Is an abnormal sound heard when the rotary table rotates? (Check daily.) When starting the machine for the first time of the day, do test running at low-speeds with the jog mode. Check that no abnormal noise is heard during test running. (Also see the instruction manual for the rotary table.) The TPC-Jr controller has a sealed structure. Therefore, the case may be hot during operation. This is not abnormal. The power plug attached is for checking the functions. Please replace the plug according to the installation condition when installing the TPC-Jr. Be sure to ground before use.

VI-4

3. ALARMS 3-1. Alarm Display When an alarm condition is detected, an alarm number and a brief message are displayed on line 1 on the display screen. At the same, RDY (ready) on line 1 changes to ALM (alarm) and the ALM lamp on the control unit blinks. Alarm display
Alarm number Alarm message

While an alarm is being displayed, an asterisk (*) blinks.

3-2. Resetting an Alarm

C key. If ALM on line 1 does not disappear, possible causes are as follows:
In addition to the alarm displayed, there is another alarm condition. A servo alarm occurred, which can be reset only by turning off the power supply. An overheat alarm occurred, which cannot be reset until the inside of the control unit cools to a normal temperature. An overtravel alarm occurred, which requires that the rotary table be moved manually. To display an alarm message for these alarms, press the 2ndF and C 3-3. Alarm Output Signals In addition to alarm display, an alarm signal is output at detection of an alarm condition. Either a/b contact can be selected for an alarm output signal by a parameter. Parameter 022: bit 3 keys.

To reset an alarm, press the

VI-5

3-4. Alarms 1) Program alarms Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Alarm message PS N PS G PS F PS R PS Nest error No sub prg Loop over W No error No program Buff full File full Dir full Copy err 1 Copy err 2 CL time out W protected Explanation Program syntax error. The N code is invalid. Program syntax error. The G code is invalid. Program syntax error. The F code is invalid. Program syntax error. The R code is invalid. Program syntax error. Thecode is invalid. An attempt was made to call subprograms nested at nine levels or more. Alternatively, there is no destination to which a subprogram returns. There is no subprogram to be called. An attempt was made to execute 20 blocks or more using G5 to G9. An attempt was made to set a work number jump, or block number, but there is no work or block number to be called. A program is not entered for the specified work number Program edit RAM is full. The program file area is full. The program directory is full. The work number (program) to be copied could not be found. A work number (program) is already present at the copy destination. Timeout occurs in clamping/Unclamping confirmation completion Programs are write-protected.

2) Serial channel alarms Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Message Format err SV Rx PE SV RX FE SV Rx OR SV Rx FULL SV Tx/Rx SV Address SV Data SV Retry SCH Rx PE SCH Rx FE SCH Rx OR SCH Rx FULL SCH CMD Err SCH DATA Err SCH No Cmd Explanation The program entered over the general serial channel is in an invalid format. Parity error during reception at the servo channel Framing error during reception at the servo channel Overrun error during reception at the servo channel The buffer is full during reception at the servo channel. Reception error on the servo side Address error on the servo side Data error on the servo side Re-sending error on the servo side Parity error during reception at the general-purpose serial channel Framing error during reception at the general-purpose channel Overrun error during reception at the general-purpose channel The buffer is full during reception at the general-purpose channel. Command error during reception in the remote mode Data error during reception in the remote mode No command is found in the remote mode.

VI-6

3) Stroke end alarm Alarm number ALM ALM ALM ALM Message + SL - SL + OT 1 - OT 1 Explanation The soft limit in the positive direction was detected. The soft limit in the negative direction was detected. + overtravel 1 is detected. - overtravel 1 is detected.

4) Servo alarm Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Message SV PRM 1 SV MAIN PWR SV PRM 2 SV COMB SV OC SV RWG SV RWG OL SV OV SV UV SV OS SV OL 1 SV OL 2 SV DB SV RC OL SV OH SV ENC BU SV ENC CHSM SV ENC BATT SV ENC ABS SV ENC OS SV ENC OH SV S A/D SV T A/D SV SYS Err SV RELS SV CL A,B SV CL C SV ENC CLR SV ENC COM SV ENC PRM Explanation A servo parameter breakage was detected. A servo main circuit detection error was detected. A servo parameter setting error was detected. A servo combination error was detected. A servo overcurrent was detected. A servo regeneration error was detected. A servo regeneration overload was detected. A servo overvoltage was detected. A servo undervoltage was detected. A servo overspeed was detected. A servo overload was detected. (Instant maximum load) A servo overload was detected. (Continuous maximum load) A servo DB overload was detected. A servo rush resistance overload was detected. A servo heat sink overheat was detected. A servo encoder backup alarm A servo encoder sum check alarm A servo encoder battery alarm A servo encoder absolute alarm Servo encoder over speed was detected. A servo encoder overheat was detected. A/D error in the serve speed command was detected. A/D error in the servo torque command was detected. A servo system error was detected. A servo runaway was detected. A disconnection was detected in the servo encoder Phase A or Phase B. A disconnection was detected in the servo encoder Phase C. A servo encoder clearing error or a multi-return limit setting error was detected. A servo encoder communication error was detected. A servo encoder parameter error was detected. Alarm trace back 0002 0003 0004 0005 0010 0030 0032 0040 0041 0051 0071 0072 0073 0074 007A 0081 0082 0083 0084 0085 0086 00B1 00B2 00BF 00C1 00C6 00C7 00C8 00C9 00CA

VI-7

Servo alarms (continued) Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM Message SV ENC ECBK SV EC MTL SV OF SV FASE SV OL SV RWG WRG SV ABS GET SV No't RDY SV Err Explanation Servo encoder echo back error Servo encoder multi-turn limit value did not match. Servo position deviation was too large. A servo power line had an open phase. Servo overload warning Servo regeneration overload warning Absolute encoder position detection error A servo is not ready. Servo alarms are not checked. Alarm trace back 00CB 00CC 00D0 00F1 0091 0092

Alarm trace back numbers are in the range of DGN020~029. It is indicated when the servo alarm trace back is monitored. 5) Other alarms Alarm number ALM100 ALM101 ALM Message Out Port OC Clamp OC Power down Explanation Short circuit of external output signal Short circuit of clamp output signal Instant power failure was detected.

VI-8

3-5. Details of Alarms 3-5-1. Program alarms 1) ALM1 PS N: Invalid N code This alarm is displayed when an attempt is made to set a parameter address undefined by a parameter or a user parameter, or when an attempt is made to set a parameter when the parameter entering is not allowed. 2) ALM2 PSG: Invalid G code This alarm is displayed when an attempt is made to set nonnumeric data as a G code or execute a nonnumeric G code. 3) ALM3 PS F: Invalid F code This alarm is displayed when an attempt is made to set nonnumeric data as a F code or execute a nonnumeric F code. 4) ALM4 PS R: Invalid R code This alarm is displayed: when an attempt is made to set nonnumeric data as an R code or execute a nonnumeric R code. When an invalid data is entered or executed as an R code according to the command method as shown below:
when an incremental method is being selected as a command method, zero is entered as an R code. when an absolute method is being selected as a command method, other than zero is entered as an R code.

When an attempt is made to set a rotating number requiring a movement amount exceeding the maximum movement amount as a G3 lead cutting command or execute it. For the maximum movement amount to be commanded with a G3 code, refer to II. PROGRAMMING, 2-4. G3: Lead Cutting Command. 5) ALM5 PS invalid code This alarm is displayed when an attempt is made to set nonnumeric data as an code or execute a nonnumeric code. When an invalid data is entered or executed as an code according to the command method as shown below:
when an incremental method is being selected as a command method, zero is entered as a code. when an absolute method is being selected as a command method, data larger than 360 is entered as a code.

6) ALM6 Nest Error This alarm is displayed when an attempt is made to nest subprogram calls (G5) at nine levels or more.
Main program Subprogram Subprogram Subprograms

G0 G5 G7

G0 G5 G6
Nesting level 1

G0 G5 G6
Nesting level 2 3 4 5 6 7 8 9

An alarm is given here.

Alternatively, this alarm occurs when a subprogram is not called but an attempt is made to execute a subprogram return (G6).

VI-9

7) ALM7 No sub prg This alarm is displayed when a subprogram call (G5) is executed but the subprogram to be called can not be found. 8) ALM8 Loop over This alarm is displayed when an attempt is made to automatically execute instructions, G5 to G9, 20 blocks or more. Example N000 G9 R0000 N001 G7 0000 9) ALM9 W No. error This alarm is displayed when the work number to be called is not found when setting a work number jump or a work number. 10) ALM10 No program This alarm is displayed when the program is not yet entered in the specified work number. 11) ALM11 Buff full This alarm is displayed when program edit RAM is full. The maximum block number for the program edit RAM is 1000. Confirm the work numbers and the block numbers in use with the directory screen. 12) ALM12 File full This alarm is displayed when the program file area is full. A file capacity is slightly larger than the program edit RAM. However, if a work number consists of programs using 8 or 15 blocks that generate many fractions of blocks, this alarm occurs. For details, refer to II. PROGRAMMING. 13) ALM13 Dir full This alarm is displayed when the program directory is full. (The maximum number of program directory that stores work numbers is 100.) 14) ALM15 Copy err 1 This alarm is displayed when a program (work number) to be copied can not be found. Alternatively, it is displayed when a specified work number to be output to an external component through a serial channel can not be found. 15) ALM16 Copy err 2 This alarm is displayed when a program (work number) already exists in a copy destination. Alternatively, it is displayed when an attempt is made to read a program from an external component through a serial channel

N000 and N001 prevent an infinite loop from occurring.

VI-10

16) ALM18 CL time out This alarm is displayed when clamping or unclamping does not complete within the specified waiting time. Set the time with Parameter 137. The standard setting is twenty seconds. While waiting for completion of clamping or unclamping, the RUN lamp blinks., If the ALM18 CL time out alarm is displayed, or the RUN lamp blinks for a long time, the clamp unit may have a problem. Check that the air pressure for clamping is normal and that actuating oil is in the air hydraulic unit when the air hydraulic clamping specifications are provided. The air-hydraulic unit sometimes requires bleeding before setup. At this time, bleed it following the procedure below: Reference How to release air from the air-hydraulic unit When the air-hydraulic unit (air and hydraulic pressure converter) is used for clamping of the rotary table, air releasing is sometimes required when setting it. To release air, loosen the air-discharging plug for the air hydraulic unit provided with the rotary table and repeat clamp output on/off alternatively. (Also refer to the instruction manual for the rotary table.) Operate the TPC-Jr as follows: (Clamp output on/off operation) Select the CHECK mode. Display the DGN screen with the 2ndF and Select Output check with the key. Select the N01 with the CR key. Enter 00000010 into the field with the ,

keys.

, and

keys.

Press the ST and SP keys alternatively. The lamp output is turned on and off repeatedly. 17) ALM19 W protected This alarm is displayed when an attempt is made to change a program under write-protection setting. Write-protection is set with Parameter 000: bit 7.

VI-11

3-5-2. Serial Channel Alarm

1) ALM20 Format err This alarm is displayed when a program or a parameter read through a general-purpose serial channel (CN4) is in an invalid format for the TPC-Jr. 2) ALM30~37 SV Rx PE, FE, OR, FULL, Tx/Rx, Address, Data, Retry These alarms are a communication error regarding the servo unit. Usually, these alarms do not occur. ALM36 SV Data is sometimes displayed when an attempt is made to set data exceeding the setting range into Parameter 100 ~ 190. 3) ALM40~42 SCH Rx PE, FE, OR These alarms are displayed when the transmission parameter or the baud rate does not match with an external component which a program or a parameter is read from through a general-purpose channel (CN4). Match the transmission parameter and the baud rate with the external components before use. Set the parameter for them with Parameter 040, 043, 050. 4) ALM43 SCH Rx FULL This alarm is displayed when a program reception buffer temporarily overflows because of delayed TPC-Jr processing during reading a program or a parameter through a general-purpose serial channel (CN4). Use a software flow control (XON/XOFF), or lower baud rate Set the software flow control with Parameter 040: bit 4, and set the baud rate with Parameter 050. 5) ALM46~48 SCH CMD Err, DATA Err, No Cmd These alarms are displayed when the remote mode specification is used. For details, refer to IV. EXTENDED FUNCTIONS 8. REMOTE MODE + M. 3-5-3. Stroke End Alarm 1) ALM50 + SL, ALM51- SL These alarms are displayed when positioning commanded leads to detection of a soft limit. Positioning is not done while the program is in operation. Set the range of the soft limit with Parameter 130, 131. 2) ALM55 + OT 1, ALM56 OT 1 These alarms are displayed when the overtravel limit switch functions during positioning. The rotary table stops. The overtravel alarm is effective only when a (tilting-axis) rotary table is provided with the limit switch for overtravel. How to reset overtravel alarms Clear the alarm with the area.

C key. Turn the rotary table in the reverse direction with the jog mode to escape from the overtravel

VI-12

3-5-4. Servo Alarms When a servo alarm condition occurs, current in the main servo circuit is cut off as soon as possible, stopping the operation. The servo alarms can not be reset with the again. The most frequent servo alarm results from loose connection of connectors. Check that the cannon plugs are securely connected to the rotary table and the TPC-Jr. It is also efficient for preventing a servo alarm to remove the cannon plug once and blow air across it. A workpiece which is too large or interference by a jig to the machine may cause a servo alarm. Remove the workpiece, jig or a rotary joint and check that the rotary table alone operates. 1) ALM60 SV PRM 1 Servo parameter breakage

key. Turn off the power once and then, turn it on

This alarm is sometimes displayed when the power is turned on after the power is turned off while a servo parameter Parameter 100~190 is being written. Enter the parameter again, and turn the power off once, and then, turn it on again. 2) ALM61 SV MAIN PWR Servo main circuit error detection

This alarm is displayed when an error is detected in the servo main circuits. Replacing the servo unit is required. 3) ALM62 SV PRM 2 Servo parameter setting error

This alarm is sometimes displayed when the power is turned on after data out of the setting range is entered to a servo parameter Parameter 100~190. Enter a correct parameter, turn off the power and then, turn it on again. 4) ALM63 SV COMB Servo combination error

This alarm is displayed when the capacity of the servo unit does not match the capacity of the combined servo motor. Check the motor capacity to be combined with the TPC-Jr and use the correct combination. Alternatively, this alarm is displayed when the encoder of the servo motor is defective. 5) ALM64 SV OC Servo overcurrent

This alarm is displayed when overcurrent flowing in the main servo circuit is detected. Check the cables for Phase U, V, and W of the servo motor for short circuits. 6) ALM65 SV RWG Servo regeneration error

This alarm is displayed when an error is detected in the regeneration circuits of the servo unit. Most of this alarm occurs resulting from malfunction of the regeneration resistance because extremely high power voltage (242Vac or higher) is kept supplied. Check the power voltage. Alternatively, this alarm is sometimes displayed when the emergency stop button is repeatedly pressed in a short time, or when the circuits chatter while the emergency stop button is pressed. For this problem, turn off the power once and then, turn it again.

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7) ALM66 SV RWG OL Servo generation overload This alarm is displayed when the regeneration circuits of the servo unit is overloaded. Take countermeasures to reduce frequency of positioning the rotary table, reduce the maximum revolution speed of the motor, or lengthen the acceleration & deceleration constant. 8) ALM67 SV OV Servo overvoltage

This alarm is displayed when an extremely high DC voltage is detected in the main circuits of the servo unit. Check that the power voltage is within the range of 200/220 Vac10% (242 Vac or lower) If extremely high power voltage is kept supplied to the servo unit, the servo unit will be broken. 9) ALM68 SV UV Servo undervoltage

This alarm is displayed when an extremely low DC voltage of the main circuits of the servo unit is detected. Check that the power voltage is within the range of 200/220 Vac10% (180 Vac or higher) 10) ALM69 SV OS This alarm is displayed when an incorrect data is set to the servo parameter Parameter 100~190, and the motor rotates at an extremely abnormal speed. Enter a correct parameter, turn off the power, and then, turn it on again. 11) ALM70 SV OL 1 ALM71 SV OL 2 Servo overload (instant maximum overload) Servo overload (continuous maximum overload)

These alarms are displayed when a servo overload is detected. ALM70 SV OL 1 occurs when an instant maximum overload is detected. It occurs mainly during acceleration or deceleration. For a countermeasure, lengthen the acceleration & deceleration constant Parameter 123, or reduce the maximum revolution speed of the motor Parameter 122. ALM71 SV OL 2 occurs when the rotary table is operated exceeding a certain period of time with a load over the motors rated capacity. As a countermeasure, reduce the maximum revolution speed of the motor Parameter 122. This alarm is also displayed when the rotary table is cool in the morning during a season with low temperatures. As a countermeasure, do test-running at low-speeds with the jog mode. If the rotary table can hardly move and this alarm is displayed, a part of the motor cables (U, V and W) may be disconnected. Check the connectors for looseness, and the cables for disconnection. 12) ALM 72 SV DB Servo DB (Dynamic brake) overload

This alarm is displayed when servo DB overload is detected. This alarm occurs when a workpiece or a jig is large and its inertia exceeds the capacity of the servo DB force. Reduce the frequency of positioning the rotary table, reduce the maximum revolution speed of the motor, or lengthen the acceleration & deceleration constant.

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13) ALM73 SV RC OL Servo rush current limit overload This alarm is displayed when rush current of the servo main circuits is overloaded. This alarm occurs when repeating power on & off, or emergency stop. Turn off the power of the TPC-Jr, wait for a while, and turn the power on again. 14) ALM74 SV OH Servo heat sink overheat

This alarm is displayed when the radiation heat sink of the servo unit overheats. (55 or higher) This alarm occurs when the rotary table is kept operating with a high load. Reduce the frequency of positioning the rotary table, reduce the maximum revolution speed of the motor, or lengthen the acceleration & deceleration constant. Check that the fan in the TPC-Jr is rotating. 15) ALM75 SV ENC BU of the servo motor. This alarm occurs when a cannon plug to detect the motor is removed, or when the voltage of the lithium battery in the rotary table for backup lowers. Check the lithium battery voltage (3.6V) or tighten the cannon plug to detect the motor. This alarm also occurs when the power is turned on & off after the multi-turn limit parameter Parameter 119 is changed. If this alarm occurs, re-setup of the absolute encoder and re-entry of return to the first origin are required. For details of the encoder setup, refer to 7. ABSOLUTE ENCODER. 16) ALM76 SV ENC CHSM Check sum error in the absolute encoder Backup error in the servo absolute encoder

This alarm is displayed when a battery backup error is detected in the absolute value encoder

This alarm is displayed when a check sum error occurs in the absolute encoder. If this alarm occurs, re-setup of the absolute encoder is required. If this alarm frequently occurs, replace the servo motor. For details, refer to 7. ABSOLUTE ENCODER. 17) ALM78 SV ENC ABS Servo absolute encoder alarm

This is an alarm of the absolute encoder of the servo motor. This alarm is displayed when the absolute encoder mis-operates because of external noise. Reduce any influence by noise by checking whether grounding is done, cable route and length. If this alarm occurs when the power is turned on, replace the servo motor. 18) ALM79 SV ENC OS power is turned on. 19) ALM80 SV ENC OH Overheat in servo absolute encoder Overspeed in servo absolute encoder

This alarm is displayed when the servo motor is rotating at 200 [r/min] or faster when the

This alarm is displayed when the temperature of the servo motor rises and the temperature in the absolute encoder becomes high. Reduce the frequency of operation of the rotary table, reduce the maximum revolution speed of the motor, or consider the load conditions.

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20) ALM81 SV S A/D ALM82 SV T A/D

A/D converter error for servo speed command A/D converter error for servo torque command

Usually, these alarms do not occur. 21) ALM84 SV RELS Servo runaway prevention detection

This alarm is displayed when the wiring for the motor encoder or the motor power (Phase U, V, and W) is incorrect and the servo motor runs uncontrollably. 22) ALM85 SV CL A, B ALM86 SV CL C Disconnection detection on the servo closed loop side (Phase A, B) Disconnection detection on the servo closed loop side (Phase C)

These alarms are displayed when feedback is not made because of disconnection of the feedback signal cable (Phase A, B and C) for an optional closed loop specification (MP scale, rotary encoder specifications). 23) ALM87 SV ENC CLR ALM88 SV ENC COM ALM89 SV ENC PRM ALM 90 SV ENC ECBK Absolute encoder clearing error/Multi-return limit setting error Absolute encoder communication error Absolute encoder parameter error Absolute encoder echo back error

These alarms are displayed when wiring for the motor encoder has a mistake. Check the wiring for the encoder. If no mistake is found, the servo unit or the servo motor has a problem. 24) ALM91 SV EC MTL Multi-return limit value error in the absolute encoder

A multi-return limit setting error of the absolute encoder of the servo motor occurs. This alarm is also displayed when the power is turned off & on after the multi-return limit parameter Parameter 119 is changed. If this alarm occurs, re-setup of the absolute encoder is required. For details about re-setup of the encoder, refer to 7. ABSOLUTE ENCODER 25) ALM92 SV OF Counter overflow in servo position deviation

This alarm is displayed when the counter for servo position deviation overflows. Check that the data for deviation counter overflow level parameter Parameter 121 is correct. A workpiece which is too large or interference by a jig to the machine may cause a servo alarm. Remove the workpiece, jig or a rotary joint and check that the rotary table alone operates. When the rotary encoder can normally rotate, reduce the frequency of positioning the rotary table, reduce the maximum revolution speed of the motor, or lengthen the acceleration & deceleration constant. This alarm is also displayed when the rotary table is cool in the morning during a season with low temperatures. For countermeasure, do test-running at low-speeds with the jog mode.

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26) ALM93 SV FASE

Servo power line open phase

This alarm is displayed when one of the servo main circuits power L1, L2, and L3 (R4, S4, T4) is not connected with the power source. Check that the power is correctly connected, and that the voltage between the phases is even. Alternatively, a solenoid switch (KA1) contact has a problem. 27) ALM97 SV ABS GET be detected. Turn the power off once, and then, turn it on again. 28) ALM98 SV Not RDY This alarm is displayed when the servo unit has an alarm or it can not communicate with the servo unit when the power is turned on. Turn the power off once, and then, turn it on again. 29) ALM99 SV Err Servo not ready Position detection error of the absolute encoder

This alarm is displayed when the position of the absolute encoder of the servo motor can not

This alarm is displayed when the servo unit communication is disabled and the alarm description can not be confirmed when a servo alarm is detected. 3-5-5. Other Alarms 1) ALM100 Out Port OC ALM101 Clamp OC Short circuit of external output signal Short circuit of clamp output signal

This alarm is given when the protection circuit for the short circuit of the output signal functions. The external output circuit and the clamp output circuit use the solid state system. The protection circuit is provided to protect these output circuits. Accordingly, if this alarm is given, the external circuit is shut off. This alarm can not be reset with the C key. Turn off the power of the TPC-Jr and turn it on again.

Use 100mA or lower current per external output signal circuit. For details, please refer to 5-7. Output Signal Equivalent Circuits. 2) Power down Instant power failure detection

This alarm is displayed when an instant power failure is detected. Turn off the power and turn it on again to reset the alarm.

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4. SELF-DIAGNOSIS (DGN) The TPC-Jr allows external input & output signals and the servo status to be checked and external output signals to be controlled on or off easily. 4-1. Checking Input & Output Signals and Servo Status Individual input & output signals and their status can be checked in any modes except for the jog mode. 4-1-1. Procedure 1) Press the 2ndF and the keys in the PROG or CHECK mode. The self-diagnosis screen appears. Press the key to select Input check. The screen in 2) below appears. 2) Press the 2ndF and the keys in the AUTO, SINGLE or the MDI mode. The screen at the right appears. The N field indicates a check address, and the field indicates the status of each signal. Select the address to be checked with the N key and the numeric keys. key.

3) To return to the previous program display, press the C

4-1-2. Details on Input & Output Signal and Servo Status Check Address List The details on signals in response to check addresses for the input & output signals and the servo status.
DGN Input checklist
Address

bit 7
External input signal Internal input signal Internal input signal External output signal Control output signal LED output signal B8 Clamp SOL overcurrent LED 2ndF JOG

bit 6
(Emergency stop) B4 External output overcurrent Input power supply change SV-REV MDI

bit 5
Work number set B2 Main circuit power supply SV-FWD PROGRAM

Contents bit 4
B1 Unclamp LS Clamp SOL CHECK

bit 3
Return to reference point Clamp LS ALM SINGLE

bit 2
Stop Servo COIN LEVEL SV-AUTO AUTO

bit 1
Start

bit 0

*Servo alarm Servo ready FIN2 SV-PCON STOP FIN1 SV-ON RUN

For N00 ~ N09, when a signal is on, 1 is displayed. When a signal is off, 0 is displayed. For signals with an asterisk (*), the status is displayed in inverse.

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DGN Input check list (continued)

Address

Contents Servo deviation counter Servo command speed Current servo speed Servo torque command Servo command pulse speed Servo accumulating load Servo regeneration load Servo regeneration resistance consumption power Servo identification inertia ratio Positioning time Servo alarm trace back No. 0 Servo alarm trace back No. 9 Servo motor type Servo motor capacity Servo encoder type Servo special specifications Servo software version Servo type Servo rotating angle 1 Servo rotating angle 2 Servo input port monitor Servo output port monitor Servo command pulse counter Servo feedback pulse counter Servo type main boat software version

The data indicated as Servo Alarm Traceback No. 0 ~ 9 is not an alarm number. The data in the column for the alarm traceback symbol of 3-4. Alarms 3) Servo alarms. Servo alarm traceback No. 0 is the latest alarm. Data 0099 indicates that there is no alarm.

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4-2. Output Signal Check Individual output signals can be turned on and off compulsorily. Output signal check is possible only in the CHECK mode. 4-2-1. Procedure 1) Press the 2ndF and the keys in the PROG or CHECK mode, and the self-diagnosis display screen appears. Press the key to select Output check. 2) Select a signal address to be output with the key and the numeric keys, or with the CR key

Set the signal to output to the code with the key and the

keys

Press the ST key and the specified output signal will be ON or OFF. An asterisk * is indicated on line 2 and blinks. Press the SP key and the output signal return to the former condition and the asterisk * disappears. (N003 All the LED light, LCD indication automatically returns to the former condition five minutes later.) Press the C key to return to the initial display screen in 1).

4-2-2. Output signal check addresses The details of signals according to output signal check addresses are described below. DGN Output Check List
Address

Contents bit External output LED 2ndF bit 6 Input power supply change bit 5 Main circuit power supply bit 4 Clamp SOL bit 3 ALM bit 2 LEVEL SV-AUT O bit 1 FIN2 SV-PCO N bit 0 FIN1 SV-ON

Control SV-REV SV-FWD output All the LEDs are on, whole LCD display

N00 and N01 output signal status will be inverse when 1 is entered. For N02 status, all the LEDs except for [2ndF] LED and the LCD screen light up for five seconds.

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4-3. Status Indicated by Lamps The TPC-Jr has the three indication LEDs on the operation panel. With these LEDs, the operating conditions of the TPC-Jr can be observed. The names and the description of the LEDs are shown below. Status when the LED lamp is blinking. The TPC-Jr is waiting for clamping or unclamping to be completed The TPC-Jr is interlocked by an interlock signal.

LED lamp RUN STOP 2ndF

Status when the LED lamp is on. The rotary table is in operation The TPC-Jr is stopped by a stop input signal or an emergency stop signal. There are second function keys.

1) RUN

[Positioning indication]

When positioning is in progress, the RUN lamp remains on. While the TPC-Jr is waiting for the confirmation of clamp or unclamp of the rotary table, the lamp is blinking. 2) STOP [Stop/Interlock indication]

The STOP lamp lights up when a stop external input signal is given. It blinks while the interlock input signal is being entered. (The stop and the interlock input signals are exclusive of each other.) When the positioning is interrupted with the SP key, this lamp also lights up. Note Set the on/off for the stop and interlock input signals with a parameter. Parameter 021: bit 0, 1 3) 2ndF [Second function on indication] The 2ndF lamp lights up when the 2ndF key is pressed. The second functions (The operations indicated on the lower right of each key.) are effective.

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5. CABLE CONNECTION 5-1. Cable List

TPC-Jr control unit

Power supply cable (Standard 5 m) with 4P plug

Interlocking cable (Standard 5 m) with 2 m-long lead wire

RS232C connecting cable Motor cable (Standard 5 m) (Optional)

Rotary table

General program I/O component To be prepared by the user.

VI-22

5-2. Accessory Cables

Cable name CN No. Part number Remarks

Motor cable Interlocking cable

CN CN2

Code at the end of a part number means a cable length. See the table below (Standard length: 5 m.) The first means the designed order.
Last figure of part number

A m

5-3. Optional Cables Cable name CN No. CN CN Part number Remarks

RS-232C connecting cable RS-232C connecting cable

9 pin25 pin 9 pin9 pin

Code at the end of a part number means a cable length. The first means the designed order.
Last figure of part number

A 1 m

B 2

C 3

D 5

5-4. Connector Pin Assignment

1)

Motor connector (CN3) Pin No. A N L M B C D F G H E J K P R S T Signal name SV PG5V SV PG0V SV +PS SV PS SV +BATT SV BATT FG SV MOTER U SV MOTER V SV MOTER V SV MOTER E +OT LS COM CLAMP LS UNCLAMP LS -OT LS CLAMP SOL

MS3102A20-29S Cable No. PG5V PG0V +PS -PS +BATT -BATT FG U V W E AT23 AT1 AT4 AT5 AT25 AT2 Remarks Servo encoder power supply Servo feedback signal Backup power supply Sealed earth Servo motor power OT optional LS, SOL signal common Clamp LS Unclamp LS OT optional Clamp SOL

2) General-purpose serial channel connector (CN4) D-sub 9 pin (Pin) RxD TxD DTR SG

3) For the interlocking connector (CN2), refer to 5-5. Connecting the Interlocking Cable.

VI-23

5-5. Connecting the Interlocking Cable 5-5-1. Connecting the interlocking cable
To connect the TPC-Jr with the parent machine such as a machining center, use the interlocking cable which is a standard accessory. Make a hole of diameter 21 mm to attach the standard interlocking cable (Electric cable 2 m, with Y shape terminal) to the machining center side. 1) Interlocking cable diagram 1
2m, with Y shape terminal

TPC-Jr side D-sub 15 pin connector

M/C side MYS connector 21(Hole) Dimensions for installing the M/C side NYS connector

2) Sample connection The indispensable signal is one M signal and the completion signal for the M signal. When the emergency stop signal on the machining center can be used, connect the cable as the stop input signal cable. This sample shows when an M70 signal is used as an M signal. To use the stop signal on the TPC-Jr, parameter change is required. Parameter 021 bit 0

Electrical control box of the machining center

AT71 AT72 AT70 AT85 AT84 MX FIN M70 Start Stop Input common M completion signal

Output common

Note 1 When receiving a completion signal through a relay cable, be sure to install a diode to absorb any surges. Use a power supply of 24Vdc or less. 100Vac or 200Vac can not be used. Note 2 Unused signals should be set to off, or insulate the cables by taping.

VI-24

3) Sample connection 2 (When the extended functions are used) An independent M signal is required respectively to use the extended functions like the external return to the reference point or the external work number set functions. Change the parameter of the TPC-JR to enable each function.

Parameter 021

Electrical control box of the machining center

AT71 AT75 AT76 AT91 AT92 AT93 AT73 AT72 AT70 M70 M71 Start
Return to the reference point

B1 B2 B4 B8 BF Stop IInput common FIN 1 LVL ALM

Positioning completion 1 Positioning completion 2

AT85 AT82 AT88 AT89 AT84

FIN 2

Positioning Alarm Output common

Note 1 When receiving a completion signal through a relay cable, be sure to install a diode to absorb any surges. Use a power supply 24Vdc or less. 100Vac or 200Vac can not be used. Note 2 Unused signals should be set to off, or insulate the cables by taping.

A qualified engineer or a fixer should conduct interlocking

CAUTION

work.

VI-25

4) Interlocking cable signal connection D-Sub 15 Pin

Pin No.

Signal name

Cable number

Remarks

12 3 2 5 4 11 10 9 1 14 6 7 13 15 FG

Input common Start Return to the reference point Stop BF B1 B2 B4 B8 Output common Positioning completion 1 Positioning completion 2 Positioning Alarm FG

AT70 AT71 AT75 AT72 AT73 AT76 AT91 AT92 AT93 AT84 AT85 AT82 AT88 AT89 -

Input signal

Output signal

Sealed earth

Note For the usage and details of each signal, refer to V. EXTENDED FUNCTIONS.

5-5-2. Interlocking signal timing

1
Start signal (M signal)

2
Positioning completion

During positioning

TPC motor

Rotary table clamp

Rotary table unclamp

1 A pulse signal (10 msec or longer) can be used as a start signal (M signal). However, use a signal that becomes off when an FIN signal is given to avoid false operation. The broken line in the figure above is a sample of a pulse signal. 2 The positioning completion signal is output as a pulse signal. A pulse width is determined by parameter. The standard width is 50 ms. However, the positioning completion signal is retained by itself until the start signal (M signal) is turned off. Parameter 030 3 To input start signals consecutively, wait at least 50 ms after the positioning completion signal is turned off before inputting the next start signal. Or, shorten the pulse width of the completion signal on the TPC-Jr side. Parameter 030

VI-26

5-5-3. Input signal used with the extended functions The explanations below applies to other than standard input signals. For details, refer to IV. EXTENDED FUNCTIONS. 1) Input signal for return to a reference point Another M signal in addition to an M signal for start is prepared to return to a reference point. When a return to a reference point signal is received, the TPC-Jr begins to return to the first reference point. When the external return to the reference point movement is completed, a completion signal is given. The completion signal is selected from either FIN1 , 2 with a parameter. Parameter 023: bit 4 To use this function, a parameter should be set. Parameter 020: bit 0 For details, refer to IV. EXTENDED FUNCTIONS. 2) Work number set input signal BF, B1, B2, B4, B8 Another M signal in addition to an M signal for start or a B signal is prepared for a work number set signal. Use this signal to select a TPC-Jr program from the machining center. When the work number jump is completed, a completion signal is given. The completion signal is selected from either FIN1, 2 with a parameter. Parameter 023: bit 2 To use this function, a parameter should be set. Parameter 030: bit 3 For details, refer to IV. EXTENDED FUNCTIONS. 4) Stop input signal Usually, an emergency stop signal is connected. When a stop signal is received, the rotary table is immediately stopped. While the stop input signal is being received, the stop lamp lights up. This signal is also used as an interlocking signal. Parameter 21: bit 1 For details, refer to IV. EXTENDED FUNCTIONS. 5-5-4. Output signals used with the extended functions The explanations below apply to other than standard output signals. For details of each signal, refer to IV. EXTENDED FUNCTIONS. 1) Positioning completion 2 output signal Positioning completion output signal 2 can be used when G7 (program end) is executed, return to a reference point by an external component, or work number set is completed. To assign each completion signal to each function, a parameter should be set. Parameter 023 For details, refer to IV. EXTENDED FUNCTIONS. 2) During positioning signal This signal is given during positioning and during the JOG mode. Use this signal as a interlock signal for the machining center. For the output timing during positioning, refer to 5-5-2. Interlocking signal timing. The positioning signal can also be used as an reference point output signal.

Parameter 023: bit 1

VI-27

3) Alarm output signal This signal is given when an alarm is detected. Each output signal can select a contact output or b contact output Parameter 022

VI-28

5-5-5. External work number set function

1) Up to 16 kinds of work numbers (program number) of the TPC-Jr can be called using a B signal (4 bit), an auxiliary function of the NC. Connect the strobe signal of the B signal with the BF input of the TPC-Jr. The work number data can be read with the strobe signal and the work number of the TPC-Jr is read. When the work number is set, a Positioning completion 1 signal is given. The Positioning completion signal can be selected from 1 or 2 by setting a parameter. Parameter 023 bit 2

Electrical control box of the machining center

AT71 AT75 AT76 AT91 AT92 AT93 AT73 AT72 AT70 M70 M71

Start Return to the reference point B1M72 B2M73 B4M74 B8M75 BFM76 Stop
Input common

AT85 AT82 AT88 AT89 AT84

FIN 2 ALM

FIN 1 LVL

Positioning completion 1 Positioning completion 2 Positioning Alarm Output common

The timing to read a B signal after receiving a strobe signal can be adjusted with Parameter 038. The timing for a strobe signal and the completion signal is the same as 5-5-2. Interlocking signal timing.

B11B48 Strobe Reading Timing Parameter: 038 [ms]

2) It is also possible to prepare a maximum of five M signals instead of the B signal, and to call five work numbers related to the M signals respectively.
When the work number is set, a Positioning completion 1 signal is given. The Positioning completion signal can be selected from 1 or 2 by setting a parameter. Parameter 023 bit 2 For details of the external work number set function, refer to IV. EXTENDED FUNCTIONS, 2. External Work Number Set Function.

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5-6. Input Signal Equivalent Circuits

+24V 1 Parameter SW

Detail of input circuit

+5V 2.2K 47K 330 0.22 2.2K 10K

Start Reset Stop

B1 B2

GND

B8
Parameter 021: bit 7 = 1 External power

Input signal common

1 Parameter SW COM

Parameter 021: bit 7 = 0 Internal power

Input circuit specifications Power voltage DC24V Circuit current About 10 mA Input filter About 10 ms

External 24Vdc power supply can be used by setting a parameter. Parameter 021: bit 7 (The diagram above shows the switch positions when the internal power is selected with the standard setting.) Because the input is bi-directional, polarity is not a problem when the external power supply is used. (With the internal power supply, the common side is fixed to -.) Note Install a surge killer in the relay circuit of the machining center to prevent noise.

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5-7. Output Signal Equivalent Circuits

+24V

Positioning completion 1

Positioning completion 2

Alarm Output common

Details of photo MOS relay

CAUTION

Output circuit voltage 24Vdc or less Output circuit current 100mA or less Never apply voltage of 100Vac or 200Vac system. The relay surely breaks.

The photo MOS relay is used for output. All the output signals are common, and the polarity does not matter. Usable photo MOS relay: OMRON G3VM-S5 The protection circuit against a short circuit is provided. If the total current of all the circuits exceeds about 450 mA, the protection circuit functions and the output is shut off. At this time, the alarm ALM100 Out Port OC is displayed. For surge protection, 68V varistors are provided between each output and the common. Note 1 Use the output photo MOS relay within the load of 24Vdc 100mA. Never apply the voltage of a AC100, 200V system. The relay will break. Note 2 Install a surge killer on the relay circuits on the machining center side to reduce noise.

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6. CIRCUIT DIAGRAMS 6-1. Wiring in the TPC-Jr Control Unit

LCD Board

KEY Board

MAIN Board

Servo Unit

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6-2. Table for Wiring in the TPC-Jr Control Unit 1) Main board
Connector No. Signal name Cable No. Connected to Cable size

J1-1 J1-2 J1-3 J1-4 J1-5

Connector No.

RxD TxD DTR SG FG

Signal name

RXD TXD DTR SG Cable No.

CN4-2 CN4-3 CN4-4 CN4-5 FG

Connected to

0.32 2 pairs shield 0.32 2 pairs shield 0.32 2 pairs shield 0.32 2 pairs shield Cable size

J2-1 J2-2
Connector No.

EMERGENCY EMERGENCY
Signal name

EXTA EXTB
Cable No.

J2-2 J2-1
Connected to

VSF 0.752 Red VSF 0.752 Red

Cable size

J3-1 J3-2 J3-3 J3-4 J3-5 J3-6

Connector No.

EMERGENCY 2 EMERGENCY 2 SV POWER ON SV POWER ON FAN FAN

Signal name

EMGA EMGB SVPA SVPB 24V 0V

Cable No.

J3-2 J3-1 KA1-A2 KA1-A1 FAN1+ (G2 Only) FAN1- (G2 Only)
Connected to

VSF 0.752 Red VSF 0.752 Red VSF 0.752 Red VSF 0.752 Red VSF 0.752 Red VSF 0.752 Red
Cable size

J4-1 J4-2 J4-3 J4-4 J45

Connector No.

ACV AC AC9V AC9V PE

Signal name

24A 24B 9A 9B PE
Cable No.

TC1-24V TC10V TC19V TC1-0V PE

Connected to

KIV 0.82 Black KIV 0.82 Black KIV 0.82 Black KIV 0.82 Black KIV1.252 Y/G
Cable size

J5-1 J5-2 J5-3 J5-4 J5-5 J5-6 J5-7 J5-8 J5-9 J5-10 J5-11 J5-12 J5-13 J5-14 J5-15

B8 ZRN START BF STOP FIN1 FIN2 FG B4 B2 B1 IN COM LEVEL OUT COM ALM

AT93 AT75 AT71 AT73 AT72 AT85 AT82 FG AT92 AT91 AT76 AT70 AT88 AT84 AT89

CN2-1 CN2-2 CN2-3 CN2-4 CN2-5 CN2-6 CN2-7 CN2-8 CN2-9 CN2-10 CN2-11 CN2-12 CN2-13 CN2-14 CN2-15

0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield FG 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield

VI-33

Connector No.

Signal name

Cable No.

Connected to

Cable size

J6-1 J6-2 J6-3 J6-4 J6-5 J6-6 J6-7 J6-8

Connector No.

+OT1 COM CLAMP LS UNCLAMP LS -OT1 CLAMP SOL+ EMERGENCY 3 EMERGENCY 3

Signal name

AT23 AT1 AT4 AT5 AT25 AT2 EMGC EMGD

Cable No.

CN3-J CN3-K CN3-P CN3-R CN3-S CN3-T J6-8 J6-7

Connected to

0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield VSF 0.752 Red VSF 0.752 Red
Cable size

J7-1 J7-2 J7-3 J7-4 J7-5

Connector No.

SV +R SV R SV +T SV T SG
Signal name

SV +R SV R SV +T SV T SG
Cable No.

SV CN3-1 SV CN3-2 SV CN3-3 SV CN3-4 SV CN3-14

Connected to

0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield
Cable size

J8-1 J8-2 J8-3 J8-4 J8-5 J8-6 J8-7 J8-8 J8-9 J8-10 J8-11 J8-12 J8-13 J8-14

SV COIN SV 0V SV RDY SV 0V SV ALM SV 0V SV SON SV PCON SV POT SV NOT SV FWD SV REV SV AUTO SV 24V

COIN 0V RDY 0V ALM 0V SON PCON POT NOT FWD REV AUTO 24V

SV CN1-25 SV CN1-26 SV CN1-29 SV CN1-30 SV CN1-31 SV CN1-32 SV CN1-40 SV CN1-41 SV CN1-42 SV CN1-43 SV CN1-44 SV CN1-45 SV CN1-46 SV CN1-47

0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield

VI-34

2) Servo unit
Connector No. Signal name Cable No. Connected to Cable size

SV CN1-25 SV CN1-26 SV CN1-29 SV CN1-30 SV CN1-31 SV CN1-32 SV CN1-40 SV CN1-41 SV CN1-42 SV CN1-43 SV CN1-44 SV CN1-45 SV CN1-46 SV CN1-47 SV-FG

SV COIN SV 0V SV RDY SV 0V SV ALM SV 0V SV SON SV PCON SV POT SV NOT SV FWD SV REV SV AUTO SV 24V FG

COIN 0V RDY 0V ALM 0V SON PCON POT NOT FWD REV AUTO 24V -

J8-1 J8-2 J8-3 J8-4 J8-5 J8-6 J8-7 J8-8 J8-9 J8-10 J8-11 J8-12 J8-13 J8-14 -

0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield 0.22 7 pairs shield FG

Connector No.

Signal name

Cable No.

Connected to

Cable size

SV-CN2-1 SV-CN2-2 SV-CN2-3 SV-CN2-4 SV-CN2-5 SV-CN2-6 SV-FG

Connector No.

SV PG5V SV PG0V SV +BATT SV BATT SV +PS SV PS FG

Signal name

PG5V PG0V +BATT BATT +PS PS Cable No.

CN3-A CN3-N CN3-L CN3-M CN3-B CN3-C CN3-D

Connected to

0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield FG
Cable size

SV CN3-1 SV CN3-2 SV CN3-3 SV CN3-4 SV CN3-14 SV CN3-6 SV CN3-7 SV CN3-FG

SV +R SV R SV +T SV T SG FG

SV +R SV R SV +T SV T SG FG

J7-1 J7-2 J7-3 J7-4 J7-5 SV CN3-7 SV CN3-6 -

0.2 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield FG
2

VI-35

3) Motor cable connector

Connector No. Signal name Cable No. Connected to Cable size

CN3-A CN3-B CN3-C CN3-D CN3-E CN3-F CN3-G CN3-H CN3-J CN3-K CN3-L CN3-M CN3-N CN3-P CN3-R CN3-S CN3-T

SV PG5V SV +PS SV PS FG SV MOTER E SV MOTER U SV MOTER V SV MOTER W +OT1 COM SV +BATT SV BATT SV PG0V CLAMP LS UNCLAMP LS -OT1 CLAMP SOL+

PG5V +PS PS E U V W AT23 AT1 +BATT BATT PG0V AT4 AT5 AT25 AT2

SV-CN2-1 SV-CN2-5 SV-CN2-6 SV-FG SV-T-E SV-T-U SV-T-V SV-T-W J6-1 J6-2 SV-CN2-3 SV-CN2-4 SV-CN2-2 J6-3 J6-4 J6-5 J6-6

0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield KIV1.252 Y/G KIV1.252 BLACK KIV1.252 BLACK KIV1.252 BLACK 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield 0.22 3 pairs shield

VI-36

6-4. Part Layout in TPC-Jr

CN2

CN4

CN3

FAN (G2 Only) AMP TC1

KA1 Z1 MAIN BOARD KEY BOARD QF1

6-5. Part List of TPC-Jr 1) Control unit
No. Part name Model Manufacturer
Quantity

Application

QF1 TC1 Z1 KA1 EV AMP CN1 CN CN3 CN4

Circuit breaker Transformer Line filter Electromagnetic relay Fan Servo unit Cable connector D-sub connector Cannon receptacle D-sub connector Main board Key board

NRLY2100F-10A NRLY2100F-15A
TL30X 210V/230V: 24V/9V 0.9A/0.9A 32VA

IZUMI IZUMI IMAI Electric TOKIN TOKIN OMRON

JAPAN SERVO Yasukawa Electric Yasukawa Electric

G2 G3

LF-210 LF-215 G7L-A-TUB TUDC24B4 SGDM04ADA-Y115 SGDM08ADA-Y115 NYS-14-G XM2A-1501 MS3102A20-29S XM2D-0901 R75185A R75186A

G2 G3

G2 Only G2 G3

DAIWA OMRON AMPHONEL OMRON

Tsudakoma Tsudakoma

2) Servo motor
No. Part name Model Manufacturer Quantity Application

Servo motor Lithium battery

SGMPH-0A1A-TF11 SGMPH-08A1A-TF11 ER17500V/3.6V VI-37

Yasukawa Electric Yasukawa Electric

G2 G3

TOSHIBA

7. ABSOLUTE ENCODER
The motor detector of the TPC-Jr uses an absolute encoder that uses a lithium battery for backup. If this lithium battery for backup has a problem, ALM SV ENC BU (ABS encoder backup error) is given when the power of the TPC-Jr is turned on. The battery is attached inside the motor cover of the rotary table. When the cannon plug for the motor detector is disconnected during maintenance or other purpose, the same alarm is given. At this time setup the absolute encoder following the procedure below: 7-1. Absolute Encoder Explanation The absolute encoder for the motor detector of the TPC-Jr remembers the current position as backup using a lithium battery. This lithium battery is in the rotary table. Accordingly, even if the cable connecting the TPC-Jr and the rotary table is disconnected, the absolute encoder of the motor is backed up by the lithium battery inside the motor cover. The connection diagram for the encoder in the rotary table is shown below:
C A N L M B C Lithium battery Motor cable Motor encoder FG V

7-2. Check As shown in the connection diagram above, the lithium battery is attached to the B pin and the C pins for the cannon plug of the motor cable. Remove the cannon plug on the rotary table side and measure the battery voltage using a tester. When it is 3.2V or more, it is normal. Note Be careful not to make a short circuit with the lead rod of the tester. 7-3. Replacement 1) Remove the motor cover of the rotary table. The lithium battery is attached inside this cover. 2) Remove the red and a black lead wires from the battery and remove the battery. 3) Connect the lead wires from the new lithium battery with solder. Wind vinyl tape onto the connection to avoid making short circuits. 4) After replacing the lithium battery, setup of the absolute encoder and the first reference point is required.

VI-38

 ER17500V/3.6V lithium battery by TOSHIBA is used. Lithium batteries of rating 3.6V by other manufacturer can also be used. Be careful of the life of the battery. The life of the lithium battery being used is 10 years or more. 7-4. Setup of the Absolute Encoder and the First Reference Point After replacing the lithium battery, setup of the absolute encoder and the first reference point is required. The procedure is shown below: 7-4-1. Setup of the absolute encoder 1) Turn on the TPC-Jrs power. Either alarm below is given. ALM SV ENC BU (ABS encoder backup error): Follow the procedure starting 6) below. ALM SV EC MTL (ABS encoder multi-turn limit value does not match): Follow the procedure starting 2) below. 2) Reset the alarm with the C key, and select the program mode with the or

key.

3) Select the parameter setting display screen with the 2ndF and keys, and press the keys: , , , , , , CR to enable parameter change. 4) Re-enter Parameter 119: multi-turn limit value with the CR key. 5) Turn off the power and turn it on again. (ALM SV EC MTL is indicated. Follow 6) below. 6) Reset the alarm with the

key, and select the program mode with the or

key.

7) Select the parameter setting display screen with the 2ndF and keys:

keys, and press the

, CR to enable parameter change.

8) Press the 2ndF and

keys to show the

absolute encoder reset display screen. 9) Press the CR key to reset the absolute encoder.

10) Turn off the power once and then, turn it on again to check that no alarm is given. The setup is completed. After the setup of the absolute encoder, the first reference point is required to be set. For setting the first reference point, refer to 7-4-2. Setting the first reference point. Note If no alarm is indicated, and you want only to reset the absolute encoder, follow the procedure above starting from 6).

VI-39

7-4-2. Setting the first reference point 1) Turn on the TPC-Jr power. 2) Select the JOG mode with the or key, and determine the first reference point using a dial gauge or other tool. Determine the first reference point in the positive area. If it is set in the negative area, backlash compensation is made and the positioning may be inaccurate. (Except for a special case like a tilting-axis rotary table.) 3) Select the PROG mode with the or key. 4) Select the parameter setting display screen with the 2ndF and key, and press the keys: CR to enable parameter change.
M 5) Press the 2ndF and ZRN keys to display the first reference point setting display screen.

6) Press the CR key to memorize the first reference point. 7) Turn off the TPC-Jr power. 8) Turn on the power again, and execute return to the first reference point to check the position.

VI-40

8. MAINTENANCE 8-1. Opening & Closing the Top Cover of the TPC-Jr 1) To prevent receiving an electrical shock, turn off the TPC-Jr power, and remove the power plug for the CN1. 2) Remove the three small set screws on the rear of the TPC-Jr. 3) Remove the two small set screws and the one small set screw on the side of the TPC-Jr. 4) Raise the whole cover to remove it. To attach the cover, follow the procedure of removing in the reverse order.

Position of the small set screws for the control unit cover

Before opening the top cover of the TPC-Jr control unit, turn off

WARNING

the breaker on the switchboard, turn off the TPC-Jr power, and remove the CN1 (power connector).

VI-41

8-2. Replacing the Main Board Assembly If replacing the main board assembly is required because of a malfunction or other reasons, replace it following the procedure below: 1) Note all the parameters and programs. 2) Turn off the TPC-Jrs power to prevent receiving an electrical shock, and remove the power connector for the CN1. 3) Open the top cover referring to Section 9-1. Opening/Closing the TPC-Jr Top Cover. 4) Remove all the connectors (J1~J9) from the main board. 5) Remove the six small screws and remove the main board assembly. 6) Attach the new main board assembly. 7) Connect the connectors removed in 4) above. 8) Attach the top cover referring to Section 9-1. Opening/Closing the TPC-Jr Top Cover. 9) Attach the power connector for the CN1, and turn the power on. 10) Enter the parameters and programs noted in 1) above, turn off the power once, then turn it on again. 11) Check each operation. Replacing the main board is completed. Note When making a note of the parameters, be sure to note the description of Parameter 200, 201. These parameters are for the reference point offset for the absolute encoder.

Positions of small set screws for the main board assembly

Main board Main board assembly connector

Only an engineer or a fixer who has a special knowledge should replace the inner parts.

CAUTION

VI-42

8-3. Replacing the Servo Unit If replacing the servo unit is required because of a malfunction, follow the procedure below: 1) Turn off the TPC-Jrs power to prevent receiving an electrical shock, and remove the CN1 power connector. 2) Open the top cover following the procedure in 9-1. Opening/Closing the Top Cover of the TPC-Jr. 3) Remove the connectors CN1~CN3 connected to the servo unit. 4) Remove the electrical cables from the servo unit terminal block. The servo unit terminal block is a connector type. It can be removed easily. The grounding wire is secured with a small screw. Use a cross-headed tip screwdriver to remove it. 5) Remove the two small screws that fix the servo unit on the rear side of the TPC-Jr, and remove the servo unit. 6) Attach the new servo unit and assemble the parts in the reverse order of disassembling. 7) 8) Turn on the power. Re-enter Parameters 100~199 by pressing the turn it on again. 9) Check each operation. Replacing the servo unit is complete. An absolute encoder alarm may be given in the procedure 7) or 8) above. If the alarm is given, after entering the parameter in the procedure 8), setup the absolute encoder again.

CR key, and turn the power off once, then,

Servo unit Detail of connectors and terminal block

VI-43

Positions of the small set screws for servo unit

Position of the fan for G2

CAUTION

An engineer or a fixer who has a special knowledge should replace the inner parts.

VI-44

 APPENDIX
OPERATION PANEL _______________________________________________ Appendix-2 DISPLAY INDICATION EXAMPLE _____________________________________ Appendix-2 TPC-Jr Operation__________________________________________________ Appendix-3 PROGRAM CODES ________________________________________________ Appendix-5 PARAMETERS ____________________________________________________ Appendix-7 ALARMS________________________________________________________ Appendix-10 DGN ADDRESSES ________________________________________________ Appendix-12

Appendix-1

 OPERATION PANEL

LED indication section

Power breaker

2nd F

RUN

STOP

TPC -Jr
R REM PRM SCH DIR CR
MODE AUTO SINGLE CHECK PROG MDI JOG

LCD

No W DGN 2nd F
M W ZRN ZRN JOG JOG

G PRG USER COPY INS

F POS FEED CLR DEL

I O

ST

SP

C ALM +/MLK

Operation keys

Program edit keys

Operation mode indication LED / Switch

DISPLAY INDICATION EXAMPLE Program indication The program of the TPC-Jr is indicated in two lines. TPC-Jr status / work number indication TPC-Jr status indication Work number indication Sub-program number indication Current position / remaining amount indication Control indication Return to the reference point indication Over-travel indication Machine lock indication File rewriting OT MLK FILE POS/REM

RDY/ALM W S

MZRN/WZRN/TZRN

Appendix-2

 TPC-Jr Operation
Only the initials are shown in the table below for some modes. AAUTO SSINGLE CCHECK PPROGRAM MMDI HJOG Key operation
Function Mode Operation M ZRN

Return to the reference point

S/M S/M A/S/M A/S JOG JOG JOG JOG

: to the first reference point

W ZRN

: to the second reference point

Parameter setting/manual setting are possible.

Operation start Operation stop Machine lock Jog feeding Jog feedrate Jog step feeding Jog step feeding amount

Program 1 begins operation with the ST

key. key: cancel

SP key: stop

ST key: re-start

2ndF +/- keys: machine lock on/off

While the
JOG

or

JOG

key is pressed, the rotary table moves in the

direction of ; or -. Select the desired feedrate from 0 ~ 9 with the numeral keys. A stroke on the
JOG

or

JOG

key conducts step feeding of the

rotary table in the + or - direction. After pressing the keys. key, set the desirable angle with the numeral

Program Edit operation

Function Mode Operation

Second function Work number setting Block number setting (N code) G code setting

C/P C/P PROG

Pressing the 2ndF letters effective.

key makes the right bottom functions in small

Enter 00009999 with the 2ndF and key. (100 kinds)

keys, and execute with the

Press the key and then, enter a 3-digit number to set or call a block number. Press the Press the

key, then enter the G code with the numeric keys.

For details of the G code, refer to PROGRAM CODE.

F code setting

PROG

F key, and then, enter the F code with the numeric keys. F0 means the fast feedrate, and F1~F9 mean cutting feedrate. To enter the feedrate for F1~F9, press the 2ndF and keys.
Press the R key, and then, enter the R code with the numeric keys. To set the repeat number of the R code, use the G code. For detail, refer to PROGRAM CODE. Press the key, and then enter the positioning angle. To enter the

R code setting

PROG

code setting Paragraph/ Save Screen scroll

PROG

decimal point, press the key. By pressing the +/- key, the sign can be changed. To start a new paragraph of the program, press the CR key. In the PROG mode, the program is saved by this operation. While the or down.
JOG

PROG C/P

or

JOG

key is pressed, the program display scrolls up

Appendix-3

 Program Edit operation

Function Mode Operation

1-block insertion 1-block deletion

PROG PROG

To insert one block, press the 2ndF and displayed. Then, press the CR key. To delete one block, press the 2ndF and displayed. Then, press the CR key.

keys. Insert? is keys. Delete? is

Directory indication

C/P

To display the registered work numbers and the specification block numbers, press the 2ndF and keys. The unused memory block number is shown at the end. (To see the next page, press the CR key.) To copy the data in a unit of work number, press the 2ndF and the

Program copy

PROG

keys. Enter the work number to be copied and press the CR key.
Then, enter the work number of the copy destination and press the CR key to execute. To start copying, press the ST key. To delete the data in a unit of work number, press the 2ndF and the

Program deletion

PROG

keys. Enter the work number to be deleted, then, press the CR key. To start deletion, press the ST key.
To store a program or a parameter in the external components, press the 2ndF and the keys. The program I/O components shall be prepared by the customer. To enter the F1~F9 feedrate, press the 2ndF and keys. (In the CHECK mode, only confirmation is possible.) To set various system parameters, press the 2ndF and keys. (In the CHECK mode, only confirmation is possible.) To set the data for various pitch error compensation or spot compensation, press the 2ndF and keys. (In the CHECK mode, only confirmation is possible.)

Serial channel

PROG

Feedrate setting Parameter setting User parameter setting

PROG PROG

PROG

Appendix-4

 Other key operations

Function Mode Operation

Current position indication Remaining amount indication Coordinate indication Program indication

A/S/M A/S/M

To display the current value, press the 2ndF and F keys. To clear the current value, press the C key. To display the remaining amount, press the 2ndF and

keys.

To return to the display screen to the coordinate from the first A/S/M reference point during the current position being indicated, press the 2ndF and A/S/M

keys.

To return to the display screen to the program indication while the current position or the remaining amount is being indicated, press the 2ndF and G keys. To set the second reference point, move to the desired position, press the 2ndF and ZRN keys. WZRN POS SET? is indicated. CR Press the key to memorize the point as the second reference point. To monitor each signal and the servo status, press the 2ndF and keys.
W

Second reference point setting

JOG

Self-diagnosis

A/S/C/ P/M

In the AUTO, SINGLE, or the MDI mode, only monitoring is possible. In the CHECK or PROG mode, output signals can be controlled on/off.

Display contrast adjustment Clear/reset

CHECK

To adjust the contrast of the LCD, press the 2ndF and +/- keys. Adjust the contrast with the +/- key and execute with the CR key. To reset an alarm and each second function, or clear the current value, press the C key.

PROGRAM CODES PROGRAM CODE W code N code G code F code R code code Work number (Program number) Setting range0000~9999 (Up to 100-work numbers can be registered.) Block number Setting range000~999 Operation executing command G0~G4: Operation command G5~G9: Auxiliary command Feedrate selection command F0: Fast feedrate F1~F9: Cutting feedrate Auxiliary command for the G code Movement amount command Commanded angle/indexing point number, etc.

Appendix-5

 G0~G4: Operation command

G code R code code

G0: Direct angular position command G1: Direct indexing point number command G2: Arc-indexing point number command G3: Lead cutting command

Switching ABS/INC 000 : ABS command 001999: INC commands Number of repetition Number of repetition 001999 Indexing point number and number of repetition 001999 Number of rotary table revolutions 000045 (360R) 000: Return to the first reference point 001: Return to the second reference point 002: Return to the third reference point

Angle commanded 000.000360.000 ABS command 000.001999.999 ABS command Indexing point number on a circle (360) 000001999999div Split angle 000.001360.000 Angle commanded 000.000360.000 (The total amount of movement is 360 R +)

G4: Reference point return command

Not required.

G5~G9: Auxiliary command

G code R code code

G5: Subprogram call command G6: Subprogram return command G7: Program end command G8: Declaration command G9: Declaration command

Number of repetitions 000(001)999 Not required Not required Not required 000: 001: 002: 003: 004: 005: 006: 007: 008: 009: 010: 011: 012: 013: No operations Clamp OFF Clamp ON Dwell OFF Dwell ON Indexing group control OFF Indexing group control ON One-directional positioning OFF One-directional positioning ON Completion signal control OFF Completion signal control ON Program display switch Current position reset command Remaining angle display command

Subprogram number 000(001)999 Not required Branch destination 000999 Reference coordinate 000.000360.000 Not required Not required Not required Not required Dwell time 001999 (10ms) Not required Not required Not required Not required Not required Completion signal selection 011 FIN1 FIN2 Not required

Current position display switch command Not required Not required

Appendix-6

 PARAMETERS
Parameter address

Parameter System parameter function selection 1 System parameter function selection 2 System parameter function selection 3 Reserved System parameter function selection 5 Reserved Work number called at power ON Block number called at power ON. Default feeding speed by jog operation Default feeding amount by jog step operation Selection of extended functions Selection of stop/interlock input functions
Selection of a/b contacts for external output signal

Change ON OFF OFF ON ON ON ON ON OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON

Standard value

Factory-set value

000 001 002 003 004 005 010 011 012 013 020 021 022 023 030 031 034 035 036 037 038 039 040 041 042 043 050 051 052 060 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075

00000000 00000000 00000000 00000000 00000000 00000000 0 0 1 1 00000000 00000000 00000000 00000000 50 50 0 0 0 0 0 8 00000000 00000000 00000000 00000000 4800 0 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

Selection of external output signal Pulse width for output signal 1 (FIN1) Pulse width for output signal 2 (FIN2) Original position signal output range 1 Original position signal output range 2 Reserved Reserved Delayed time for reading B signal input Contrast data Selection of serial channel code Selection of serial channel remote mode Selection of serial channel control Selection of serial channel operation Serial channel baud rate Waiting time for using FANUC PPR Reserved Work number for B signal data 0 Work number for B signal data 1 Work number for B signal data 2 Work number for B signal data 3 Work number for B signal data 4 Work number for B signal data 5 Work number for B signal data 6 Work number for B signal data 7 Work number for B signal data 8 Work number for B signal data 9 Work number for B signal data 10 Work number for B signal data 11 Work number for B signal data 12 Work number for B signal data 13 Work number for B signal data 14 Work number for B signal data 15

Appendix-7

Parameter address

Parameter Servo specification selection 1 Servo specification selection 2 Servo specification selection 3 Servo specification selection 4 Servo specification selection 5 Reserved Reserved Position loop gain Speed loop gain Speed loop integral time constant Load inertia ratio Speed bias Speed bias summing width Total reduction ratio Numerator of electronic gear ratio Denominator of electronic gear ratio Multi-turn limit Positioning completion range Over-flow level for positioning deviation counter Maximum motor feedrate Acceleration/deceleration time Reserved Reserved Reserved Backlash compensation amount 2nd reference point 3rd reference point Soft limit in the positive direction Soft limit in the negative direction Over-travelling amount during one-directional positioning Waiting time for clamping Waiting time for unclamping P operation timing P operation torque level Clamping/unclamping completion time-out Reserved Reserved Servo specification selection 6 Servo specification selection 7 Servo specification selection 8

Change OFF OFF OFF OFF OFF ON ON ON ON ON ON OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF

Standard value

Factory-set value

100 101 102 103 104 105 106 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 150 151 152

00000010 00000000 00000000 00000002 00000110 00000000 00000000 60 60 1000 0 0 7 60 1500 16384 59 10 40 3000 200 0 0 0 0 0 0 0 0 -2000 200 100 1000 70 20 0 0 00000000 00000004 00000000

Appendix-8

Parameter address

Parameter 2nd position loop gain 2nd speed loop gain 2nd speed loop integral time constant Feed forward gain Feed forward filter time constant Mode switch operation level: Torque command Mode switch operation level: Speed command Mode switch operation level: Acceleration Mode switch operation level: Deviation pulse Speed feedback compensation Torque command filter Torque limit in forward operation Torque limit in reverse operation Emergency stop torque Operation retaining time at instantaneous power failure Regenerative resistance capacity Notch filter switch Notch filter frequency Reserved Reserved Offset amount for an absolute encoder ABSRN) Offset amount for an absolute encoder ABSPS)

Change ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON ON OFF OFF

Standard value

Factory-set value

160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 200 201

40 40 2000 0 0 200 3000 0 0 100 100 800 800 800 20 0 0 2000 0 0 (auto-set) (auto-set)

Appendix-9

 ALARMS 1) Program alarms Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Alarm message PS N PS G PS F PS R PS Nest error No sub prg Loop over W No error No program Buff full File full Dir full Copy err 1 Copy err 2 CL time out W protected Explanation Program syntax error. The N code is invalid. Program syntax error. The G code is invalid. Program syntax error. The F code is invalid. Program syntax error. The R code is invalid. Program syntax error. Thecode is invalid. An attempt was made to call subprograms nested at nine levels or more. Alternatively, there is no destination to which a subprogram returns. There is no subprogram to be called. An attempt was made to execute 20 blocks or more using G5 to G9. An attempt was made to set a work number jump, or block number, but there is no work or block number to be called. A program is not entered for the specified work number Program edit RAM is full. The program file area is full. The program directory is full. The work number (program) to be copied could not be found. A work number (program) is already present at the copy destination. Timeout occurs in clamping/Unclamping confirmation completion Programs are write-protected.

2) Serial channel alarms Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Message Format err SV Rx PE SV RX FE SV Rx OR SV Rx FULL SV Tx/Rx SV Address SV Data SV Retry SCH Rx PE SCH Rx FE SCH Rx OR SCH Rx FULL SCH CMD Err SCH DATA Err SCH No Cmd Explanation The program entered over the general serial channel is in an invalid format. Parity error during reception at the servo channel Framing error during reception at the servo channel Overrun error during reception at the servo channel The buffer is full during reception at the servo channel. Reception error on the servo side Address error on the servo side Data error on the servo side Re-sending error on the servo side Parity error during reception at the general-purpose serial channel Framing error during reception at the general-purpose channel Overrun error during reception at the general-purpose channel The buffer is full during reception at the general-purpose channel. Command error during reception in the remote mode Data error during reception in the remote mode No command is found in the remote mode.

Appendix-10

3) Stroke end alarm Alarm number ALM ALM ALM ALM Message + SL - SL + OT 1 - OT 1 Explanation The soft limit in the positive direction was detected. The soft limit in the negative direction was detected. + overtravel 1 is detected. - overtravel 1 is detected.

4) Servo alarm Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM ALM Message SV PRM 1 SV MAIN PWR SV PRM 2 SV COMB SV OC SV RWG SV RWG OL SV OV SV UV SV OS SV OL 1 SV OL 2 SV DB SV RC OL SV OH SV ENC BU SV ENC CHSM SV ENC BATT SV ENC ABS SV ENC OS SV ENC OH SV S A/D SV T A/D SV SYS Err SV RELS SV CL A,B SV CL C SV ENC CLR SV ENC COM SV ENC PRM Explanation A servo parameter breakage was detected. A servo main circuit detection error was detected. A servo parameter setting error was detected. A servo combination error was detected. A servo overcurrent was detected. A servo regeneration error was detected. A servo regeneration overload was detected. A servo overvoltage was detected. A servo undervoltage was detected. A servo overspeed was detected. A servo overload was detected. (Instant maximum load) A servo overload was detected. (Continuous maximum load) A servo DB overload was detected. A servo rush resistance overload was detected. A servo heat sink overheat was detected. A servo encoder backup alarm A servo encoder sum check alarm A servo encoder battery alarm A servo encoder absolute alarm Servo encoder over speed was detected. A servo encoder overheat was detected. A/D error in the serve speed command was detected. A/D error in the servo torque command was detected. A servo system error was detected. A servo runaway was detected. A disconnection was detected in the servo encoder Phase A or Phase B. A disconnection was detected in the servo encoder Phase C. A servo encoder clearing error or a multi-return limit setting error was detected. A servo encoder communication error was detected. A servo encoder parameter error was detected. Alarm trace back 0002 0003 0004 0005 0010 0030 0032 0040 0041 0051 0071 0072 0073 0074 007A 0081 0082 0083 0084 0085 0086 00B1 00B2 00BF 00C1 00C6 00C7 00C8 00C9 00CA

Appendix-11

Servo alarms (continued) Alarm number ALM ALM ALM ALM ALM ALM ALM ALM ALM Message SV ENC ECBK SV EC MTL SV OF SV FASE SV OL SV RWG WRG SV ABS GET SV No't RDY SV Err Explanation Servo encoder echo back error Servo encoder multi-turn limit value did not match. Servo position deviation was too large. A servo power line had an open phase. Servo overload warning Servo regeneration overload warning Absolute encoder position detection error A servo is not ready. Servo alarms are not checked. Alarm trace back 00CB 00CC 00D0 00F1 0091 0092

Alarm trace back numbers are in the range of DGN020~029. It is indicated when the servo alarm trace back is monitored. 5) Other alarms Alarm number ALM100 ALM101 ALM Message Out Port OC Clamp OC Power down Explanation Short circuit of external output signal Short circuit of clamp output signal Instant power failure was detected.

DGN ADDRESSES
DGN Input checklist
Address

bit 7
External input signal Internal input signal Internal input signal External output signal Control output signal LED output signal B8 Clamp SOL overcurrent LED 2ndF JOG

bit 6
(Emergency stop) B4 External output overcurrent Input power supply change SV-REV MDI

bit 5
Work number set B2 Main circuit power supply SV-FWD PROGRAM

Contents bit 4
B1 Unclamp LS Clamp SOL CHECK

bit 3
Return to reference point Clamp LS ALM SINGLE

bit 2
Stop Servo COIN LEVEL SV-AUTO AUTO

bit 1
Start

bit 0

*Servo alarm Servo ready FIN2 SV-PCON STOP FIN1 SV-ON RUN

For N00 ~ N09, when a signal is on, 1 is displayed. When a signal is off, 0 is displayed. For signals with an asterisk (*), the status is displayed in inverse.

Appendix-12

DGN Input check list (continued)

Address

Contents Servo deviation counter Servo command speed Current servo speed Servo torque command Servo command pulse speed Servo accumulating load Servo regeneration load Servo regeneration resistance consumption power Servo identification inertia ratio Positioning time Servo alarm trace back No. 0 Servo alarm trace back No. 9 Servo motor type Servo motor capacity Servo encoder type Servo special specifications Servo software version Servo type Servo rotating angle 1 Servo rotating angle 2 Servo input port monitor Servo output port monitor Servo command pulse counter Servo feedback pulse counter Servo type main boat software version

The data indicated as Servo Alarm Traceback No. 0 ~ 9 is not an alarm number. The data in the column for the alarm traceback symbol of 3-4. Alarms 3) Servo alarms. Servo alarm traceback No. 0 is the latest alarm. Data 0099 indicates that there is no alarm. DGN OUTPUT CHECK LIST
Address

Contents bit External output LED 2ndF bit 6 Input power supply change bit 5 Main circuit power supply bit 4 Clamp SOL bit 3 ALM bit 2 LEVEL SV-AUT O bit 1 FIN2 SV-PCO N bit 0 FIN1 SV-ON

Control SV-REV SV-FWD output All the LEDs are on, whole LCD display (Excluding: 2ndF LED)

N00 and N01 output signal status will be inverse when 1 is entered. For N02 status, all the LEDs except for [2ndF] LED and the LCD screen light up for five seconds.

Appendix-13

MEMO

Appendix-14

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