4.1 INTRODUCTION ‘This chapter deals with the power distribution from the 4 wire input to the de power distribution from power supply. Refer to figure 4.1 for the power distribution in block diagram. For specific details, refer to the system schematics at the end of this chapter. 4.2 SYSTEM OVERVIEW The system input power is a 4-wire connection: 3 phases with a green wire ground. The ground system must be continuous from the ground origin to the machine ground terminal. Conduit will not suffice as a current carrying component in the ground system. Check the voltage plate attached to the control to determine the correct voltage required for the control. NOTE ‘The incoming phases do not have to be phased for correct operation of this control. AC POWER DISTRIBUTION ‘The incoming power is switched on and off by the main disconnect. The output goes through fuses FU1, 2, and 3. The output of these fuses then branch to three different circuits. ‘The major branch circuit is to the spindle motor controller. 1L1, 1L2, and 1L3 is connected to FU4, FUS, and FU6. The output of these fuses on wires 2L1, 2L2, and 2L3 is connected to contactor CR3. The output of CR3 supplies power to the spindle controller at pins T, S, and R and the spindle motor fan overload, MOLI. The output of MOLI is wires Tl and T2 which are connected to the spindle motor fan at terminals U and V. 5L1, SL2, and 5L3 have a transient filter across the three phases to catch transients caused by CR3 opening. A single phase branch is from 1L1 and 1L2 through FU7 and FU8 to wires 3L1 and 3L2 to the input of transformer T1. The input of transformer T1 is, multi-tapped to give it the ability to handle different input voltages. The appropriate connections are: 208 vac: connect 3L1 to HI, 3L2 to H2, jumper HI to H4 and H2 to HS. 230 vac: connect 3L1 to Hi, 3L2 to H3, jumper HI to H4 and H3 to H6. 416 vac: connect 3L1 to H1, 3L2 to HS, jumper H2 toH4, 460 vac: connect 3L1 to HI, 3L2 to H6, jumper H3 toH4. ‘Transformer T1 supplies 115 vac @ 4.3 amps to the ow level power supply and the monitor. T1 is designed with a split bobbin transformer with a gound shield inserted between the the primary and secondary to reduce the capacitance coupling. It also as an air gap that will saturate at about 160 volts, which means that transients above 160 volts will not be coupled to the load. The RC network on the secondary further reduces any fast rising voltages. Asecond branch circuit is from 1L2 and 1L3 to transformer T2 through fuses FU9 and FU10 and wires 4L2 and 41.3. Transformer T2 has a multi tapped primary that can be tapped for the following voltages. 208 vac:connect 4L3 to H1, 4L2 to H6, jumper HI to H5 and H2 to HE. 230 vac:connect 4L3 to HI, 4L2 to H7, jumper HI to H5 and H3 to H7. 245 vac: connect 4L3 to H1, 41.2 to H8, jumper HI to H5 and H4 to H8. 416 vac:connect 4L3 to H1, 41.2 to H6, jumper H2 to HS. 460 vac: connect 4L3 to H1, 412 to H7, jumper H3 to HS. 490 vac: connect 4L3 to H1, 4L2 to H8, jumper H4 to HS. SSF 4111 INCOMING, <4 POWER 2 |SPINDLE aWiRE ig DRIVE GROUND 2. s2vac ‘axis 115 vac va vag axis | m mR ne POWER CRT ee ‘SUPPLY MONITOR| 1225 voc] Jov s9vac COMPUTER Rae POWER 115 vac —>| ‘SUPPLY ORIVE ov vt 115 VAC +| 24 VDC ; 1 Power | | YAS 496 OX. HARD FLOPPY SUPPLY 4 MOTHER DISK DISK BOARD DRIVE DRIVE 24 Zaxis oc wo ov ove |_| 400 BOARD A axis ORVE KEY BOARD AUX aur {OY __| vertaur 808 BOARD [15VAC_| BOARD Coe 115 VAC soc | xe 24voc 808, ov BOARD vor, BOARD Figure 4-1. Power Distribution - Functional Block Diagram 42e crime tn ‘! 3 31542958 YASKAWA ‘SPINDLE DRIVE 31942616 AUF 31506101 CR 456 31942745 31503497 ona LeTLAUF 31044036 MOTHER BOARD 31943798 495 VOLT PS 31949828 31842304 31943888 (9) & OPTIONAL BMDC ASS'Y XTPS BRIDGEPORT DRIVE Figure 4-2: Electrical Cabinet Breakdown (with Part Numbers) 43———— ‘Transformer T2 supplies the 115 vac @ 3 amps from both windings for the AUF board, 92 or 100 vac @ 12 amps from both windings for the DC motor drives, and 19 vac @ 10 amps for the 24 Volt DC power supply. NOTE The two 115 volt AC windings on this transformer are wired so that they appear as, 230 volts AC center tapped. This voltage is required to operate the Tool Arm and the Carousel motors. The 92/100 volts AC for the motor power supply is also wired as a 184/200 center tapped voltage. 24 VOLT DC POWER SUPPLY The 19 volts AC from terminal 15 on transformer T2is connected to FUI through wire 8. The output FULL is connected to the AC input of BR1 through wire 9. The output of this seconary coil at terminal 16 is connected to the other side of the AC bridge, BRI, through wire 7. The minus output of BRI is connected to C1 and the input terminal of the AUF at connector JP12 pin 2A through wire 39. The positive output of BR1 is connected to FU12 through wire 18. The output of FU12 is connected to the input of the AUF at connector JP12 pin 1A through wire 40. This power supply is rated at 6 amps de maximum. The 24 volts DC on the AUF card is used to supply power to the Z brake, the perimeter door guard shot pin, the high gear solenoid, the spindle off light, the ‘work light, the low gear solenoid, the stop pin solenoid, and the A-axis brake, if this option is installed. 115 AND 230 VOLT SUPPLY ‘Terminals 11 and 12 of transformer T2 are jumpered together and tied to chassis ground through wire 2. This connection forms the center tap for these two windings and the chassis ground referance for the axis drive motor power supply. Wire 2 also connects to the AC input terminal on the AUF at connector JP22 pin 1A. ‘The 115 volt AC output of T2 at terminal 9 is, connected to FU14 through wire 94. The output of FUI4 is connected to the 115 volt AC input on the AUF at connector JP22 pin 3A through wire 4. The other 115 volt AC output at terminal 14 is connected to FU15 through wire 95. The other side of FUIS is connected to the 115 volt AC input terminal of the AUF at connector JP22 pin 2A. The voltage measured from the 115 volt input terminals (2A and 3A) to chassis ground is 115 volts. But when terminal 2A is measured to terminal 3A, the voltage is 230 volts AC. The outputs of the AUF is wired to use 115 volts AC while the outputs of the LeTLAUF is wired to use the 230 volts AC. ‘The 115 volts AC on the AUF is used to supply power to the following: 1. The cabinet fan through fuse FU4. 2. The miscellaneous outputs through fuse FU3. 3. The CRT enclosure fan through fuse FU6. 4, The flood coolant receptacle through fuse FUI 5. The lube pump motor through fuse FU8. 6. The index relay through fuse FU9. On the LeTLAUF both phases of the 240 volts AC are fused with fuses FU1 and FU2. The LoTLAUF supplies voltages to the following: 1. 115 volts AC to the tool unclamp solenoid. 2. 115 volts AC to the air blast solenoid. 3, 240 volts AC to the tool arm motor. 4, 240 volts AC to the carousel motor. 5. 240 volts AC to the tool arm motor brake. THE DC MOTOR POWER SUPPLY ‘Transformer T2 is tapped at 92 volts AC and 100 volts AC. These two taps permit a choice of 128 or 140 volts DC applied to the axis motor drive cards.4. Power Distribution The voltage may have to be selected to accommodate the weight of the Z axis when accelerating to rapid in the plus direction. The 92 volt taps are terminals 10 and 13. The 100 volt taps are terminals 17 and 18. To change voltages, change wire 1 from terminal 13 to terminal 18 and wire 3 from terminal 10 to terminal 17. Wire 1 is connected from terminal 13 to CB16. The output of CB16 is connected to D1 through wire 5, Wire 3 is connected from terminal 10 to CB17. The output of CB17 is connected to D2 through wire 6. The DC output of D1 and D2 is connected to the plus side of the filter capacitor and the bleed resister through wire 50. _ Wire 2 connects the transformer terminals 11. and 12 to the minus side of the capacitor and the bleed resistor. The positive output of the power supply, wire 50, connects to JP3 pin 3 on all axis drive cards, The negative output of the power supply, wire 2, connects to JP3 pin 1 on all axis drive cards. JP3 pin 2 on al axis drive cards is connected to chassis ground. 4.3 SYSTEM PROTECTION 43.1 Signal Ground Each module, separated device or separate circuit, is referenced to the System Ground as close as practical to the System Ground Stud. Because these circuits branch out independently from the ground stud, they will not carry current from other modules. The Signal Ground (a zero-volt reference) is con- nected to the protective ground at only one point. 43.2 Shielding Certain shiélded cables for signal purposes are continuous shields grounded at one end only (the point closest to the System Ground Stud). 4.3.3 Noise Suppression Suitable RC circuits are applied across ac relays and starters as well as at the main 3 phase ac induction motor for the spindle. De relays are protected by diodes. FUSE CHART FUSE # |VALUE_| DESCRIPTION | PART# _| LOCATION _|REMARKS FUL, 2,3 50 amps _| FLRS 600 vac 31542293 _| DISC #1 FOR 200/240 VAC } FUL. 2.3. [25 amps _| FLRS 600 vac __} 31542292_| DISC #1 FOR 440 VAC _ ISE REDUCER FOR USE W/25 AMPS 31542285_| DISC #1 USE W/31542292 FUI3 Samps__| MCR.S 250 vac__| 31542838_| TB-1 [FULA Samps _ | 229-2AG-5 250vac| 11597535__ | AUFFUIA __|COOLANT PUMP. |FU2A,3A,4A,6A AUF FU2, 3, 4 |FU7A.8A.9A __|2.5 amps _| 22902.5 250vac__| 31542413 _| 6,7, 8,9 FUSA 10 amps__| MDA 250 vac 31542411_| AUF FS. FUIB, 2B Samps | MDA 250 vac 31508852 | LeTLAUF F1,2| Figure 4-3. Fuse Chart Ee 4544 PROTECTIVE GROUND Protective ground is required. It minimizes the exposure to personal shocks in the event of circuit shorts or other mal- functions. Failure to ensure protective ground may create electrical shock hazard, causing serious personal injury or death. Protective Ground (Chassis or Safety Ground) establishes a low impedance path from the electrical cabinet and other mechanical parts of the system to earth ground. Protective Ground assures that all conductive parts of the enclosure are safe. If any circuit inadvertently touches the chassis, the voltage will be reduced to zero and the enclosure will be safe to touch. Because safety requirements vary in different localities, be sure to consult local govern- ing codes. These codes take precedence over the practical guidelines presented, which are based upon: National Electrical Code; California "Electrical Safety Orders"; and Pennsylvania "Electrical Safety Regulations". ‘The four methods listed below are commonly used to establish earth ground: Continuous Metal Water Pipe — When properly buried, length is installed below the permanent moisture level, impedance is typically 3 ohms. Copper Stake (3/4 in. dia, 6-8 ft. long). — When properly driven into the ground below permanent moisture level, the impedance of this type is typically below 5 ohms. Fourth Wire Ground — Although a copper ground stake is preferred, an alternative is a fourth wire for ground included with the power wires from the enclosure ground stud to the power company service panel ground bus. (See Note 1, below.) Other Metal Electrodes (Well Castings or the Like) — Must be well chosen since they ‘generally exceed an impedance of 5 ohms but are well below 25 ohms. NOTE1 ‘The resistance of the earth ground connection is measured from the enclosure ground stud, through the ground wire, to the earth ground connection; then through the earth ground to another earth ground connection (at least 20 feet away), and through its associated wire to another ground stud. The resistance should not exceed 5 ohms. The wire used between the ground stud and the earth ground should be AWG10 or larger and should be braided cable to minimize resistance at high frequencies (cable resistance less than 0.075 ohm). The ground wire should be inspected for mechanical abuse periodically. 4.5 VAC DISTRIBUTION BRANCH The 115 vac output from TI feeds the DX power supply, color monitor, and hour meter. The 115 vac distribution branch originates at transformer T2 and steps the line voltage down to 115 vac single phase. 46 24 VDC POWER SUPPLY DISTRIBUTION ‘The 24 vdc Power Supply provides +24 vde power that is fed to the AUF board and is used by the following devices: 1. Pneumatics - The pneumatic system provides power to the power drawbar assembly, to knock ‘out the tool during a tool change cycle. It also enables gearbox shifting, and supplies air to the air blast system, to blow chips away from the spindle. Emergency Stop Switch — The Front Panel switches provide communications between the machine and the operator. Power to the EMERGENCY STOP is from the AUF board. rr3. ‘When pressed, the E-STOP switch will remove 4.7 VOLTAGE power from the servomotors, stop the spindle This machine was designed for 240 vac or 460 vac. ‘motor, disable the spindle control system, and However, it may be re-tapped to run on 200 vac stop all functions in the process (tool change, coolants, ete.) The signal is transmitted to the ps==xxy machine controller (BMDC) board where the Reaxcen proper firmware is enabled to control the logic circuitry on the AUF board. This logic circuitry is used to control the electromechanical devices in the system. HOME Switches ~ A home switch is located on each axis. When a home switch is activated, a path is created to ground for the logic circuitry ‘on the AUF board. Before changing any wires, ensure personal safety by opening disconnect installed in control enclosure door.