DIAS Control Layout

Monday, May 10, 2010

Dais 3 Dias 4
P/N 970949 P/N 1228236

POWER OFF
Unplug the green
RF cable and set
DVM to Ohms.
Black Lead on the
Shield Red Lead
on the center =
3.74 M ohms
@ the cutting Head
measured the
resistance at the
Head Position =
6.54 km

1278019 DIAS Plus PC new TGS

Replacement for ( 970949 )
Replaced by Mat. - NR ( 1488573 ) /TAT932KU 2606008

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DMP Modules
M+30 A8

DMP Module

P/N 131442

5
Cables interconnection between the Dias and the Cutting Heads

green cable (long) 3030/2530 343390

green cable (long) 4030/6030 343389
green cable (short) with connector 954499
short green cable only 1.5M 343391
Black Dias Cable 118542
green cable for 3050 12M 347615

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 Oscillators
P/N 938351

Ceramics Nozzle

P/N 260432

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DIAS CONTROL for the Tubematic

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 Dias Control Part 2 Electrical Connections
Numerical
Control Kernel
(NCK)

Part
Program
Execution
Error

Command = Programmed Position + Error

Command
Encorder Feedback Data Encorder Feedback Data
Error = Actual Position - Programmed Position
---------------------------------- ----------------------------------
Rotational Postion Rotational Postion
Speed Speed
Axis Position Axis Position
Sheet Height
Motor/Encorder Unit

DIAS3
Servo Control Feedback LED Displays
Frequency of
Feedback
Encorder
Oscillator or if Flashing
Current Limiting Error Number
Velocity Limiting
AC Phase Calculation

Height Regulation

Command AC Axis Motor

Command = Speed + (Command - Actual)

AC Phase Calculated from Rotational Position

Laser Cutting Head

Capacidence Chages as
Distant Between Nozzle
and Sheet Changes

Sheet

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Dias Control Part 3 Electrical Connections

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Technical Reference
APC DIAS Plus DIAS3 DIAS4 PCS
Flash on the diagnostic display.
0 General error Internal processes disrupted
Positive edge at digital input "Start", Reset telegram, Main
switch OFF, then ON again
1 Insufficient main memory
Main memory is not sufficient Main switch OFF, then ON
again
2 Time basis setting error
Controller time basis cannot be Set Load original file with
DIAS3 - software, set the valid time basis
3 Interrupt-Controller
number error Allocation error by Interrupt controller Reload
DIAS3 software
4 Positive software limit switch
The distance axis has reached the positive software limit
switch Incorrect value for software limit switch Reference
point synchronization failed (software error) Move distance
axis into valid Ranges Correct / Overwrite the "INI" file
5 Negative software
limit switch The distance axis has reached the negative
software limit switch Incorrect value for software
limit switch Reference point synchronization
failed (software error) Move distance axis into valid
ranges Correct / Overwrite the "INI" file
6 Positive servo lag overshot
The distance axis has too great a contouring error in
positive direction of the distance axis Teach the curve again,
examine the set value connection / encoder connection at the
distance axis, Examine the axis
7 Negative servo lag overshot
The distance axis has too great a contouring error in
negative direction of the distance axis Teach the curve again,
examine the set value connection / encoder connection at the
distance axis, Examine the axis
8 Positive lag speed overshot
The distance axis does not follow the set values in
positive axis direction as it should Teach the curve again,
examine the set value connection / encoder connection at
distance axis, Examine the axis
9 Negative lag speed overshot
The distance axis does not follow the set values in
negative axis direction as it should Teach the curve again,
examine the set value connection / encoder connection at
distance axis, Examine the axis
10 Undefined controller state Internal state of controller
is not correct
Positive edge at digital input "Start", Reset telegram,
Main switch OFF, then ON again
11 Incorrect machine data
Error in the "INI" file, wrong "INI" file Correct / Overwrite the
"INI" file
12 Errors in file Errors in the curve file Positive edge at
digital input
"Start", Reset telegram, then teach the curve again
13 Frequency constancy error In curve teaching, the
frequency fluctuated excessively in the uppermost
position of the distance axis
Teach the curve again, check the sensor in the cutting
head (sensor cable, adapter plate with oscillator)
14 No frequency change In curve teaching, the sensor
reported the wrong values when sensing for the sheet
surface
Teach the curve again, check the sensor in the cutting
head (sensor cable, adapter plate with oscillator)
15 Invalid telegram DIAS3 has received an undefined
telegram
Check the telegram connection, Check the telegram
16 Incorrect federate The feedrate is not within the
valid limits
Input the correct federate (cutting feedrate)
17 Incorrect cutting Height The cutting height is not
within the valid limits
Input the correct cutting height Range: 0.3mm to 8.0mm
(0.3mm-20mm)
18 Incorrect piercing height The piercing height is not
within the valid limits
Input the correct piercing height Range: 0.3mm to 8.0mm
(0.3mm-20mm)
19 Invalid curve
Number An invalid number was assigned in curve teaching
Is no longer output since only one curve now exists!
20 Measuring range not reached
No sheet under the cutting head Specify a valid start-up
position
21 Nozzle collision Nozzle collision
Poor cutting conditions Short-circuit in sensor From software
version V2.1 onward, height regulation was Deactivated
Eliminate the collision Correct the cutting parameters
Eliminate the short-circuit
22 Telegram buffer full
The internal telegram buffer is full, more telegrams are
to be input Positive edge at digital input "Start", Reset
telegram, Main switch OFF, then ON again
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 Technical Reference
APC DIAS Plus DIAS3 DIAS4 PCS
Flash on the diagnostic display.
23 Telegram buffer empty
The internal telegram buffer is empty although telegrams are
to supposed to be output Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON again
24 Timeout One of the internal processes
has exceeded the Timeout time
Positive edge at digital input "Start", Reset telegram, Main
switch OFF, then ON again
25 Auxiliary point missing
It was not possible in curve teaching to determine an
auxiliary point Teach the curve again 26 Timeout while
transmitting The Timeout time was exceeded while a
telegram was being transmitted Main switch OFF, then ON
again
27 Timeout while receiving
The Timeout time was
exceeded while a telegram was being received,
acknowledgement took too long Main switch OFF, then ON
again
28 General interface error
General error at an interface Main switch OFF, then ON
again
29 Wrong buffer length
The length of the internal communication buffer is not valid
Main switch OFF, then ON again
30 Lag error in curve teaching
An impermissible lag error occurred in curve teaching – the
cutting head is pressing on the work piece.
Work piece is not suitable (becomes deformed)
31 In pos monitoring in curve teaching
In curve teaching, the preset position cannot be reached
without error Set the distance axis drift, Check axis for
smooth motion 32 Sensor was unplugged, teach
new curve No valid curve exists for this
sensor Teach the curve
33 Sensor is unplugged
The connection from the DIAS3 to the sensor (adapter plate,
sensor body, oscillator) has been disrupted Plug in the
sensor
34 Sensor short-circuit
The connection from the DIAS3 to the sensor (adapter plate,
sensor body, oscillator) has short-circuited Eliminate the
short-circuit
35 Invalid controller parameter set
The controller parameter set (plane/rotary axis machining)
has not been defined Main switch OFF, then ON
again
36 +5V F counter error
The +5V supply to the frequency counter has overshot the
limit values
Positive edge at digital input "Start", Reset telegram,
Main switch OFF, then ON again
37 -5V F counter error
The -5V supply to the frequency counter has
overshot the limit values Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON again
38 +15V F counter
Error The +15V supply to the frequency counter has
overshot the limit values Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON
Again
39 Temperature limits overshot
DIAS3 temperature monitoring has overshot the limit values
Positive edge at digital input "Start", Reset telegram,
Main switch OFF, then ON again
Check the DIAS3 temperature
40 Drift voltage limits overshot
The value determined by the automatic drift voltage
compensation during curve teaching exceeds the limits
Set the drift voltage of the distance axis Check the wiring of
the analog set value
41 Speed amplification limits overshot
The value obtained through speed amplification
determination during curve teaching exceeds the limits
Inspect the connection to the distance axis, Check the drive
actuator Amplification
42 Minimum frequency undershot
The attached sensor did not attain the minimum frequency
during curve teaching, sensor does not oscillate correctly
Inspect the sensor and cable
43 Maximum frequency overshot
The attached sensor overshot the maximum frequency when
the height regulation was activated at cutting height or
piercing height. Poor connection between adapter plate and
ceramic part Inspect the sensor and cable Clean the spring
contact of the adapter plate and ceramic terminal lug
44 Timeout A/D converter
The A/D converter does not respond to a request within
the allotted time. Positive edge at digital input "Start", Reset
telegram, Main switch OFF, then ON again
45 Plasma not extinguished
The plasma suppression was unable to extinguish the
plasma even with an axis stop (path motion only) Check the
cutting process.
46 Plasma suppression inactive
An attempt was made to activate the plasma suppression
although the latter was not functional. Possible cause:
Distance sensor has no plasma sensor Curve was taught on
a non-conductive surface Use distance sensor with
plasma sensor Teach the curve on a
conductive material
47 Curve error After curve teaching, a logic
error was discovered when the curve was checked.
Make sure the sheet is clean and does not spring back.
Check the ceramic part and cutting nozzle for proper seating.
Teach the curve again.
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Technical Reference
APC DIAS Plus DIAS3 DIAS4 PCS
Flash on the diagnostic display
48 Sensor still in warm-up phase (max. 30s)
The cutting head was removed and re-attached while a CNC
program was active Wait until the time expires
49 Command rejected due to Feed Hold
Signal overlap or wiring error Repeat the activity Check the
wiring
50 Nozzle collision during controller operation
Nozzle collision, poor cutting conditions, sensor has
short-circuited Eliminate the collision, correct the cutting
parameters, eliminate the short-circuit
51 Spatial frequency exceeded
Ceramic part loose, damaged
or incorrectly set Re-mount the ceramic part or, if necessary,
replace it
52 Target position too big
Sheet support is not 35 mm below the reference point
during curve recording Increase distance from sheet support
to reference point to min. 35 mm.
53 Manual output of analog voltage during regulation
Mode
Manual output of analog voltage was activated although Dias
is in regulation mode. Press Feed Hold or deactivate
height regulation
54 PMS or PCS pierce monitor inactive
An attempt was made to activate the PMS or PCS
pierce monitor although the latter was not functional.
Possible cause: Distance sensor has no plasma sensor
Curve was taught on a non-conductive surface Use distance
sensor with plasma sensor Teach the curve on a conductive
material
55 Bios Patch is missing Safeguarding mechanism for
the BIOS of the DIAS3 PC is missing.
Positive edge at digital input "Start", Reset telegram, Main
switch OFF, then ON again 56 +/-15V analog output error
The +/-15V supply to the analog output has overshot the limit
values. Positive edge at digital input "Start", Reset telegram,
Main switch OFF, then ON again.
57 +15V PC error The +15V supply to the PC has
overshot the limit values.
Positive edge at digital input "Start", Reset telegram, Main
switch OFF, then ON again
58 -15V PC error
The -15V supply to the PC has
overshot the limit values. Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON again
59 Ground F counter error
The ground potential of the frequency counter has overshot
the limit values. Positive edge at digital input "Start", Reset
telegram, Main switch OFF, then ON again
60 CPU fan error
The CPU fan in the DIAS3 PC has failed.
Positive edge at digital input "Start", Reset telegram, Main
switch OFF, then ON again
61 CPU fan runs too slowly
The CPU fan runs too slowly. Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON again
62 checksum error
The calculated checksum of a telegram is different to the
transmitted. Positive edge at digital input
"Start", Reset telegram, Main switch OFF, then ON again
63 Configuration error
The configuration data of the Profibus doesn't correspond to
the example. Positive edge at digital input "Start", Reset
telegram, Main switch OFF, then ON again
64 Internal watchdog monitor is triggered
Although the Profibus connection is built up, no data
are exchanged. Main switch OFF, then ON again.
65 Synchronization unsuccessful
Although the Profibus connection is built up, no
synchronization has been carried out between Master and
Slave. Positive edge at digital input "Start", Reset telegram,
Main switch OFF, then ON again
66 PCS no process signal
Several times in succession, no process light was emitted
although the laser was switched on. Laser OK? Sensor head
intact? Optics OK?
67 No end of piercing detected by PCS
Several times in succession, PCS did not detect end of
Piercing Sensor over modulated? Sensor head intact?
68 PCS: Initialization failed
Error occurred when loading software for the PCS DSP.
Positive edge at digital input “Start“, Reset telegram,
Main switch OFF and On again
69 Timeout Profibus digital interface
Monitoring of Profibus digital interface was tripped.
Positive edge at digital input “Start“, Reset telegram
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