3e

Agiecut wire-cutting EDM systems (except Vertex)
S Service manual
S3
Supply,
Safety
This document is for authorized technical staff only.

All rights reserved
11.2002
AGIE
CH-6616 Losone
Telephone +41 / 91 / 806 91 11
Telefax +41 / 91 / 806 92 60
Hotline CUT:
Telephone: +41 / 91 / 806 90 60 Telefax +41 / 91 / 806 90 61
e-mail: hotlinecut@agie.ch
Hotline TRON:
Telephone: +41 / 91 / 806 90 88 Telefax +41 / 91 / 806 93 47
e-mail: hotlinetron@agie.ch
AGIE CHARMILLES Group

GEORG FISCHER +GF+ Manufacturing Technology
Table of contents
1. Supply distribution...................................................................................5
1.1 General description of supplies: .................................................................5
1.2 Components of the supplies rack ...............................................................5
2. HPS-10/11/14 Power unit..........................................................................6
2.1 Description and make-up of the power modules ........................................6
2.2 Signalling LED status HPS .........................................................................6
2.3 Connection of the HPS - 10/11/14..............................................................7
2.3.1 X1: POWER CONTROL BUS .............................................................................................8
2.3.2 X3:POWON (HPSON).........................................................................................................8
2.3.3 X4:POWER (Main AC/DC)..................................................................................................9
2.3.4 X14:TEST SUPPLY.............................................................................................................9
2.3.5 XT1:GND.............................................................................................................................9
2.3.6 XT2: UOUT..........................................................................................................................9
2.4 Flow diagrams for operating function supplies .........................................10
2.4.1 The Soft Start flow diagram...............................................................................................11
2.4.2 The start-up flow chart.......................................................................................................12
2.4.3 The status check flow chart...............................................................................................13
3. HPS-10 Power unit .................................................................................14
3.1 Specifications of the HPS-10:...................................................................14
3.2 Personalised data HPS-10 .......................................................................15
3.2.1 X5: Command lines ...........................................................................................................15
3.2.2 X6: Status lines .................................................................................................................15
4. HPS-11 Power unit .................................................................................16
4.1 Specifications of HPS-11:.........................................................................16
4.2 Personalised data for HPS-11 ..................................................................17
4.2.1 X5: Command lines ...........................................................................................................17
4.2.2 X6: Status lines .................................................................................................................17
5. HPS-14 Power unit .................................................................................18
5.1 Specifications of HPS-14..........................................................................18
5.2 Personalised data of HPS-14 ...................................................................19
5.2.1 X5: Command lines ...........................................................................................................19
5.2.2 X6: Status lines .................................................................................................................19
6. PSC-04 (WID-96) Control unit ................................................................20
6.1 Purpose of the control unit PSC-04: .........................................................20
6.1.1 Fixing of PSC-04 on WID-96.............................................................................................20
6.2 Functions of module WID-96 ....................................................................21
Agiecut (except Vertex) S3 Supply, Safety

©AGIE 11.2002 -2-
6.3 Technical specifications ...........................................................................22
6.3.1 Principal specifications of PSC-04 ....................................................................................22
6.4 Signalling by the PSC-04 (WID-96) ..........................................................23
6.4.1 LEDs indicating presence and status:...............................................................................23
6.4.2 Voltages generated by PSC-04 and a description of them:..............................................23
6.4.3 Starting circuit....................................................................................................................24
6.4.4 Functions of the ACLow part.............................................................................................25
6.4.5 Functions of the MONITORING part .................................................................................25
6.4.6 Functions of the EMERGENCY part .................................................................................25
6.4.7 Functions of the BATTERY CHARGER part.....................................................................26
6.4.8 Functioning of the STEP-UP part......................................................................................26
6.5 Accessible connections on the WID-96 ....................................................27
6.5.1 X1:Main AC/DC .................................................................................................................27
6.5.2 X3A: RS232.......................................................................................................................28
6.5.3 X3B+C: BITBUS................................................................................................................28
6.5.4 X12:HPS............................................................................................................................29
6.5.5 X13:TEST SUPPLY...........................................................................................................29
6.5.6 X14:PSD-14/16/17 ............................................................................................................30
6.5.7 X15:NTC............................................................................................................................31
6.5.8 XT4:24VBAT .....................................................................................................................31
6.5.9 XT3:BAT............................................................................................................................31
6.5.10 XT2:24VDC .......................................................................................................................31
6.5.11 XT1:GND...........................................................................................................................31
6.6 Display (U1) of error messages................................................................32
6.7 Display (U1) of error messages................................................................33
7. PSD-14/16/17 Equipment safety concept .............................................34
7.1 Standards .................................................................................................34
7.1.1 General definition ..............................................................................................................34
7.1.2 Conformity .........................................................................................................................34
7.2 Elements controlled..................................................................................35
7.2.1 The cabin...........................................................................................................................35
7.2.2 The activator button...........................................................................................................35
7.2.3 Movement of the work tank ...............................................................................................35
7.2.4 Closure of the tank ............................................................................................................35
7.2.5 Safety level with the tank raised or lowered (SL9)............................................................35
7.2.6 Movement of the axes .......................................................................................................36
7.2.7 The generator....................................................................................................................36
7.2.8 Linea consenso erosione ..................................................................................................36
7.2.9 The emergency circuit (internal+external).........................................................................36
7.3 Operating principle ...................................................................................37
7.3.1 PSD-14/16/17....................................................................................................................37
7.3.2 Optical indications on the PSD-14/16/17. .........................................................................37
7.3.3 Check of the state of the 24V predection fuses. ...............................................................37

©AGIE 11.2002 -3-
7.4 Safety Central Units Elobau .....................................................................38
8. Diagnostics .............................................................................................40
8.1 The machine and the PSC-04 do not start up ..........................................40
8.2 The PSC-04 shows a certain activity but the machine does not start up..41
8.3 Error 00: FBCore not functioning..............................................................43
8.4 Error 30: 24VDC (HPS-10) outside of tolerance.......................................44
8.5 Error 31: Generator voltage (HPS-15) out of tolerance ............................46
8.6 Error 32: HPS-11 120V DC motors outside tolerance ..............................48
8.7 Error 33: 24V DC, generated by the battery outside tolerance .................50
8.8 Error 36: Charge level of battery GB1 ≤ 25% ...........................................51
8.9 Error 37: Battery GB1 completely discharged ..........................................52
8.10 Error 38: Intervention by the temperature predection of HPS-10..............53
8.11 Error 39: Intervention by the temperature predection of HPS -14.............54
8.12 Error 3A: Temperature predection of HPS-11 ..........................................54
8.13 Error 3B, 3C, 3D: Driver of the HPS bus in FAULT condition ...................55
8.14 Error 40: Error in the emergency procedure .............................................57
8.15 Error 41: Overload predection DA Group .................................................57
8.16 Error 42: Overload predection motor group ..............................................57
8.17 Error 43: Overload predection generator group........................................57
8.18 Error 44: Overload predection CNC group ...............................................58
8.19 Error 45: Overload predection supply PSD ..............................................58
9. Information messages ...........................................................................59
9.1 Message 84: emergency situation............................................................59
9.2 Message A7: cabin open ..........................................................................59

©AGIE 11.2002 -4-
1. Supply distribution
1.1 General description of supplies:

HPS 10/11/14 and PSC-04
The power supply unit on machines is a modular supply concept with an integral management system for
all supply, safety and emergency functions in order to comply with the requirements stipulated under the
CE standards in force since 1 January 1996.
The basic unit named IPS (Integrated Power Supply) is gathered in a standard 19” rack for p.c. boards of
220X233.5 mm size (compatible MULTIBUS II). It is composed by a control unit and input/output PSC-
04, and in addition:
• a power unit 24V (HPS-10), a programmable power unit for the generator of 30/45/60/75V (HPS-14)
and a power unit for the motors of 120V (HPS-11).
The active power elements are the IGB (Insulated Gate Bipolar) transistors with VCE voltages of 900-
1200V (according to the type of HPS) and currents of the order of 50A.
The transformers (one for each half bridge) are based on EC70 cores (for HPS 10 and 11) and on PM74
cores for the HPS-14. The maximum transformable ratings with these arrangements are approx. 2kW for
the HPS-10 and 11, and 4 kW with the HPS-14. Each unit can be put in parallel in order to obtain the
ratings necessary for use in other AGIE applications.
Each power unit is provided with a plug-in AUX80 "soft start" module allowing the current peak during
switch on to be limited to approx. 20A maximum.
Regulation of the output power from the power units is entrusted to a plug-in module PSC-01 (HPS-10),
PSC-02 (HPS-14) or PSC-03 (HPS-11).
The power units are completed by an interconnection module WID-93 which also functions as a front
panel ensuring fixture in the rack and the front screening. The same functions are carried out by module
WID-96 for management unit PSC-04.
1.2 Components of the supplies rack

The components of the supplies rack can be seen on drawings 742.042 (Classic) and 741.482
(Challenge, Evolution and Excellence) in the SE manual.

©AGIE 11.2002 -5-
2. HPS-10/11/14 Power unit
2.1 Description and make-up of the power modules
The power units HPS-10/11/14 are in fact made up of four distinct modules:
• The interconnecting base unit supporting the power elements
• The AUX-80 "soft start" unit limiting the start-up current to 20A
• The PSC-01/02/03 "driver" units for regulation
• The WID-93 front panel label according to the power unit in which it is incorporated
The combinations which we find in the IPS group are the following:
Power unit Base unit Soft Start Driver Front panel Labelling # Diagram of
the assembly
HPS-10 HPS-10 AUX-80 PSC-01 WID-93 HPS-10 765.653.1

2.2 Signalling LED status HPS
Five signalling LEDs located on the WID-93 indicate the operating status of the HPS power units:
LED name Indication

POWER OK V5 The output voltage is within the require tolerance of ± 5%
POWER ON V4 The start-up command coming from the PSC-04 is present
+5V V3 The 5V internal supply to the HPS unit is present (it does not indicate the
tolerance)
+ 15V V2 The 15V internal supply to the HPS unit is present (it does not indicate
the tolerance)
+ 23 V V1 The 23V internal supply to the HPS unit is present (it does not indicate
the tolerance)

©AGIE 11.2002 -6-
2.3 Connection of the HPS - 10/11/14
The WID-93 is an interconnection, screening, fixing module in the rack and at the same time the front
panel of the HPS-10/11/14.
The connections available on the front panel of the WID-93 are:
Nam Symbol Type Description

e
X1 POWER 2x10 pin male plug 90° Interconnection bus from the HPS power unit to
CONTROL per flat cable the PSC-04.
BUS
X3 POWON 2 pin male plug 90° Input for the HPS start-up signal (external
PHOENIX conmand)
X4 POWER 2x3 pin AMP DYNAMIC Input 3x400VAC and output 540VDC
5.08 mm 90°
X14 TEST 2x5 pin female socket Supplies and signals present in the HPS
SUPPLY available for the operating test (for tests
executed outside of AGIE)
XT1 – POWER Small plate 20x12 mm Negative output connection
XT2 + POWER Small plate 20x12 mm Positive output connection

©AGIE 11.2002 -7-
2.3.1 X1: POWER CONTROL BUS
The X1 POWER CONTROL BUS contains the command and status signals from and for the PSC-04, it is
a connecting bus made up of a 20 pin flat cable connected to all the HPS units.
The signals present in X1 from all the units used are:
Pin Code Description HPS Pin Code Description HPS

10/11/14 10/11/14
1 24V 24V 2 24V 24V

3 STA1 Line 1 status HPS-10 4 STA2 Line 2 status HPS-11 Z status
status
5 CTRL1 Line 1 check HPS-10 6 CTRL2 Line 2 check HPS-11
start-up switch-on
7 CTRL3 Line 3 check HPS-14 8 CTRL4 Line 4 check HPS-14
start-up Set Uout Bit 0
9 GND Ground 10 GND Ground
11 CTRL5 Line 5 chec HPS-14 12 CTRL6 Line 6 check
Set Uout Bit1
13 CTRL7 Line 7 check 14 CTRL8 Line 8 check
15 STA3 Line 3 status HPS-14 status 16 STA4 Line 4 status All HPS
Over temperature
17 STA5 Line 5 status 18 STA6 Line 6 status
2.3.2 X3:POWON (HPSON)
A of 24VDC available on X3 allows the HPS unit to be started up.

This connector is used for certain fault search sequences voltage
The signals are:
Pin Code Description Pin Code Description
1 0V 0V for command 2 ON 24VDC start-up signal

©AGIE 11.2002 -8-
2.3.3 X4:POWER (Main AC/DC)
Mains voltage connection 3x400VAC and output for 540VDC voltage:
1A L1 Phase 1 mains 400VAC 1B HALF Median point of 540VDC

2A L2 Phase 2 mains 400VAC 2B 0V_540 Earth for 540 VDC
3A L3 Phase 3 mains 400VAC 3B 540VDC 540 VDC supply
The 540VDC present on X4 of HPS-10 is used as power supply voltage by the PSC-04.
2.3.4 X14:TEST SUPPLY

On connector X14 the various supply voltages and the check and status signals for the HPS unit are
present.
The connector X14 is not cabled but is used solely for the functional TEST of the HPS unit and for certain
failure search sequences.
The signals present are:

1 23V 23VDC internal (rectified) 2 GND Earth
(18 ÷ 26V)
3 15V (± 5%) 15VDC internal stabilised 4 5V (± 1%) 5VDC internal stabilised
5 ENABLE 24V start-up command 6 STATUS Output voltage status
7 NC Not connected 8 NC Not connected
9 POWER Main output voltage 10 NC Not connected
2.3.5 XT1:GND
XT1 is a small 20X20x12 mm metal plate intended for the negative connection to HPS-10/11//14.
2.3.6 XT2: UOUT

XT2 is a small 20x20x12 mm metal plate intended for the positive connection to HPS-10/11/14.

©AGIE 11.2002 -9-
2.4 Flow diagrams for operating function supplies
The flow diagrams refer to operating functions controlled internally by the hardware installed on the HPS
units.
The diagrams are presented as a sequential flow, but in reality all operations and checks are practically
simultaneous (except those involving measurement and delay functions, such as in Soft Start) because
they are executed by independent modules.
The general flow is as follows:
1 Inserimento 3x400VAC
2 Soft start
3 Accensione ?
6 Spegnimento
4 Controllo stato
7
In caso di OVP l'alimentazione viene spenta e
il solo modo di ripartire è di spegnere e
5 OVP ? riaccendere dopo qualche decina di secondi
l'interruttore generale della macchina
Questa sequenza indica che l'HPS è accesa
Translation of the Flow Chart texts:

1 Connection 3x400VAC
2 Soft start
3 Switch on?
4 Status check
5 This sequence indicates that the HPS is switched on.
6 Switching off
7 In the case of OVP, the power supply is turned off and the only method of restarting is to switch the
main switch on the machine off and on again after a few tenths of a second.

©AGIE 11.2002 - 10 -
2.4.1 The Soft Start flow diagram
Soft start
AUX80
K1 aperto Carica i condensatori della HPS attraverso resistenze da
1 SSOK=1 820 Ohm e PTC di protezione
HPS spenta
4
Verifica che la tensione di carica dei condensatori

AUX80 raggiunga un livello che corrisponda al minimo
UDC>350V? ammissibile (rete più bassa possibile e tolleranze dei
componenti)
5
AUX80 Permette ai condensatori di caricarsi ulteriormente fino

Delay 0,5s a circa 350V
6
AUX80 Cortocircuita le resistenze e le PTC di carica Inserendo

2 Chiusura K1 la rete direttamente e indica con SSOK=0 che il ciclo di
SSOK=0 soft start è terminato
7
3 Accensione

1 AUX80 K! turned off SSOK-1 HPS turned off
2 AUX80 K1 closing SSKO=0
3 Switch on
4 Charges capacitors on the HPS through resistances of 820 ohm and predection PTC
5 Checks that the charging voltage on the capacitors reaches a level equal to the minimum admissible
(lowest possible mains supply and component tolerances)
6 Allows the capacitors to be charged later to approx. 350V.
7 Short-circuits the resistances and the charging PTC by plugging in the mains supply directly and
indicates with SSOK-0 that the soft start cycle has been terminated.

©AGIE 11.2002 - 11 -
2.4.2 The start-up flow chart
1 A c c e n sio n e
O N =1? R ic h ie sta d 'a c c e n sio n e d e lla P S C -0 4

8
V e rific a se il 2 3 V d 'a lim e n ta z io n e in te rn o è

23V >18V ? 9 s u p e rio re a l m in im o a m m issib ile d i 1 8 V
SSO K =0? 10 V e rific a se il c ic lo d i s o ft sta rt è te rm in a to
V e rific a se la te m p e ra tu ra d e i ra ffre d d a to ri è
2 Tem p ok? 11 in fe rio re a l m a s sim o a m m issib ile d i 8 0 °C
3 A c c e n d e l'H P S
S e le c o n d iz io n i so n o v e ric a te a c c e n d e l'H P S
A c c e n d e il d io d o 12 e lo in d ic a su u n d io d o lu m in o so , in c a so
4 PO W ER O N
6 N o n a c c e n d e l'H P S c o n tra rio n o n a c c e n d e e rite sta tu tte le
c o n d iz io n i
5 C o n tro llo sta to 7 A c c e n sio n e

1 Switch on
2 Temperature OK?
3 Switches on HPS
4 The POWER ON diode lights up
5 Status check
6 Does not switch HPS on
7 Switch on
8 Requests switch of PSC-04
9 Checks if the 23V internal power supply is greater than the minimum admissible 18V.
10 Checks if the soft start cycle has been terminated
11 Checks if the temperature of the coolers is lower than the maximum admissible 80°C
12 If conditions have been checked, it switches on the HPS indicating this on a diode, otherwise it does
not switch on and retests all conditions.

©AGIE 11.2002 - 12 -
2.4.3 The status check flow chart
1 Controllo di stato
Verifica se la tensione d'uscita dell'HPS è

-5%<Uout<+5% compresa nella tolleranza richiesta di più o
meno 5%
2 Accendi LED 4
POWER OK
Se è il caso viene acceso il diodo luminoso che
indica il buon funzionamento dell'HPS e messo a
0 il segnale STA destinato alla PSC-04
STA=0
OVP
Translations of the Flow Chart texts:

1 Status check
2 POWER OK LED lights up.
3 Checks if the HPS output voltage is within the required tolerance of plus or minus 5%.
4 If that is the case, the luminous diode lights up indicating the correct functioning of the HPS and sets
the STA signal destined for PSC-04 to 0.

©AGIE 11.2002 - 13 -
3. HPS-10 Power unit
Diagram # 765.653.1
3.1 Specifications of the HPS-10:
Specification Value Observations
Supply voltage 3x400VAC-15% +25%

Operating temperature 0÷50°C without derating
Relative operating humidity 85% maximum
Output voltage 24VDC ±1% For loads from 0 ÷ 100%
Output current Limited to 50A maximum
Short circuit predection Of unlimited duration
Over-voltage predection OVP at +20% of Uout nominal Against over-voltage surges
caused by the supply itself
Output ripples 200mV p-p at maximum load
Efficiency η ≥ 80% For loads of 20 ÷ 100% and
mains supply fluctuations ± 15%
The HPS-10 generates a voltage of 24VDC distributed by means of a connector (metal square) XT2
(UOUT) on p.c.board PSD-14/16/17.
The three-phase supply line from the HPS-10 can be interrupted by means of KM8, by a circuit located
on the PSC-04 in the case of detection of overvoltage at the output of the HPS-10 itself.
In addition, the HPS-10 has its own OVP circuit which turns off the supply in the event of the presence of
an accidental overvoltage of 20% more than the rated value. In order to return to a normal situation after
an OVP situation, the AC supply to the HPS-10 must be interrupted by switching off the main switch S1
for ten seconds.
In the case of normal functioning. the three-phase supply to the HPS-10 must always be present in order
to supply the 540VDC necessary for operation of the PSC-04, which generates a start command
switching on the HPS-10. Once switched on, the HPS-10 will remain on until a possible OVP intervention,
as mentioned above, or until the main switch S1 is switched off manually.

©AGIE 11.2002 - 14 -
3.2 Personalised data HPS-10
Die Personalisierungen, um die Steuer- und Statusleitungen festzulegen, welche von der PSC-04 an der
HPS-10 einlaufen, sind auf den Zeichnungen # 690.614.3 und 765.653.1 zu sehen.
3.2.1 X5: Command lines
The command lines are personalised on the line of bridges X5 located on the power board of HPS-10:
Bridge Description
3-8 Start-up of the HPS-10 commanded by line CTRL1 of PSC-04
3.2.2 X6: Status lines
The status lines are personalised on the line of bridges X6 located on the power board of the HPS-10:
Bridge Description
2-6 Over-temperature of the HPS-10 read by line STA4 of PSC-04
3-4 Status of HPS-10 read by line STA1 of PSC-04

©AGIE 11.2002 - 15 -
Diagram # 765.663.0
4.1 Specifications of HPS-11:

Supply voltage 400VAC-15% +25%
Operating temperature 0÷50°C without
derating
Relative operating 85% maximum
humidity
Output voltage 120VDC ±1% For loads from 0÷100%
Output current Auf 10A max.
maximum.
Overvoltage predection OVP a +20% of Uout Against overvoltage surges caused by the
nominal supply itself
Output ripple 1V p-p at maximum
load
Efficiency η≥80% For loads from 20 ÷ 100% and mains
supply fluctuations of ±15%
HPS-11 generates the 120 V voltage used by the motors of axes X and Y.
HPS-11 is managed by the PSC-04, its three-phase supply lines can be interrupted directly by the
emergency circuits (by KM91) and safety circuits (by KM5 on p.c.board WID-129).
In addition, HPS-11 has its own OVP circuit which switches off the power supply in the case of the
occurrence of an accidental overcurrent 20% higher than the normal value. In order to return to a normal
situation after an OVP situation, it is necessary to interrupt the AC supply to HPS-11 by switching off the
main switch S1 for ten seconds or by creating an emergency, for example by means of the "Function
stop" button.

©AGIE 11.2002 - 16 -
4.2 Personalised data for HPS-11
The personalised data intended to define the command lines allotted to HPS-11 by PSC-04 areshown on
diagrams 690.624.2 and 765.663.0.

Bridge Description
5-8 Start-up of HPS-11 commanded by line CTRL1 of PSC-04

The status lines are personalised on the line of bridges X6 located on the power board of HPS-11:
Bridge Description
2-6 Overtemperature of HPS-11 read on line STA4 of PSC-04
5-4 Status of HPS-11 read by line STA1 of PSC-04

©AGIE 11.2002 - 17 -
Diagram # 765.643.2
5.1 Specifications of HPS-14

Supply voltage 400VAC-15% +25%
Relative operating humidity 85% maximum
Output voltage Programmable at four levels: For loads from 0÷100%
75VDC ±1%
60VDC ±1%
45VDC ±1%
30VDC ±1%
Output current Limited to 50A maximum
Overvoltage predection OVP bei +20% of Uout Against overvoltage surges caused
nominal by the power supply itself
Output ripple 500mV p-p at maximum load
Leistung η≥80% For loads from 20 ÷ 100% and
fluctuations in mains power supply of
±15%
HPS-14 supplies a voltage programmable at four levels from 30 to 75VDC intended for the generator
power supply.
HPS-14 is managed by PSC-04, its three-phase supply line can be interrupted directly by the emergency
circuit (KM9) and the safety circuits (KM6 and KM7), fitted in serial redundancy on p.c.board WID-129).
It should be noted that the medium power unit HPS-12 fitted in the generator rack is supplied from the
same three-phase line from HPS-14.
In addition, HPS-14 has its own OVP circuit which switches off the supply in the case of the occurrence
of an accidental overvoltage 20% greater than the rated value. In order to return to a normal situation
after an OVP situation, it is necessary to interrupt the AC supply to HPS-14 by turning off the main switch
S1 for ten seconds or by creating an emergency, for example by means of the "Function stop" button.
It should be noticed that the medium power unit HPS-12 situated in the generator cabinet is fed by the
same threephase line as the HPS-14!

©AGIE 11.2002 - 18 -
5.2 Personalised data of HPS-14
The following figure shows the appearance of HPS-14, the position of the various modules, the
personalisation bridges and their configuration.
The personalised data intended to define the command and status lines allotted to HPS-14 by PSC-04
are shown on diagrams # 690.634.1 and 765.643.2

Bridge Description
1-4 Bit 1 of programming of HPS-14 commanded by line CTRL5 of PSC-04

6-9 Bit 0 of programming of HPS-14 commanded by line CTRL4 of PSC-04
7-8 Start-up of HPS-14 commanded by line CTRL3 of PSC-04

The status lines are personalised on the line of bridges X6 located on the power board of HPS-14:
Bridge Description
1-4 Stato della HPS-14 letto dalla linea STA3 della PSC-04
2-6 Sovratemperatura della HPS-14 read by line STA4 of PSC-04

©AGIE 11.2002 - 19 -
6. PSC-04 (WID-96) Control unit
Diagram # 765.693.7
6.1 Purpose of the control unit PSC-04:
• Manage the power unit HPS

• Manage drops in the mains supply and permit the sequences of switching the machine off and on for
all eventualities
• Generate 24VDC maintained by battery and manage the battery. For correct management of the
battery, the main switch of the machine should always be switched on; switching the machine itself on
and off should be carried by functions implemented for this purpose on PSC-04, namely:
- Start-up by means of the REMOTEON button located on the console
- Automatic start-up by means of the clock-calendar functions integrated on PSC-04 (programmed
switch on by date time)
- Switch-off by means of a command input on numerical control.
• Manage a certain number of I/O linked with the machine's supply
• Manage the machine's emergency functions (EMERGENCY OFF) and the I/O linked to them
• Manage a certain number of I/O linked to the machine's safety functions
• Manage communication with the numerical keyboard
6.1.1 Fixing of PSC-04 on WID-96
The PSC-04 is mechanically fixed to the rack by means of four unlosable M 2.5 screws fitted on four
PEM located on the WID-96.
These screws must be fitted for normal functioning of the machine given that they function as a low
impedance earth connection and are indispensable for ensuring good immunity to interference on the
PSC-04.

©AGIE 11.2002 - 20 -
6.2 Functions of module WID-96
The functions of the WID-96 are:

• Interconnection of BITBUS with numerical control
• Interconnection of RS232 for the purpose of testing and initialisation
• Filter and interconnection of the HPS power units
• Interconnection for the test of voltages and internal statuses on PSC-04
• Filter and interconnection with the PSD-14/16/17
• Filter and interconnection NTC for measuring the battery temperature
• Connection of 24VDCB maintained from battery to the PSD-14/16/17
• Interconnection of the battery
• Connection of the 24VDC and the earth of the HPS-10
• Display of the statuses and internal supplies by means of 8 LEDs
• Display of work and error messages by many of a display with two seven-segments digits
• TEST button with 3 functions:
- if pressed after the start-up phase, it allows entry to the software applied without waiting for the
START command from numerical control
- if pressed during normal functioning (in application) it cancels the error messages shown on the 2-digit display of the WID-96
• General RESET button: if activated it switches off all outputs and the power supplies and causes the
firmware on the PSC-04 to restart from the RESET vector
Warning!
The RESET push-button shall be used only in case the NCNC is jammed !

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6.3 Technical specifications
6.3.1 Principal specifications of PSC-04

Supply voltage AC 3x400VAC-15% +25% Supply voltage for the internal circuits
and for the start-up of the main supply
Supply voltage DC 480VDC-700VDC coming Supply voltage for the main DC/DC
from HPS-10 converter on the PSC-04.
Input voltage DC 24VDC ± 5% coming from Voltage intended for generating the
HPS-10 24VDCB maintained by battery on the
PSC-04.
OVP input 24V+20% OVP redundant from the input voltage
coming from HPS-10.
Battery 12V 15A/h Used to maintain the 24VDCB
Battery charge 5A typical U/A charge specification with
measurement of temperature by the
NTC on the battery
Output voltage maintained 24VDC ±5% For loads from 0 ÷ 100%
Output current maintained Limited to 15A maximum
OVP output 24V+20% OVP on the output voltage maintained
by battery
ACLow detection Detection: 400VAC-15% Detection ACLow on any phase
Resetting: 400VAC-10%
ACLow reaction time 25ms typical (1 maximum ACLow is in practice to be able to detect
mains supply period) a gap of 2 periods in the mains supply
Processor INTEL 80C152 Module µP FBCore from the SYSLOGIC
company
Communication channels 1xRS232C Intended for initialisation or test
BITBUS RS485 or TTL Communication with numerical control
Inputs 40 total inputs of which:
14 internal Internally filtered level 5V
1 internal reserve
22 external Externally filtered level 24V
3 external reserve
Outputs 25 total outputs of which: Sink:max. 50V 350mA
5 internal sink Source:24V 350mA
2 internal source reserve
3 external sink
10 external source
4 external source
Relative operating humidity 85% max.
Estimated MTBF 20000 hours Half load Uin = 400VAC

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6.4 Signalling by the PSC-04 (WID-96)
The PSC-04 has two groups of signals:

• LEDs indicating presence and status
• Display (U1) Message display 7 segments of 2 characters
6.4.1 LEDs indicating presence and status:
Led Display Colour Description
GL 1 24VSTA G Indicates that the main internal 24VDC on the PSC-04

is within the required tolerance of ± 5%
GL 2 24VBATSTATU G Indicates that the 24VDC generated on the PSC-04
S from the 12VDC from the battery is within the required
tolerance of ± 5% (22.5V idle or 24V under load)
GL 3 BATLOW R Indicates that the battery's charge level is less than
25%
GL 4 +23V R Indicates the presence of the 23VDC stepped-up on an
internal basis by PSC-04 (indispensable)
GL 5 +5VDRV R Indicates the presence of the 5VDC stabilised on an
GL 6 LOADISP G Indicates that the battery charger is active.
GL 7 +15VDRV R Indicates the presence of the 15VDC stabilised on an
GL 8 +5V R Indicates the presence of the stabilised 5VDC
supplying the internal logic of the PSC-04 and the
module FBCore
6.4.2 Voltages generated by PSC-04 and a description of them:
Name Description
24VBAT 24VDC voltage maintained by battery during 4 minutes after shut-down;

connector XT4 ! PSD-14/16/17/X4
24VCTRL 24VDC voltage present when the processor on PSC-04 is supplied and intended
for I/O circuits for switching the machine on as well as for controlling all QMs;
connector X14 ! PSD-14/16/17/X6
24VE Separate 24VDC voltage present with AC supply to the PSC-04 and intended for
the supply of safety and emergency circuits; connector X14 ! PSD-14/16/17/X6

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6.4.3 Starting circuit
When main switch S1 is turned on the 3 phase 400V AC supply from the mains is connected, coming
from filter Z1 which is always live.
Passing through switch QM8, the 400V AC goes to supply the PSC 04 and the latter generates a pulse
(24V on, 24V start / ) of 1s, which actuates the relay switch KM8 on WID 129. In its turn this supplies the
HPS 10.
After the initial switch-on, the relay holds automatically and can be opened by the monitoring circuit OVP
or by a drop in the mains supply (AC-Low or manual switch-off). the timing of the start is as follows:
Input AC AC<ACnom-15%
ACLow
1s 1s 1s
Start
Check: Switch-on of display U1 present on PSC-04; 00 must appear.

If not OK: Check that QM8 on WID-129 is switched on; otherwise there is a problem with the PSC-
04
As soon as the PSC-04 has a power supply, the controller present on this board (FB-CORE 1/E) starts its
internal tests. This procedure takes approx. 10 seconds.
Check: After approx. 10 sec. 93 must appear on the display on the PSC-04
If not OK: Problem with PSC-04
The end of the initialisation procedure for the PSC-04 also coincides with the switch on of 24V on the
HPS-10.
Check: Lighting up of the LED's present on the HPS-10
If not OK: Check that KM8 on WID-129 has "fired":
If it has fired: HPS-10 OK, otherwise problem on the PSC-04
Note
The commutation of KM8 on WID-129 is monitored by the PSC-04; if it fails to function, it causes an
internal error which signalled by an error message (display U1, PSC-04 = 3B)

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6.4.4 Functions of the ACLow part
The functions of the ACLow part are:
• Generation of the PFAIL signal if the mains voltage is 15% below the rated value of 400 VAC -10%
(out of tolerance, being less than 340 VAC)
• Resetting of the PFAIL signal occours as soon as the mains voltage returns to be within the tolerance
range of the rated value of 400 VAC -10% (i.e., higher than 360 VAC)
• Detection of gaps in the supply from the mains of a minimum of 2 periods (33ms for 60 Hz supplies
and 40 ms for 50 Hz supplies
6.4.5 Functions of the MONITORING part

The functions of the OVP part are:
• Detection and redundant predection of OVP on 24VDC coming from the HPS-10
• Detection and predection of OVP on the main 24VDC generated on the PSC-04
• After an OVP or an ACLow (disappearance of the mains supply or manual switch-off), the initial
starting circuit which generates a 1s pulse when switched on, closes relay KM8 which supplies the
HPS-10 with 3x400VAC.
6.4.6 Functions of the EMERGENCY part

The functions of the EMERGENCY part are:
• Management of the serial emergency consent line (EMERGENCY OFF)
• Output for activating the emergency relays
• Autogeneration of an emergency (in case of a dangerous situation or at a command from numerical
control)
• Generation of the pulse for output of the emergency situation

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6.4.7 Functions of the BATTERY CHARGER part
• Current/Voltage charging curve with measurement of the battery temperature; the maximum current is
limited to 6A ± 20% respectively, while the charging voltage is a function of the temperature according
to the following curve:
Ucarica[V]
14,6 14,61V
14,5
14,4
14,3
14,2
14,1
14
13,9
13,8
13,7 13,71V
10 20 30 40 50 T[°C]
• Detection of charging activity

• Misura Measurement of the charge status with an assumed charge of 4,7Ω
• Measurement of the charge status of the battery at 3 levels
- Capacity ≥ 50%: ein Minimum von 10 power fails sind möglich
- Capacity ≥ 25%: ein Minimum von 5 power fails sind möglich
- Capacity 0%: battery discharged, a power fail at this moment could not be completed correctly
6.4.8 Functioning of the STEP-UP part

The STEP-UP converter which generates the 24V BAT, obtained by starting from the battery (12V DC),
behaves in the following manner:
• the switch-on by means of relay K3 of the 24V DC generated by the converter, can take place only if
the signal <24V BAT STA> is present which confirms the actual presence of the 24V
• it can be switched by relay K3 only if the voltage supplied by its own circuit, measured before relay
K3, and the 24V DC supplied by the HPS-10 are within tolerance; this is for to ensure that the
switch-on of the battery takes place at zero current.
• when the 24VDC coming from HPS-10 is present, the converter stands in reserve with a voltage of
23V DC, which ensures that it is up to the HPS-10 to supply current. If the 24V DC from the HPS-10
should be missing, the converter voltage rises immediately to 24V DC
• the converter ensures that the value of its output voltage is ±5% with respect to the rated value (23
or 24V DC respectively, according to the two situations described here above)
• in the case of AC-Low, the converter keeps the 24VBAT until the command to switch off, but only for
a maximum of 4 minutes; after that it is switched off automatically.

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6.5 Accessible connections on the WID-96
Index Symbol Type Description
X1 MAIN AC/DC 2x3 pins AMP DYNAMIC 5.08 mm Input 3x400VAC and 540VDC
90°
(X3A) RS232 Sub-D 9 pins male 90° double (inf.) Interface RS232 to user
(X3B+C) BITBUS 2 Sub-D 9 pins female in parallel (flat Interface RS485 BITBUS for 2
cable with independent connectors to connections (BUS arrival and departure)
be connected to X8 (internal)
X12 HPS 2x10 pins male for flat cable Interconnection BUS of the HPS power
units
X13 TEST 2x5 pins female Supplies and supply status for production
SUPPLY test
X14 PSD-14/16/17 2x17 pins male for flat cable I/O and supplies from and for the board
PSD-14/16/17
X15 NTC 3 pins AMP DYNAMIC 3.81 mm Connection of the NTX for measuring the
battery temperature
XT4 24VBAT Metal plate 20x12mm Output of the 24V maintained by battery
XT3 BATT Metal plate 20x12mm Connection to positive on battery
XT2 24VDC Metal plate 20x12mm 24V coming from the HPS-10
XT1 GND Metal plate 20x12mm General earth
6.5.1 X1:Main AC/DC

Connection of the mains 3x400VAC supply and input for the 540VDC supply coming from the HPS-10:
1A L1 Phase 1 mains 400 VAC 1B

2A L2 Phase 2 mains 400 VAC 2B 0V_540 Earth of 540VDC
3A L3 Phase 3 mains 400 VAC 3B 540VDC Supply 540VDC

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6.5.2 X3A: RS232
Intended for connection with a terminal or with a PC used as a terminal (e.g. TERMINAL program under
WINDOWS) with the following parameters:
• BAUD rate: 9600
• Bits: 8
• Parity: none
• Stop bits: 1
It is used for displaying operations in progress and for possible error messages
The signals present on X3A are:
1 RTS RS232 Request to Send 6 DTR RS232 Data Transmit Ready

2 TxDATA RS232 Transmit data 7 NU Non used
3 RxDATA RS232 Receive data 8 DTR RS232 Data Transmit Ready
4 CTS RS232 Clear to send 9 NU Non used
5 GND Ground
6.5.3 X3B+C: BITBUS

The BITBUS channel permits communication with numerical control by means of a connection in
accordance with standard RS485.
The PSC-04 is the final node of the line on the machine and thus also supports the bus terminating
resistance.
The connector X3B+C is in fact made up of two connectors in parallel with the same identical function,
just one of the two is connected, given that as explained in this case PSC-04 is the final node.
The connections are:
1 ISO_VCC +5V isolated 6 NU Not used
2 ISO_GND GND isolated 7 ISO_GND GND isolated

3 DATA- Signal RS485 DATA- 8 DATA+ Signal RS485 DATA+
4 NU Not used 9 NU Not used
5 RGND Return GND
ISO_VCC E ISO_GND are the isolated voltages generated on the FBCore and used on it for the drivers
RS485

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6.5.4 X12:HPS
The connector X12 is connected with the X1 connectors (POWER CONTROL BUS) of all the HPS
controlled by the PSC-04 by means of a 20 core flat cable containing all the command and status signals:
1 24V 24V 2 24V 24V

5 CTRL1 Line 1 control 6 CTRL2 Line 2 control
9 GND Ground 10 GND Ground
6.5.5 X13:TEST SUPPLY

On connector X13 various supply voltages and control and PSC-04 status signals are present.
The connector X13 is not cables but is used solely for functional TESTS of the unit PSC-04.
The signals present are:
1 +5V Supply 5 V processor 2 GND Ground

3 5VDRV Supply 5 V driver 4 15VDRV Supply 15 V driver
5 23V Supply 23 V driver 6 24VSTA Status of the main 24V
7 24VBATSTA Status of maintained 24V 8 24VE 24 V emergency
9 24VCTRL Supply 24V I/O 10 GND Ground

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6.5.6 X14:PSD-14/16/17
X14 (Flat cable) 1 to 1:
I/O Connections to PSD-14/16/17:

1 +24VCTRL 24V supply for I/O 2 +24VCTRL 24V supply for I/O
3 DAPDSW Input of the status of the DA 4 MOTPDSW Input of the status of the motor
predections predections
5 GENPDSW Input of the status of the 6 CNCPDSW Input of the status of the
generator predections numerical control predections
7 PSD-14/16/17 Input of the status of the PSD- 8 MANUSW Input of the status of the main
PDSW 14/16/17 predections switch
9 REMOTEON Input of the remote start-up 10 REMOTEOFF Input of the remote switch-off
button(s) button(s)
11 E1SW Input of the status of the 12 E2SW Input of the status of the wire
safety control box for the safety control box
(tank)n door
13 FIRESTA Input of the position-status of 14 ACTIVATE Input of activator button
the fire predection system
15 SECSTA Input of the status of the 16 STARTGEN Input of the request to start up
safety device command relays the main supply and the
managed by the control boxes auxiliary circuits of the
generator
17 EMSTOPS Input of the status of the 18
emergency remote-control
switches
19 TEMPSTA Not in use 20 24VE 24V supply for the emergency
and safety devices
21 24VE 24V supply for the emergency 22 EMSTOPIN Input of the serial line of the
and safety devices consents for emergencies
23 EMSTOPOUT 24V output for the emergency 24 24VSTART Output of the closing pulse of
remote-control switches the remote-control switch for
the supply of HPS-10 and
PSC-04
25 HPS11ON Auxiliary start-up output for 26 HPS15ON Auxiliary start-up output for
the supply for motors the main supply for the
generator
HPS-15
27 24VON 24V output for the remote- 28 SMOKEON Output for starting up the
control switch for the supply smoke extraction system
for HPS-10 and PSC-04
29 GENON Generator start-up output 30 SASYOFF Output for switching off the
control boxes
31 PFAIL Output OC signal of ACLow 32 24VCTRL 24V supply for I/O
33 RESOUT3 Reserve output 34 RESOUT4 Reserve output

©AGIE 11.2002 - 30 -
6.5.7 X15:NTC
Pin Code Description
1 NTCIN Connection of the thermistor for measuring the battery temperature

2 NC Not connected
3 NTCOUT Connection of the thermistor for measuring the battery temperature
6.5.8 XT4:24VBAT
XT4 is a square 20X20x12 mm metal plate for connecting the 24VBAT (24VDC maintained by battery) to
the machine.
6.5.9 XT3:BAT
XT3 is a square 20x20x12 mm metal plate for connection to the positive pole of the battery.
Connection must be made by means of a cable of at least 6 mm2 given the high currents involved
Note
If it is necessary to handle this cable, take the precaution of first disconnecting and removing it from the
battery terminal as, given the very low impedance of the latter, in the event of an accidental short circuit,
currents of 200-300A may flow and cause damage to the cabling or to the battery itself.
6.5.10 XT2:24VDC
XT2 is a square 20x20x12 mm metal plate for connection of the 24VDC coming from HPS-10.
6.5.11 XT1:GND
XT1 is a square 20x20x12 mm metal plate for connection of earth to HPS-10 and to the negative pole of
the battery.
Connection of the battery must be made by means of a cable of at least 6mm² given the high currents
involved.
Note:
If it is necessary to handle this cable, take the precaution of first disconnecting and removing the cable
from the positive terminal of the battery as, given the very low impedance of the latter, in the event of an
accidental short circuit currents of 200-300A may flow and cause damage to the cabling or to the battery
itself.

©AGIE 11.2002 - 31 -
6.6 Display (U1) of error messages
The two character display manages two categories of messages with the following codes:
Hexadecimal from 00 to 7F:
These messages indicate an error situation or an abnormal state in the IPS part of the machine which
may require intervention by the operator to reset it. The messages regarding this section will be analysed
with a fault search procedure in the paragraph:
00 PROC_NOT_OK FBCore not functioning or in a waiting state after a shut-down

30 U24VDC_TOL_ERR 24VDC (HPS-10) outside tolerance
31 UGEN_TOL_ERR Generator voltage (HPS-14) outside tolerance
32 UMOT_TOL_ERR 120VDC motors (HPS-11) outside tolerance
33 U24VBATT_TOL_ERR 24VDC generated from battery outside tolerance

36 UBATT_25 Charge level of the battery ≤ 25%
37 UBATT_0 Battery completely discharged
38 U24VDC_TEMP_OVL_ERR Temperature predection intervention of HPS-10 (24VDC)
39 UGEN_TEMP_OVL_ERR Temperature predection intervention of HPS-14 (generator)
3A UMOT_TEMP_OVL_ERR Temperature predection intervention of HPS-11 (120VDC motors)
3B U24VDC_FAULT_ERR Driver of BUS HPS in FAULT condition

3C UMOT_FAULT_ERR Driver of BUS HPS in FAULT condition
3D UGEN_FAULT_ERR Driver of BUS HPS in FAULT condition
3E SMOKE_ERR Some extraction not functioning
40 EMSTOPS_ERR Error in the emergency procedure, one of the contacts of one of
the emergency relays has not opened
41 DAPD_ERR Intervention by an overload predection cut-off for the DA group
42 MOTPD_ERR Intervention by an overload predection cut-off for the motor group
43 GENPD_ERR Intervention by an overload predection cut-off for the generator
group
44 CNCPD_ERR Intervention by an overload predection cut-off for the CNC group
45 PSD-14/16/17 PD_SW Intervention by an overload predection cutout switch for the PSD
50 WD_ERR Intervention by the communication Watchdog

©AGIE 11.2002 - 32 -
6.7 Display (U1) of error messages
The two character display manages two categories of messages with the following codes:
Hexadecimal from 80 to FF:
These information messages indicate the status of an operation in progress or completed during normal
functioning of the IPS part of the machine:
83 ACLOW_IN_CORSO ACLow in progress (mains failure)

84 EMERGENZA_IN_CORSO Interruption of the serial line of emergency consents
86 REMOTEOFF_IN_CORSO Request for switch-off by means of REMOTEOFF (not
implemented)
87 AUTO_OFF_IN_CORSO Request for automatic switch-off
90 ACC_24V_IN_CORSO Start-up of 24VDC (HPS-10) in progress
91 ACC_UGEN_IN_CORSO Start-up of generator voltage (HPS-14) in progress
92 ACC_UMOT_IN_CORSO Start-up of the 120VDC motors (HPS-11) in progress
93 ACC_24VBAT_IN_CORSO Start-up of the 24VBAT maintained by battery in progress
98 UBATT_50 Charge level of the battery ≤ 50%
A1 VASCA_ABBASSATA Tank lowering phase in progress or tank lowered
A2 VASCA_ALZATA Tank raising phase in progress or tank raised
A3 ATTIVATORE_ON Activator pressed
A4 ATTIVATORE_OFF Activator released
A5
A6
A7 CABINA_APERTA Intervention by the cabin safety control box (opening)
A8 CABINA_CHIUSA Output by the cabin safety status (closure)
AA TEST_PREMUTO Activation of the TEST button on the WID-96
B0 STOP_START_GEN_MIN Interval between generator start-stop less than 1 s
FF All orders were executed correctly
All the messages are also sent on the serial communication channel RS232 (Connector X3A) and are
displayed on a terminal.

©AGIE 11.2002 - 33 -
7. PSD-14/16/17 Equipment safety concept
Drawing # 626.721.4
7.1 Standards
7.1.1 General definition

The safety circuit implemented on the EVOLUTION 2/3 has the task of predecting man and the
environment from incorrect operations or malfunctioning due to failures and/or programming errors.
The safety circuit can find one failure at a time, blocking those functions considered dangerous.
It is necessary to imagine the safety circuit as a sentry checking the functions considered as dangerous,
and if the case arises, it intervenes, blocking them thus avoiding possible damage.
In the normal operating condition, the safety circuit must be passive, that is to say it must not obstruct the
operations or commands given by the CNC.
7.1.2 Conformity
The safety circuit implemented on the EVOLUTION 2/3 complies with the following regulations:
• Directive 89/392/EEC of the Council of the 14th June 1989 for the harmonisation in member states of
regulations for machines, including the subsequent amendments
• Directive 73/23/EEC of the Council of the 12th February 1973 for the harmonisation in member states
of regulations concerning electrical equipment for use within certain voltages, including the
subsequent amendments
• EN 292-1 Machine safety - part 1, November 1991.
• EN 292-2 Machine safety - part 2, November 1991
• EN 60204-1 Machine safety - electrical equipment of machines, part 1, “General requirements”, Octo
ber 1992.
• EN 954-1

©AGIE 11.2002 - 34 -
7.2 Elements controlled
7.2.1 The cabin

The two doors of the cabin giving access to the work tank area are under the control of an appropriate
safety control unit. The access door to the DA area is controlled only if there is an electrode changer
present (optional).
7.2.2 The activator button

This obliges the operator to keep both his hands on the manual command simultaneously, thus avoiding
any possible incidents.
7.2.3 Movement of the work tank

The electric circuit controlling the movement of the work tank switches itself off (KM3) when the cabin is
open. In this case it is reinstated if the activator button is actuated.
The presence of liquid in the work area causes the shutdown of the command circuit thus avoiding that,
for whatever reason, the tank might descend.
7.2.4 Closure of the tank

By means of a supplementary safety cut-off switch a check is made of the closure of the tank, blocking
filling with dielectric if it should be negative.
7.2.5 Safety level with the tank raised or lowered (SL9)

The check is made by means of the supplementary float SL9a.
The float checks the overflow with the tank raised (SL9a), and that there is no filling with the tank lowered
(SL9).
The safety circuit checks the state of the float and that of the work tank (SQ33).
In the case of error, the circulation/filling pump is switched off, signalling the relevant error message on
the CNC.
The safety sensors SP71 and 72 guarantee the pressure of the worktank packing.
The causes which “generate” an error of this type can be manifold:
• An obstruction in the discharge tube.
• A defect in the command circuit for filling the work tank.
• A defect in the filling valve YV10a/b.
• Etc.

©AGIE 11.2002 - 35 -
7.2.6 Movement of the axes
The supplies of all axes (X, Y, U, V, Z) are deactivated when the cabin is opened (KM3 out) and in this
condition it is possible to press the activator button to make the shifts.
7.2.7 The generator

The dangerous voltages which are present during ED machining are switched off when the cabin is
opened thus interrupting as a result the machining in progress.
7.2.8 Linea consenso erosione

The command to start ED machining reaches the PSD-14/16/17 through the PSC-04. The PSD-14/16/17
receives the Start ED machining and activates the two remote-control switches which supply the HPS-14
(+75V generator) only if all the elements checked making up the safety circuit are OK (closed). If that is
not the case, the Start EDM is not possible and the machine signals the relevant error message.
7.2.9 The emergency circuit (internal+external)

The emergency circuit looks after the switching off of all the supplies which are considered dangerous,
leaving the CNC and the intelligent peripherals in service
The possible causes of an emergency are manifold:
a) Stop button on the CNC pressed
b) Stop button on the manual control pressed
c) Emergency limit switch of axes X, Y; U, V, Z
d) A fire in the dielectric (if there is an appropriate anti-fire device present - optional)
Emergencies coming from external appliances if the latter are connected in series to the internal
emergency line nd.
If the PSC 04 (which controls the emergency circuit) sees the circuit open, it interrupts KM9 on WID 129
and KM1 KM2 on PSD 14 by removing the supplies listed in the table.
KM9 on WID 129 400AC QM1 QM2 QM3 QM4 QM5 QM6 QM7
KM1 on PSD 14 24VDCS1 SBX 08 X3 Motors Tank

KM1 on PSD 14 24VDCS2 SUS 39 X7 Brakes Motors Axes
KM1 on PSD 14 24VDCN2 SUS 37 X7
KM2 on PSD 14 24VDCN1 SBX 08 X3 DBE 10 X34
KM2 on PSD 14 24VDC1 Ventilators 24 V.

©AGIE 11.2002 - 36 -
7.3 Operating principle
7.3.1 PSD-14/16/17
The circuit controlling all functions linked with safety is made up of the PSD-14/16/17 and the PSC-04.
All the elements or parts which are considered dangerous pass through the PSD-14/16/17.
The PSD-14/16/17 has the function of managing all the elements described in chapter 2 thus
guaranteeing their functioning or blocking in normal conditions.
Another function of the PSD-14/16/17 is the distribution of the 24V supplies through predection fuses
which in their turn are under the control of the PSC-04.
The central safety control units E1 and E2 look after the switches of the equipment doors and through an
internal control line check the state of the relays which make up the safety circuit.
It is interesting to point that the safety circuit has been designed in such a manner as to put itself into
error condition (thus no consent to the peripherals) when there is an anomaly in the circuit itself.
The state of the safety circuit is checked constantly by the PSC-04 which deals with communication with
the CNC.
If necessary, the internal emergency circuit can also be extended to external apparatuses.
Some reserve connections are provided on the PSD-14/16/17.
7.3.2 Optical indications on the PSD-14/16/17.

The PSD-14/16/17 has been provided with optical indications (LEDs) which facilitate a possible diagnosis
in the case of a search for an error.
In general, the green LED alight is to be interpreted, according to the cases, as the “normal”, “everything
OK” or “in operation” state.
7.3.3 Check of the state of the 24V predection fuses.

If the LED is out, this signals that the fuse concerned has blown because of a short circuit or a current
surge (see table)
LED Supply Fuse - value Description

V3 24VDCB_5 F1 - 6.3A Generator
V26 24VDCB_4 F4 – 3.15A Gen. N or poss. BOOSTER
V44 24VDCB_2 F10 – 6.3A Axes motors (SUS-36)
V11 24VDCB_3 F3 - 0.5A CM (DBE-10)
V3 24VDCB_1 F2 - 6.3A CNC (BAB-21)
V51 24VEP F13 - 2A PSD-14/16/17 (safety)
V1 24VDC_1 F1 - 3.15A Ventilators 24V
V46 24VDCS_1 F12 - 4A Tank lifting motor
V45 24VDCS_2 F11 - 4A Brakes axes motors
V40 24VDCN_2 F6 - 6.3A Generator SUS-37
V39 24VDCN_1 F5 - 4A SBX-08/DBE-10 (I/O)
V43 24VDCN_3 F9 - 4A SUS-39

©AGIE 11.2002 - 37 -
7.4 Safety Central Units Elobau
The outputs OUT 1 and OUT 2 are guaranteed only when the following conditions have been met:
• Supply +24VDC available (LED 2 lit)
• Sensors SQ 20, 50 and 51 activated
• The READY contact activated during initialisation of the Safety Central Units (LED 25 lit)
The green LED’s lit indicate that the respective line (function) is OK.
The red LED 24 lit

• with the below mentioned green LED’s out indicates that at least one equipment door is open. Check
the message/s on the screen and act accordingly;
• without message about an open door on the screen signifies that the READY line of the
corresponding Central Unit was not closed during initialisation or that its sensors have not been
closed in the pre-set order (the two contacts in the sensors do not react simultaneously but one after
the other. The sequence of closure must be observed in order that the sensor can be considered as
being activated).
Central E1 (Elobau 1)
LED Colour State Signification

2 green lit 24VEP supply for Safety Central Units OK
25 green lit Central E1 ready
24 red lit Central E1 not ready
8/19 green lit SQ 50 right door closed
12/15 green lit SQ 51 left door closed
Central E2 (Elobau 2)
LED Colour State Signification

2 green lit 24VEP supply for Safety Central Units OK
25 green lit Central E2 ready
24 red lit Central E2 not ready
8/19 green lit SQ 50 new wire spool door closed
12/15 green not used

©AGIE 11.2002 - 38 -
The two contacts inside the sensor do not react simultaneously, but in sequence. The sequence of
closure must be observed in order that the sensor can be considered as being activated.

©AGIE 11.2002 - 39 -
8. Diagnostics
The diagnostics of the HW part of the IPS group and its peripherals consist in implementing a fault
search starting from the error indication in order to seek to identify the cause, remove it and check the
functioning. If this does not have any success, you are recommended to make a replacement with a
follow-up check, and if after all this the system should still not be in an operating state, contact the AGIE
Service Department.
8.1 The machine and the PSC-04 do not start up

If the non-start is characterised by a complete absence of any activity by machine, in particular the
PSC-04 does not have any LEDs lit.
Non accensione Translation of the Flow Chart
1
S1 inserito
1 No switch on
2
2 S1 connected
Inserire S1
9
3 QM8 connected
ok?
La situazione ok è caratterizzata dall'accensione
dei diodi luminosi +23V, +5VDRV e +15VDRV
4 chine connected to the mains
della PSC-04 supply
15
QM8 inserito 5 Mains supply present
3 QM6 inserito
Inserire QM8 6 X1 PSC-04 and X4 HPS-10

10 Inserire QM6 connected?
7 Replace the PSC-04 group
ok?
8 Problem solved
Macchina
connessa
4 alla rete 9 Connect S1
Connettere la macchina
alla rete 10 Connect QM6
11
11 Connect the machine to the
ok? mains supply
12 Search for and eliminate the
5
Rete presente cause
Ricercare e eliminare la
causa 13 Connect X1 PSC-04 anD/or X4
12 HPS-10
ok?
14 Contact AGIE Development
15 Situation OK is characterized by
X1 PSC-04 e X4 the fact that the diodes of -23V,
HPS-10 inseriti?
6 -5VDRV and -15V DRV flash on
Inserire X1 PSC-04
e/o X4 HPS-10
the PSC-04
13
ok?
Sostituire il gruppo
PSC-04
7
ok?
Contattare lo
Problema risolto
sviluppo AGIE
8 14

©AGIE 11.2002 - 40 -
8.2 The PSC-04 shows a certain activity but the machine does not
start up
The activity of the PSC-04 is indicates by the lighting up of the two LEDs showing the presence of 23V,
+5VDRV and +15VDRV. If both the message display and the LEDs 24VSTA and +5V remain off, carry
out the following search for faults:
1 Non accensione
avanzata
X1 PSC-04
2 X4 HPS-10
inseriti?
7 Inserire X1 PSC-04
e/o X4 HPS-10
La situazione ok è caratterizzata
dall'accensione dei diodi luminosi +23V, 22
+5VDRV, +15VDRV, +5V, 24VSTA e
LOADISP della PSC-04
ok?
3 KM8 eccitato?
8
KM8 alimentato?
HPS-10
3x400VAC Sostituire KM8 20
4 presente?
Verificare le connessioni
Verificare le connessioni di KM8 9
13 dell'HPS-10 21
KM8 eccitato?
14 10
HPS-10
3x400VAC KM8 eccitato?
presente?
ok?
HPS-10
5 540VDC Sostituire il gruppo
presente? PSC-04
11
15 HPS-10
12
PSC-04
16 KM8 eccitato?
HPS-10
F1 ok? 540VDC
presente?
6 ok?
PSC-04
ok 17 Sostituire F1 sulla
PSC-04
ok
Contattare lo
Problema risolto
18 sviluppo AGIE 19

©AGIE 11.2002 - 41 -
The KM8 command block diagram is as follows:
OVP
KM
1s
01943a_x.ds4

1 No switch on remains
2 X1 PSC-04 X4 HPS-10 connected?
3 KM8 energised?
4 HPS-10 3x400 VAC present?
5 HPS-10 540 VDC present?
7 Connect X1 PSC-04 and/or X4 HPS-10
8 KM8 supplied?
9 Check the connections of KM8?
10 KM8 energised?
12 KM8 energised?
13 Check the connections of HPS-10
14 HPS-10 3x400 VAC present?
15 Replace the HPS-10 group
16 HPS-10 540 VDC present?
17 Replace F1 on PSC-04.
18 Problem solved
20 Replace KM8
21 KM8 energised?
22 The OK situation is marked by the switch on of the LEDs +23V, +5VDRV, +15VDRV, +5V, 24VSTA
and LOADISP of the PSC-04.

©AGIE 11.2002 - 42 -
8.3 Error 00: FBCore not functioning
1 E rro re 0 0
W ID -9 6 X 1 3 -1
+ 5 V = 5 V ±5 %
W ID -9 6 X 1 3 -3
5 V D R V = 5 ±1 %
2 S o s titu ire m o d u lo FB C o re
W ID -9 6 X 1 3 -4
ok? 1 5 V D R V = 1 5 V ±5 %
6 S o s titu ire g ru p p o P S C -0 4
W ID -9 6 X 1 3 -5
23V>16V
ok?
W ID -9 6 L E D
24VSTA on
S o s titu ire F 4
5
P S C -0 4 F 4 o k
3 C o n ta tta re lo
P ro b le m a ris o lto 4 s v ilu p p o A G IE
1 Error 00
2 Replace the FBCore module
3 Problem solved
5 Replace F4

©AGIE 11.2002 - 43 -
8.4 Error 30: 24VDC (HPS-10) outside of tolerance
Errore 30
1
WID-93
HPS-10 X14-4
5VDRV=5V±1%
?
WID-93
HPS-10 X14-3
15VDRV=15V±5%
?
WID-93
HPS-10 X14-1
23V>18V
?
5 HPS-10
HPS-10
LED POWER ON
2 sempre acceso Occorre verificare l'accensione permanente e non
? temporanea dei LEDs durante la fase di accensione
(spegnere e riaccendere la macchina)
16
HPS-10
LED POWER OK
3 sempre acceso
?
6 Sconnettere X1
Collegare X3 e X14
HPS-10 con cavo test
7 accensione
La situazione ok è caratterizzata dall'accensione di tutti

i LED dell'HPS-10
ok? 15
11 HPS-10
Sostituire il flat cable di
8 connessione
PSC-04-HPS Ripristinare le connessioni
12 originali su HPS-10
Ripristinare le
9 connessioni originali
ok?
ok?
13 PSC-04
ok?
Non esiste Contattare lo

Problema risolto
4 il problema 10 14 sviluppo AGIE

©AGIE 11.2002 - 44 -
1 Error 30
2 HPS-10 LED POWER ON always alight?
3 HPS-10 LED POWER OK always alight?
4 The problem does not exist.
6 Disconnect X1
7 Connect X3 and X14 HPS-10 with switch on test cable
8 Replace the flat connection cable PSC-04-HPS
9 Reinstate the original connections
10 Problem solved
12 Reinstate the original connections to HPS-10
15 The OK situation is marked by the lighting up of all the LEDs on the HPS-10
16 It is necessary to check that the lighting up of the LEDs during the switch-on phase is permanent and
not temporary (switch the machine off and on again).

©AGIE 11.2002 - 45 -
8.5 Error 31: Generator voltage (HPS-15) out of tolerance
Errore 31
1
Sconnettere X4 HPS-14
2
Sconnettere XT1 e XT2
HPS-14
3
Connettere su X4 HPS-14
il cavo che va a X4
HPS-11
4
Far partire l'applicazione
con il pulsante TEST della
WID-96
5
i LED dell'HPS-14 9
ok?
Ricercare la causa dal lato

KM6,KM7,PSD- 14 o E1
10
WID-93
HPS-14 X14-4 Ripristinar e le
5VDRV=5V±1%
?
connessioni originali
11
ok?
WID-93
HPS-14 X14-3
15VDRV=15V±5%
?
WID-93
HPS-14 X14-1
23V>18V
?
HPS-14 12
HPS-14
LED POWER ON
6 sempre acceso
?
Occorre verificare l'accensione
permanente e non temporanea dei LEDs
durante la fase di accensione (spegnere
e riaccendere la macchina)
HPS-14
7 LED POWER OK
sempre acceso
13
?
Sconnettere X1 14
Collegare X3 e X14
HPS-14 con cavo test 15
accensione
ok?
19 Sostituire il gruppo
HPS-14
Sostituire il flat cable di
connessione
16
PSC-04-HPS 20
Ripristinare le connessioni
originali su HPS-14
Ripristinare le
17
connessioni originali
ok?
ok?
18
PSC-04
ok?
8 21 22
Non esiste Contattare lo
Problema risolto
il problema sviluppo AGIE

©AGIE 11.2002 - 46 -
1 Error 31
2 Disconnect X4 HPS-14
3 Disconnect XT1 and XT2 HPS-14
4 Connect to X4 HPS-14 the cable going to X4 HPS-11.
5 Make the application start up with the TEST button on W ID-96.
8 The problem does not exist.
9 The OK situation is marked by the lighting up of all the LEDs on the HPS-14
10 Search for the cause from the KM6, KM7, PSD-14/16/17 side
13 It is necessary to check that the lighting up of the LEDs during the switch-on phase is permanent
and not temporary (switch the machine off and on again).
14 Disconnect X1
15 Connect X3 and X14 HPS-14 to the switch-on test cable
21 Problem solved

©AGIE 11.2002 - 47 -
8.6 Error 32: HPS-11 120V DC motors outside tolerance
1 Errore
E rro re 332
1
X 4 H P S -1 1
2 connesso?
8 C o n n e tte re X 4 H P S -1 1
ok?
3 S c o n n e tte re X T 1 e X T 2
H P S -1 1
F a r p a rtire l'a p p lic a zio n e

4 c o n il p u ls a n te T E S T d e lla
W ID -9 6
9
L a s itu a zio n e o k è c a ra tte rizza ta d a ll'a c c e n s io n e d i tu tti
i L E D d e ll'H P S -1 1
ok?
R ic e rc a re la c a u s a d a l
la to K M 5 o E 1 10
W ID -9 3
H P S -1 1 X 1 4 -4 R ip ris tin a re le
5VD R V=5V±1% c o n n e s s io n i o rig in a li 11
?
ok?
W ID -9 3
H P S -1 1 X 1 4 -3
15VD R V=15V±5%
?
W ID -9 3
H P S -1 1 X 1 4 -1
23V>18V
?
S o s titu ire il g ru p p o
H P S -1 1 12
H P S -1 1
LED POW ER ON
5 s e m p re a c c e s o
?
O c c o rre v e rific a re l'a c c e n s io n e
p e rm a n e n te e n o n te m p o ra n e a d e i
L E D s d u ra n te la fa s e d i a c c e n s io n e
(s p e g n e re e ria c c e n d e re la m a c c h in a )
H P S -1 1
6 LED POW ER OK
s e m p re a c c e s o
13
?
S c o n n e tte re X 1 14
C o lle g a re X 3 e X 1 4
H P S -1 1 c o n c a v o te s t
a c c e n s io n e
15
ok? 19
H P S -1 1
S o s titu ire il fla t c a b le d i
c o n n e s s io n e 16
P S C -0 4 -H P S R ip ris tin a re le c o n n e s s io n i
o rig in a li s u H P S -1 1
R ip ris tin a re le
c o n n e s s io n i o rig in a li 17 20
ok?
ok?
P S C -0 4 18
ok?
N o n e s is te C o n ta tta re lo
7 il p ro b le m a 22 P ro b le m a ris o lto 21 s v ilu p p o A G IE

©AGIE 11.2002 - 48 -
Translation of the Flow Chart texts
1 Error 32
2 X4 HPS-11 connected?
3 Disconnect XT1 and XT2 HPS-11
4 Make the application start up with the TEST button on WID-96
7 The problem does not exist
8 Connect X4 HPS-11.
9 The OK situation is marked by the lighting up of all the LEDs on HPS-11
10 Search for the cause from the KM5 or E1 side
13 It is necessary to check that the lighting up of the LEDs during the switch-on phase is permanent and
not temporary (switch the machine off and on again).
14 Disconnect X1
15 Connect X3 and X14 HPS-11 with the switch-on test cable.
17 Reinstate the original connections.
18 Replace the PSC-04 group.
19 Replace the HPS-11 group.
21 Contact AGIE Development.
22 Problem solved

©AGIE 11.2002 - 49 -
8.7 Error 33: 24V DC, generated by the battery outside tolerance
1 E rro re 3 3
24VD C ±1% su
2 X T 2 P S C -0 4 ?
5
24VD C ±1% su
X T 2 H P S -1 0
N o r m a lm e n te è p r e s e n te
l'e r r o r e 3 0
V e r ific a r e la c o n n e s s io n e
X T 1 ,X T 2 fra H P S -1 0 e 6 9
P S C -0 4
ok?
P S C -0 4
F5 ok?
7 S o s titu ir e F 5
ok?
3 S o s titu ir e la P S C - 0 4
ok?
4 C o n ta tta r e lo 8 10 A n a lis i u lte r io r e

P r o b le m a r is o lto
s v ilu p p o A G IE p r o b le m a
1 Error 33
2 24VDC +/- 1% on XT2 PSC-04?
3 Replace the PSC-04.
4 Contact AGIE Development.
5 24VDC +/- 1% on XT2 HPS-10
6 Check the connection XT1, XT2 between HPS-10 and PSC-04.
7 Replace F5.
8 Problem solved
9 Normally Error 30 is present
10 Analyse further problem.

©AGIE 11.2002 - 50 -
8.8 Error 36: Charge level of battery GB1 ≤ 25%
This error must not normally be displayed in permanent mode. If the battery GB1 is frequently
overstrained by sequences of ACLow or switch-offs, after a certain time it should display error 37. If the
battery GB1 is not being overstrained and the machine is functioning normally, first of all message 98
(Battery charge level ≤50%) should reappear and then also disappear again after about 2 hours with the
charging of battery GB1.

©AGIE 11.2002 - 51 -
8.9 Error 37: Battery GB1 completely discharged
Errore 37
1
Aspettare 2 ore con

macchina in funzione
normalmente
3 Errore 37?
5
Connessione
batteria ok?
PSC-04 XT3
13V<U<15V?
6 7 11
Connettere la batteria Sostituire il gruppo
Sostituire la batteria
correttamente PSC-04
Aspettare 2 ore con

8 macchina in funzione
normalmente
9 Errore 37?
Nessun problema Contattare lo

Problema risolto
4 batteria in carica 10 12 sviluppo AGIE
Translation of the Flow Chart texts gramm:
1 Error 37
2 Wait 2 hours with the machine functioning normally
3 Error 37?
4 No problem, battery being charged
5 Battery connection OK?
6 Connect the battery correctly
8 Wait 2 hours with the machine functioning normally
9 Error 37?
10 Problem solved
11 Replace the battery

©AGIE 11.2002 - 52 -
8.10 Error 38: Intervention by the temperature predection of HPS-10
1 E rro re 3 8
2 S p e g n e re la m a c c h in a
A s p e tta re 1 5 m in u ti
3
4 R ia c c e n d e r e la m a c c h in a
E lim in a r e e la c a u s a o
10 s o s titu ir e i v e n tila to r i
V e n tila to r i IP S
5 fu n z io n a n o tu tti?
E lim in a r e la c a u s a o
11 s o s titu ir e lo s c a m b ia to r e
S c a m b ia to r e
6 d i c a lo r e
fu n z io n a ?
7 S o s titu ir e l'H P S - 1 0
A c c e n d e r e la m a c c h in a e
8 la v o r a r e 3 0 m in u ti
o k ?
C o n ta tta r e lo
9 P r o b le m a r is o lto 12 s v ilu p p o A G IE
1 Error 38
2 Switch the machine off.
3 Wait 15 minutes.
4 Switch the machine on again.
5 Are all the IPS fans functioning?
6 Is the heat exchanger functioning?
7 Replace the HPS-10
8 Switch the machine on and work for 30 minutes
9 Problem solved
10 Eliminate the cause or replace the fans
11 Eliminate the cause or replace the exchanger

©AGIE 11.2002 - 53 -
8.11 Error 39: Intervention by the temperature predection of HPS -14
To be treated like error 38, substituting HPS-10 for HPS-14.
8.12 Error 3A: Temperature predection of HPS-11

To be treated like error 38, substituting HPS-10 for HPS-11.

©AGIE 11.2002 - 54 -
8.13 Error 3B, 3C, 3D: Driver of the HPS bus in FAULT condition
Errore 3B
1
2 Sconnettere X1 della
HPS-10/11/14
HPS-10/11/15
16 Attenzione:
Sconnettere X12 della HPS-10/11/14
HPS-10/11/15
3
PSC-04
Collegare X3 e X14
4 HPS-10/11/14
HPS-10/11/15 con
con cavo
cavo
test accensione
5 Accendere la macchina
Far partire l'applicazione

6 con il pulsante TEST della
WID-96

ii LED
LED dell’HPS-10/11/15
dell'HPS-10/11/14 ee dall’assenza
dall'assenza di
di errori
errori sul
sul
display della PSC-04
ok? 10
11 Errore 3B?
Sostituire il cavo piatto di
7 collegamento
PSC-04-HPS Una o più HPS
13 difettose?
12 Sostituire la PSC-04
Sostituire la o le HPS
14 difettose
Ricollegare normalmente
8 il gruppo IPS
ok?
Contattare lo
Problema risolto
9 15 sviluppo AGIE

©AGIE 11.2002 - 55 -
1 Error 3B
2 Disconnect X1 of the HPS-10/11/14
3 Disconnect X12 of the PSC-04
4 Connect X3 and X14 HPS-10/11/14 with the switch-on test cable
5 Switch the machine on
6 Make the application start with TEST button on the WID-96
8 Reconnect the IPS group normally
9 Problem solved
10 The OK situation is marked by the switching on of all the LEDs of the HPS-10/11/14 and the absence
of errors in the display on the PSC-04
11 Error 38?
12 Replace the PSC-04
13 One or more HPS defective?
14 Replace the defective HPS
15 Contact AGIE development

©AGIE 11.2002 - 56 -
8.14 Error 40: Error in the emergency procedure
This error indicates that at least one of the remote control switches KM1, KM2 on PSD-14/16/17, 16, 17,
or KM9 on WID-129, 169 (Evo) on WID-141, 170 (Cla) respectively, has not opened correctly in a case of
emergency; normally this indicates that at least one of the contacts has remained stuck. Switch the
machine off and replace the defective remote control switch.
If the error should persist without any contact being stuck, contact AGIE Development.
8.15 Error 41: Overload predection DA Group

It idicates that at least one of the overload predection cutout switches QM1, QM2, QM3, QM4 on WID-
129, 169 (Evo) or QM1, QM2 on WID-141, 170 (Cla) or one of the fuses F3, F5, F12 on PSD-14/16/17,
16, 17 (Evo) or F3, F5 on PSD-1616 (Cla), QM3 on WID-129 has opened; switch it on again manually or
replace the blown fuse and start up again.
If the error should occur again, this is a sign that there is an overload. Search for the cause of this and
eliminate it. Then switch the cutout on again.
If the error should persist, contact AGIE Development..
8.16 Error 42: Overload predection motor group

It indicates that the overload predection cutout switch QM5 on WID-129, 169 (Evo) or one of the fuses
F8, F9, F10, F11 (PSD-14/16/17, 16, 17 Evo and Cla) has opened; switch it on again manually or replace
the blown fuse and start up again.
If the error should persist, contact AGIE Development..
8.17 Error 43: Overload predection generator group

It indicates that at least one of the overload predection cutout switches or one of the fuses F1, F6, F4, F7,
(PSD-14/16/17, 16, 17), QM6 or QM7 on WID-129, 169 (Evo) or on WID-141, 170 (Cla) has opened;
switch it on again manually or replace the blown fuse and start up again.
If the error should persist, contact AGIE Development.

©AGIE 11.2002 - 57 -
8.18 Error 44: Overload predection CNC group
Indicates that F2 on PSD-14/16/17, 16, 17 has cut out. Replace it and start again.
8.19 Error 45: Overload predection supply PSD

Indicates that F13 on PSD-14/16/17, 16, 17 has cut out. Replace it and start again.

©AGIE 11.2002 - 58 -
9. Information messages
As already mentioned, the information messages give indications of the status of the machine and do not
normally require any operations on the user's part. However, it is worth-while to say a few words
concerning messages 84 and A7.
9.1 Message 84: emergency situation

The emergency situation is characterised by the switching off of all supplies which may be dangerous or
which are used for movements. All the intelligent units normally remain supplied in order to be able
to manage the emergency situation adequately.
The emergency situation can be brought about by interrupting the serial line of emergency consents:
• By the operator by actuating the "Function stop" buttons on the console or the remote control box
• By any unit on the machine for which the possibility has been foreseen.
During the start-up phase, the machine is always in an emergency situation, even if everything is OK,
exit from this emergency situation can be implemented:
• By actuating the Test button on the PSC-04
• By the PSC-04 on receipt of the START command from numerical control and during functioning, after
having remedied the cause of the emergency:
• With the consent of the operator from the console.
9.2 Message A7: cabin open

This message indicates that the machine is in a safety hazard situation caused by opening the access
doors to the work area. In order to reset the normal situation, the doors must be shut.

©AGIE 11.2002 - 59 -
©AGIE 11.2002 - 60 -

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Agiecut wire-cutting EDM systems (except Vertex)

This document is for authorized technical staff only.

AGIE CHARMILLES Group

Agiecut (except Vertex) S3 Supply, Safety

Agiecut (except Vertex) S3 Supply, Safety

Agiecut (except Vertex) S3 Supply, Safety

1.1 General description of supplies:

1.2 Components of the supplies rack

Agiecut (except Vertex) S3 Supply, Safety

2.1 Description and make-up of the power modules

HPS-10 HPS-10 AUX-80 PSC-01 WID-93 HPS-10 765.653.1

2.2 Signalling LED status HPS

LED name Indication

Agiecut (except Vertex) S3 Supply, Safety

Nam Symbol Type Description

Agiecut (except Vertex) S3 Supply, Safety

Pin Code Description HPS Pin Code Description HPS

1 24V 24V 2 24V 24V

2.3.2 X3:POWON (HPSON)

A of 24VDC available on X3 allows the HPS unit to be started up.

Pin Code Description Pin Code Description

1 0V 0V for command 2 ON 24VDC start-up signal

Agiecut (except Vertex) S3 Supply, Safety

Mains voltage connection 3x400VAC and output for 540VDC voltage:

Pin Code Description Pin Code Description

1A L1 Phase 1 mains 400VAC 1B HALF Median point of 540VDC

2.3.4 X14:TEST SUPPLY

Pin Code Description Pin Code Description

2.3.6 XT2: UOUT

Agiecut (except Vertex) S3 Supply, Safety

Questa sequenza indica che l'HPS è accesa

Translation of the Flow Chart texts:

Agiecut (except Vertex) S3 Supply, Safety

Verifica che la tensione di carica dei condensatori

AUX80 Permette ai condensatori di caricarsi ulteriormente fino

AUX80 Cortocircuita le resistenze e le PTC di carica Inserendo

Translation of the Flow Chart texts:

Agiecut (except Vertex) S3 Supply, Safety

O N =1? R ic h ie sta d 'a c c e n sio n e d e lla P S C -0 4

V e rific a se il 2 3 V d 'a lim e n ta z io n e in te rn o è

SSO K =0? 10 V e rific a se il c ic lo d i s o ft sta rt è te rm in a to

5 C o n tro llo sta to 7 A c c e n sio n e

Translation of the Flow Chart texts:

Agiecut (except Vertex) S3 Supply, Safety

Verifica se la tensione d'uscita dell'HPS è

Translations of the Flow Chart texts:

Agiecut (except Vertex) S3 Supply, Safety

3.1 Specifications of the HPS-10:

Specification Value Observations

Supply voltage 3x400VAC-15% +25%

Agiecut (except Vertex) S3 Supply, Safety

3.2.1 X5: Command lines

3.2.2 X6: Status lines

Agiecut (except Vertex) S3 Supply, Safety

4.1 Specifications of HPS-11:

Specification Value Observations

Agiecut (except Vertex) S3 Supply, Safety

4.2.1 X5: Command lines

4.2.2 X6: Status lines

Agiecut (except Vertex) S3 Supply, Safety