CS-Lab CSMIO/IP-M Manual de usuario

Applies to firmware version: v1.200

First edition Rev 1.2

Index

1. General...........................................................................................................................................4

1.1 Signs used in this guide ............................................................................................................... 4

1.2 Contents ...................................................................................................................................... 5

1.3 Standards compliance.................................................................................................................. 6

1.4 Specification................................................................................................................................ 6

2. Safety ............................................................................................................................................7

2.1 Example of E-STOP signal connection .......................................................................................... 8

3. Recommendation for mechanical installation ...................................................................................9

4. Connectors, controls and electrical installation of the device ..........................................................10

4.1 Arrangement of the connectors on the device ............................................................................ 10

4.2 STEP/DIR controlling signals and digital outputs connector ....................................................... 11

4.3 Digital inputs connector............................................................................................................. 13

4.4 Analog I/O connector ................................................................................................................. 14

4.5 Expansion modules connector.................................................................................................... 14

4.6 Power connector........................................................................................................................ 15

4.7 Communication connector – Ethernet........................................................................................ 15

4.8 Recommended cables................................................................................................................ 16

4.9 Installation examples................................................................................................................. 17

4.9.1 The simplest connection of Inverter using a CSMIO IP-M analog output.......................... 17

4.9.2 Simplified diagram of a XYZ plotter................................................................................... 18

4.9.3 Automatic control of drives power supply (HV) ................................................................. 20

4.10 LED Status lights........................................................................................................................ 21

5. Recommendations and drive selection (motor drives).....................................................................22

6. Precise homing with use of the servo drive and the encoder INDEX signal........................................24

7. LAN connection and configuration .................................................................................................26

7.1 PC direct connection.................................................................................................................. 26

7.2 Local network with router and DHCP .......................................................................................... 28

8. Mach3 program – general information ...........................................................................................29

8.1 Recommended PC configuration ................................................................................................ 31

9. Software installation.....................................................................................................................32

9.1 Mach3 installation ..................................................................................................................... 32

9.2 Microsoft® .Net installation (older operating systems) .............................................................. 33

9.3 Installation of the plug-in for Mach3........................................................................................... 33

9.4 Administrator rights in Windows® Vista and Windows® 7.......................................................... 34

10.Mach3 program configuration........................................................................................................35

10.1 Configuration profile .................................................................................................................. 35

10.2 The first run ............................................................................................................................... 36

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10.3 Configuration of axes used in the machine................................................................................. 37

10.4 Configuration of the digital input signals.................................................................................... 38

10.5 Configuration of digital output signals........................................................................................ 40

10.6 Configuration of spindle and cooling controlling......................................................................... 42

10.7 Configuration of the resolution, speed and acceleration of the axes............................................ 44

10.8 Configuration of motion directions, homing and software limits ................................................. 45

10.9 Additional configuration functions in the plug-in window ........................................................... 46

10.9.1 Servo drive fault signals.................................................................................................... 46

10.9.2 Override sources tab, feed rate correction speed and spindle revs .................................... 47

10.9.3 Spindle tab, selection of analog output that controls the spindle revs............................... 47

10.9.4 Special functions tab, HVEnable and ServoReset. ............................................................. 48

10.10 Selection of inch/mm units ........................................................................................................ 49

10.11 Parameters in the General Config window. ................................................................................. 49

11.First tests.....................................................................................................................................51

11.1 Checking the input signals ......................................................................................................... 51

11.2 Verification of axes scaling and motion directions...................................................................... 52

11.3 HOMING and software limit switches test................................................................................... 53

11.3.1 First homing...................................................................................................................... 53

11.3.2 SoftLimit switches. ........................................................................................................... 53

11.4 Test of spindle and cooling. ....................................................................................................... 54

12.Sample processing step by step.....................................................................................................55

12.1 Preparation of project and G-Code files...................................................................................... 55

12.2 Preparation of the machine and the Mach program .................................................................... 59

12.3 We begin the work...................................................................................................................... 61

13.A few practical notes about Mach3 program and CSMIO/ IP-M.........................................................63

14.VisualBasic® macros .....................................................................................................................65

14.1 Automatic tool-length measurement.......................................................................................... 65

14.1.1 Configuration .................................................................................................................... 66

14.2 Automatic tool change macro .................................................................................................... 67

15.Addition A – CSMIO/IP-M software updates ...................................................................................68

15.1 How to check your software version........................................................................................... 68

15.2 Updating application (uploader) ................................................................................................. 68

15.3 Plugins file update ..................................................................................................................... 69

15.4 Checking the update .................................................................................................................. 69

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1. General

CSMIO/IP-M product was designed for customers, who are looking for a compromise between advanced

CSMIO/IP-S controller and a simple LPT based device. The biggest advantage of the CSMIO/IP-M

controller is its reasonable price.

The main designing assumption was working stability – hence the use of Controller to PC connection via

Ethernet (its physical layer is galvanically isolated and protocols we use ensure reliable and fast

transmission even in tough industrial environment). Practically any other interface does not provide the

continuity and reliability of transmission on such a high level as the ETHERNET. That is why it is currently

the worldwide standard for high-speed digital communication.

Another important assumption was simplicity of installation. CSMIO/IP-M does not require any external

electronics for proper operation. Inputs/outputs signals are inside optically isolated, filtered, protected

against short circuit, overheating etc. All signals are adjusted to industry standard 24V. The device is

enclosed in a compact cover, mounted on a DIN-rail, which makes the mechanical and electronic

installation in the control cabinet take less time due to its simplicity.

CSMIO/IP-M works with Mach3 program because of its low price, popularity and enormous ability to adapt

to specific requirements. As a drives control interface the choice was a popular step/direction (step / dir)

standard. It allows controlling both the stepper motor drives and the most modern servo drives. Max.

frequency of stop signal is 125 kHz so it is sufficient value for many uses. What is important the controller

is responsible for pulses generation, the same it ensures that the signal is stable in the frequency domain

and its duty cycle 50%. This enables greater culture of machine work than it is while using LPT based

controller.

1.1 Signs used in this guide

________________________________________________________________________________________________________

Potential danger, possible injury risk.

________________________________________________________________________________________________________

Useful information, tips.

________________________________________________________________________________________________________

Warning, failure to comply with these warnings may lead to inappropriate functioning or damage of

the device.

________________________________________________________________________________________________________

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1.2 Content

The CSMIO/IP-M package includes DB->Terminal Block adapters for easier wires connection in the control

cabinet. Basic components supplied are:

•1xDB25 -> Terminal Block adapter

•1xDB25 + 1xDB9 -> Terminal Block adapter

•2xDB25 connection tape

•1xDB9 connection tape

In case of lack of any elements listed above, please contact your distributor.

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1.3 Standards compliance

CSMIO/IP-M controllers were designed and made in accordance with the national and international

standards for industrial control systems based on electronic components:

•Detailed requirements for programmable controllers: working characteristics, shock resistance,

safety etc. EN61131-2 (IEC1131-2), CSA 22.2, UL508

•Compliance with European Guidelines (low voltage, the level of electromagnetic interference

Electromagnetic Compability), the CE marking.

•Electrical and non-combustible properties of insulation materials: UL 746C, UL 94, etc.

•The Product made in lead-free technology, RoHS compliant.

1.4 Specification

Parameter

Value

Digital inputs

Digital outputs

Relay outputs

Analog inputs

Analog outputs

Supply voltage

24VDC +/-10%

Power consumption

Maximum I/O Voltage

30VDC

Maximum output line load

250mA

Analog Input Voltage

0-10VDC

Analog Output - Maximum Load

5mA

Axis Drives control type

(STEP/DIR)

Maximum frequency of the STEP signal

125kHz

STEP Signal Duty Cycle

50%

PC communications

Ethernet 10/100Mb

Ambient temperature range

0oC to +60oC

Relative Humidity (Non-Condensing)

10% to 95%

(without condensation)

The STEP outputs signal frequency is in no way limited by the „Kernel speed” settings in Mach3 program.

While using the CSMIO/IP-M controller this Mach3’s configuration parameter is unused and can be set at

any value.

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2. Safety

The CSMIO / IP-M device is powered by 24V safe voltage. I / O control lines are optically isolated, also the

PC connection is galvanically isolated. The device does not constitute a direct threat to the health and life

of the user.

Designing a complete control system (control cabinet), you should draw attention to several issues, so

that the entire system does not pose any hazard during use.

Always use the NC contacts for limit switches and safety switch. Thanks to it - a wiring mistake or i.e.

plug-ins disconnection will stop the machine.

Pay special attention to the emergency stop circuit. The control system must be designed in such a way

that when you press the emergency stop mushroom, controlled machine stops immediately in all axes.

You should also take into account the possibility of failure of particular system components such as the

main controller, or axis drives.

For that purpose you can use (not required) a standard safety relay (i.e. from PILZ Company). The safety

switch mushroom, FAULT signals of the drives and inverter and eventually other alarm signals – you

should connect to the input circuits. The output or outputs should be connected to the CSMIO/IP-M

controller, and defined as the emergency stop. Outputs of the security module should be also connected to

the axis drives, inverters, etc. This way we get double protection – if, by inappropriate configuration or

CSMIO/IP-M controller failure - the emergency would not work, the information goes to the axis drives,

which can properly respond to it. It works both sides: if the drives would not react, you always have the

controller.

CSMIO-IP/M Controller in the active state on the input line - defined as E-Stop, blocks the STEP signals

within 0.0001 s. It happens autonomously, without Mach3 program and thus the machine stops very fast.

The same happens with reaction to signals from limit switches.

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2.1 Example of E-STOP signal connection

The simple example above shows the E-Stop signal connection to the CSMIO/IP-M controller and to the

axis drives, using a Pilz company safety relay (PNOZ X7 24V). S1 is a reset button (safety relay switching

on), S2 is an emergency stop.

This module has one input with all the alarm sources connected to this input (A1). In addition to the

mentioned emergency stop (S2) there are NC contacts - NC1 and NC2, which may be, i.e. opening sensors

for the cover and the control cabinet. Moreover, there are drives’ FAULT signals connected in series. Two

outputs of the safety relay were used as an E-Stop signal for the CSMIO/IP-M controller and axis drives.

This combination assures the machine stops in case of failure on any axis (FAULT signals of the drives),

by pressing emergency stop mushroom and opening the cabinet or cover. Separation of the safety relay

output channels gives double protection for the system and significantly increases the reliability of the

entire system.

PILZ

PNOZ X7 24 V

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3. Recommendation for mechanical installation

CSMIO/IP-M controller and DB->Terminal block - connection modules were designed to be installed on

standard DIN-rail. It is the quickest and best way of installation.

The Controller uses a small amount of energy and creates a negligible amount of heat.The aluminum

housing provides adequate cooling for the electronics inside, even if the ambient temperature reaches

40OC (104OF).

As for the controller, there are no special precautions for ventilation and the minimum clearance

distances. However, usually, next to the controller in the control cabinet, there are also inverters, power

supplies, motor drives - these components emit a lot of heat, so you should always remember about their

proper location and proper ventilation of the cabinet.

Here is an example of components arrangement in the control cabinet.

Caution is advised during the mechanical and electrical installation. Poorly tightened cable may cause

many problems; it is also very difficult to find such a defect while launching/using the system.

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4. Connectors, controls and electrical installation of the device

4.1 Arrangement of the connectors on the device

Detailed description of signals on individual connectors is in the following section.

DB->Terminal block modules have the same pin numbers as DB connectors in CSMIO/IP-M device.

For example: the 15 pins of DB25 connector match with the 15 pins on the terminal block.

Signals that control the drives (STEP/DIR)

and digital outputs (relays etc.)

Analog inputs and outputs (0-10V)

Expansion module connector

Power connector

Digital inputs

Communication

connector (ETHERNET)

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