System box/signal distributor board
Contents
1. 1 Components and Dimensions The adaptor board consists of a printed circuit board mounted on an aluminum plate or an angled support and two sub d cables 15 pins and 25 pins with a length of 1 through 5 m Dimensions Mounted on an Aluminum Plate 3 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC ie Motor Controller Module Mikroprozessor Steuerungen amp Mounted on an Angled Support RAA 4x B4 4 2x The circuit board may be turned by 180 degs and mounted on the support 4 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC ie Motor Controller Module Mikroprozessor Steuerungen a 2 Cabling The adapter is connected to the controller with 2 sub d cables with 15 and 25 pins The step and direction signals for the motor amplifiers are transmitted through the 15 pins cable the input and output signals to the other peripheral devices are transmitted through the 25 pins cable 3 Connection to Amplifiers and Peripheral Devices Amplifiers and peripheral devices are connected to the following terminals at the adapter board Terminal strips for 8 step motor amplifiers Terminals for 2 limit actuators each for max 4 axis Reference input terminals coarse and fine for the axis X Y and Z2. 4 free input ports C1 through C4 C3 and C4 may be used as limit inputs of the axis U 1 emergency stop input terminal 1 analogue output type TURBO Step 45 PCI 1 only When operating more than 4 axis 2 axis groups must be created The limit inputs must be assigned to both groups Inputs and outputs are isolated from the voltages within the PC except for the analogue output Also the inputs and the outputs are isolated from each other 3 1 Connection to the Step Motor Amplifiers The properties of the inputs of the step motor amplifiers are important to decide which one of the connection options is to be used Several options are available Carefully select the correct one described in this chapter Also refer to the schematic drawing 30134 04 STR C When using RS422 line drivers twisted pairs and appropriate load resistors are required at the ends of the lines or at the inputs of the line receivers within the amplifiers This is necessary to prevent signal distortion and eventually erroneous steps Please refer to the respective amplifier description 5 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC i Motor Controller Module Mikroprozessor Steuerungen a 3 2 Grounding the Adaptor The adaptor is already connected to ground by the shields of both SUB D cables which are grounded at the computer However it is mand
3. e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller fiir PC Motor Controller Module Mikroprozessor Steuerungen A low side switch initiates each step pulse by switching the opto coupler current to the voltage reference V MOT Select the logical sense active low for the step pulses by means of the instruction TSLEV or within PCT25 G10 within the initialization phase of your program 3 4 Amplifier Inputs with Opto Couplers with a Voltage Level of 12 Volts The circuit of this amplifier inputs consists of a series connection of a light emitting diode and a resistor of approximately 1 kOhm An external voltage source with 12 Volts is neccessary It must not be stabilized A DC voltage smoothed with an electrolytic capacitor is sufficient The step and direction signals at the terminals STPX1D and DIRXD respectively are connected to the cathode sides of the opto coupler s light emitter diodes 2 ESE E cee jenen je 2 waka Ez XIB MIT 116 seo H RE Kl om Us sp 6 IE nino H VEPST RR ER EINGANG A IEIER ADAPTER IMPUT Use isolated outputs for the step and direction outputs on the controller board and select the low going edge of the step pulse to execute each step For this selection the jumpers below the cover of the adaptor remain unchanged as factory default setting The same applies for the jumper setting on the controller board 7 Dipl
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5. is 0 to 5 volts while the signals on both lines go into opposite directions This connection mode refers to such an amplifier with RS422 inputs the zero reference of which is not or must not be tied to ground whereby an external voltage source supplying 8 through 12 volts dc SE E S 2 2 y p AL VM zum a year le vun 87 Sr M ene STEP IT ops g pe Te DIR 9 ADAPTER VERGI MARER EI NEANE j MRLIFIER INPUT Fi Bi APY By VOLT ABE is SUPPLY 10 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC Motor Controller Module Mikroprozessor Steuerungen x Use isolated outputs of step and direction signals on the controller board Adapt the active edge of the step pulse active high or active low to the specification of the respective amplifier Ensure that this specification will really be observed In case you use 2 axis groups it is important that the low going edge of the step pulse within the controller initiates the step in order to ensure that no unintended step will be caused when changing the axis group If this condition does not fit to the prescribed sense of pulses at the amplifier input simply exchange the lines STPX with STPX The same applies for every axis For this connection mode the jumper setting must be modified according to this table and the previous figure Contro
6. 4 04 STR C Connect both sub d cables to the controller installed in the computer 6 1 Ensure Noise Immunity in Operation Inductive peak voltages will be shorted within the adaptor however this is often not sufficient to suppress burst disturbances Ensure safe operation by these additional measures 12 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC i Motor Controller Module Mikroprozessor Steuerungen A Suppress the voltage peaks caused when the current through an inductive load solenoid relay etc is switched off by connecting an extra diode directly at the inductive load with short leads This prevents the surge pulses from causing noise interferences before they will be absorbed within the adaptor Compensate for brush noise of a dc motor by connecting a capacitor directly at the motor terminals Brush sparks will cause high frequent noise on the leads which can also increase within the life time of the equipment One of the ground screws on the adaptor should be tied to a ground screw of the PC and to the rack or case supporting the control components Use short protection ground wires with at least 2 5 qmm 0 0039 sq inch This ensures the stability of the ground potential within the adaptor even when the protection ground within the PC plug should be unstable As the zero reference of the 5V supply inside each
7. Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC ie Motor Controller Module Mikroprozessor Steuerungen amp The settings are shown in the following table Controller Adaptor X8 1 3 5 7 6 8 X16 1 3 2 4 5 7 6 8 9 11 10 12 13 15 14 16 X17 same setting as X16 X18 same setting as X16 X11 1 3 or remove all Connect the external voltage source to the terminal strip X3 as follows V MOT Plus V MOT Minus A low side switch initiates each step pulse by switching the opto coupler current to the voltage reference V MOT Select the logical sense active low of the step pulses by means of the instruction TSLEV or within PCT25 G10 within the initialization phase of your program 3 5 Amplifier Inputs with RS422 Line Receivers with grounded Voltage Reference RS422 receivers require a pair of twisted wires for each step and direction signal The voltage level on each line is O to 5 volts while the signals on both lines go into opposite directions This refers only to amplifiers with grounded zero voltage Also the PC s zero voltage is grounded 2 E mm mmm Wun XIA HK HI ADAPTER WERST AARER EI NGANG AL IEIER 1u m _ Si Use direct coupling for the step and direction outputs Adapt the active edge of the step pulse active high or active low to the specification of the respectiv
8. KUNDLER CONTROLLERS 2 Motor Controller f r PC i Motor Controller Module id Mikroprozessor Steuerungen S Adaptor Board for Step Motor Controller TURBO STEP 45 PCI July 2010 www KundlerControllers com Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS S Motor Controller f r PC r Motor Controller Module Mikroprozessor Steuerungen s Index Page 1 Components and dimensions 3 2 Cabling 5 3 Connection to amplifiers and peripheral devices 5 3 1 Connection to the step motor amplifiers 5 3 2 Grounding the adaptor 6 3 3 Amplifier inputs with opto couplers with a 6 voltage level of 5 Volts 3 4 Amplifier inputs with opto couplers with a 7 voltage level of 12 Volts 3 5 Amplifier inputs with RS422 line receivers with 8 grounded voltage reference 3 6 Amplifier inputs with RS422 line receivers with 9 5 volts supply isolated from the PC 3 7 Amplifier inputs with RS422 line receivers with 10 8 through 12 volts supply isolated from the PC 4 Connection to external actuators and loads 11 5 Connection to READY contacts within motor amplifiers 12 6 Installation and starting operation 12 6 1 Ensure noise immunity in operation 12 7 Circuit diagram 13 2 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS t Motor Controller f r PC ie Motor Controller Module Mikroprozessor Steuerungen a
9. PC is tied to the case the recommended connections contribute to ensure noise and disturbance immunity Submit to technical changes without notice 7 Circuit diagram see next page 13 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 T coaduas3u uerg TW me WOINHOSL SIHI Y04 MOA SITE STW SNN YIM NALWH3E ZOVTWBINN 3HISINHJ3L 35310 wand Sauna Se wana sua s a H a Steuerungen Mikroprozessor Motor Controller Module 14 KUNDLER CONTROLLERS Motor Controller f r PC J H1LS O ELBE Zeie unna uawnvsonnwaraz ES EE ETE GEN era ea 1 1dd St d3LS OBuNL 4 es HOLMBIHLSIO IvNSIS BE ET BAT SLYSA mmer awn nuva oe 2x D Di six Di ex Di Ce D o D I ga Z D d 1 9 S EI i L 9 S El z D 9 S E z 9 S EI Z 3 zm me E 12 Is s a la s clalalclcla la
10. TU VM WU 2 MMI 118 XIF HI IT Struo STEF 5TPY S ADAPTER ERGTKAEER EINGANG HPLIFIER IT Use isolated outputs of step and direction signals on the controller board Adapt the active edge of the step pulse active high or active low to the specification of the 9 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller fiir PC Motor Controller Module Mikroprozessor Steuerungen 4 respective amplifier Ensure that this specification will really be observed In case you use 2 axis groups it is important that the low going edge of the step pulse within the controller initiates the step in order to ensure that no unintended step will be caused when changing the axis group If this condition does not fit to the prescribed sense of pulses at the amplifier input simply exchange the lines STPX with STPX The same applies for every axis For this connection mode the jumper setting must be modified according to this table and the previous figure Controller Adaptor X8 1 3 2 4 5 6 X16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X17 same setting as X16 X18 same setting as X16 X11 1 3 2 4 3 7 Amplifier Inputs with RS422 Line Receivers with 8 through 12 Volts Supply Isolated from the PC RS422 receivers require a pair of twisted wires for each step and direction signal The voltage level on each line
11. atory to connect at least one of the grounding screws additionally to ground with a short line The connections to the motor amplifiers must be shielded Twisted pairs are required if RS422 line drivers are used The shield should be grounded on both ends of the cable It should be soldered to the sheet cover of the plug when using SUB D plugs 3 3 Amplifier Inputs with Opto Couplers with a Voltage Level of 5 Volts These amplifier inputs are very common The input circuit is a serial connection of a light emitting diode and a resistor with approximately 330 Ohms 2 SEES SEES EES o vun ei d vip WI vie spo eH CZ all VERE ARR ER EINGANG AMPLIFIER INPUT ADAPTER The step and direction signals at the terminals STPX1D and DIRXD respectively are connected to the cathode sides of the opto coupler s light emitter diodes Use the direct outputs of the step and direction signals on the controller board and select the low going edge of the step pulse to execute each step For this selection the jumpers below the cover of the adaptor remain unchanged as factory default setting However the jumpers on the controller board must be set according to the following table shown in the above figure Controller Adaptor X8 1 2 3 4 7 8 X16 1 3 2 4 5 7 6 8 9 11 10 12 13 15 14 16 X17 same setting as X16 X18 same setting as X16 X11 1 3 or remove all 6 Dipl Ing Walter Kundler Moltkestra
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13. e amplifier 8 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller fiir PC i Motor Controller Module i Mikroprozessor Steuerungen d Ensure that this specification will really be observed In case you use 2 axis groups it is important that the low going edge of the step pulse within the controller initiates the step in order to ensure that no unintended step will be caused when changing the axis group If this condition does not fit to the prescribed sense of pulses at the amplifier input simply exchange the lines STPX with STPX The same applies for every axis For this connection mode the jumper setting must be modified according to this table and the previous figure Controller Adaptor X8 1 2 3 4 7 8 X16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X17 same setting as X16 X18 same setting as X16 X11 1 3 2 4 3 6 Amplifier Inputs with RS422 Line Receivers with 5 Volts Supply Isolated from the PC RS422 receivers require a pair of twisted wires for each step and direction signal The voltage level on each line is 0 to 5 volts while the signals on both lines go into opposite directions This connection mode refers to such an amplifier with RS422 inputs the zero reference of which is not or must not be tied to ground and which has a 5 volts output to supply the RS422 line drivers within the adaptor Ty 3 3 I
14. ive surge by diodes 11 Dipl Ing Walter Kundler Moltkestra e 26 D 79183 Waldkirch Tel 07681 23649 Fax 2097816 KUNDLER CONTROLLERS Motor Controller f r PC ie Motor Controller Module Mikroprozessor Steuerungen d When driving external loads please observe the recommendations for noise immunity following below 5 Connection to READY Contacts within Motor Amplifiers Many amplifiers contain make break contacts indicating if the corresponding drive is ready to operate Such contact signal can be detected by the control program For each axis exists a pair of terminals RDY and RDY which are all serially connected If each pair is connected to the respective contacts the serialized contact signal will indicate wether all amplifiers are ready or one of them fails Replace any missing contacts with a bridge wire Select the controller input which is to be used by placing the appropriate jumper on the jumper field X12 Please refer to the schematic at the end of this manual 6 Installation and Starting Operation Important note Switch off the computer prior to connecting the adaptor to the controller or changing the jumper setting Adjust the jumpers on the jumper field X8 of the controller according to the controller manual or to the above instructions Select symmetrical or unsymmetrical signal shape of step direction outputs according to the above instructions Refer to the circuit diagram 3013
15. ller Adaptor X8 1 3 5 7 6 8 X16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X17 same setting as X16 X18 same setting as X16 X11 1 2 3 4 4 Connection to External Actuators and Loads External actuators may supply positive voltages of 5 through 24 volts referred to the terminal GND_INPUTS The input resistance is 2 2 kOhms The input current returns through the terminal GND_INPUTS For detailed information about the circuits of the inputs and outputs please refer to the user manual of the controller External loads such as solenoids lamps relays etc require an external voltage source of 24 volts dc which must be connected to the terminals V _OUTPUTS and GND_OUTPUTS with its positive and negative terminal respectively The supply voltage must not be stabilized however a smoothing electrolytic capacitor is necessary The outputs OUT_V1 through OUT_V4 switch the respective load to zero by low side switches When the respective output is activated it will connect the external load to GND_OUTPUTS Caution prevent any short circuit between the external supply voltage 24 volts connected to V OUTPUTS and anyone of the terminals OUT_V1 through OUT_V4 Such short circuit will damage the respective power CMOS switch on the controller The potentials GND_INPUTS and GND_OUTPUTS are not tied together The user may connect these potentials externally however The power CMOS switches are protected agains induct
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