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OEM CNC Installation

OEM CNC Installation P/N 70000506H - Contents

All rights reserved. Subject to change without notice. iii October 2009

Section 1 - Introduction ANILAM's Commitment to You ......................................................................................................... 1-1

Effectivity Notation ........................................................................................................................ 1-2

Section 2 - Theory of Operation Closed-Loop System ........................................................................................................................ 2-1 Isolated Input/Output ........................................................................................................................ 2-1 Overview .......................................................................................................................................... 2-1

The Closed-Loop System ............................................................................................................. 2-1 CNC System Overview ................................................................................................................. 2-5 CNC Spindle Control .................................................................................................................... 2-9

Section 3 - Specifications and Power Requirements Power Requirements ........................................................................................................................ 3-1 Power Supplies ................................................................................................................................ 3-1

OEM External Servo Power Supply for ANILAM Amplifiers .......................................................... 3-1 Environmental Requirements ........................................................................................................... 3-2 The Servo System ............................................................................................................................ 3-3 Feedback ......................................................................................................................................... 3-3 OEM Console with Liquid Crystal Display (LCD) Flat Panel Display ................................................ 3-3

LCD Specifications and Power Requirements .............................................................................. 3-4 LCD Environmental Requirements ............................................................................................... 3-5 Handling the LCD Console ........................................................................................................... 3-5 VGA to OEM CNC Chassis Connection ....................................................................................... 3-5

Amplifier ........................................................................................................................................... 3-6 Motors .............................................................................................................................................. 3-6

Section 4 - Amplifiers and Motors Digital Brushless Servo Amplifier ..................................................................................................... 4-1 AC Brushless Servo Motors ............................................................................................................. 4-3

AM 96 Series – Motor Specifications ............................................................................................ 4-3 AM 96 Series – Torque Characteristic Graphs ............................................................................. 4-4

AM 96A, AM 96AB - Torque Characteristic Graph ........................................................... 4-5 AM 96C, AM 96CB - Torque Characteristic Graph .......................................................... 4-5 AM 96E, AM 96EB - Torque Characteristic Graph ........................................................... 4-6

AM 130 Series – Motor Specifications .......................................................................................... 4-6 AM 130 Series – Torque Characteristic Graphs ........................................................................... 4-8

AM 130A, AM 130AB - Torque Characteristic Graph ....................................................... 4-8 AM 130C, AM 130CB - Torque Characteristic Graph ...................................................... 4-9 AM 130E, AM 130EB - Torque Characteristic Graph ....................................................... 4-9

AM Series Cables and Connectors ............................................................................................. 4-10 AM Series Motors Nameplate Conventions ................................................................................ 4-11

OEM System Interconnect ............................................................................................................. 4-12

Section 5 - Dimensions and Installation Wiring Guidelines and Grounding Concepts .................................................................................... 5-1

General Wiring Guidelines ............................................................................................................ 5-1 General Grounding Guidelines ..................................................................................................... 5-2 Establish Bonding Points on the Machine .................................................................................... 5-2

Use Interior or Exterior Tooth Lock Washers Between Points of Contact ........................ 5-2 Clean all Stand-Off and Mounting Assemblies to Bare Metal at Points of Contact .......... 5-2


iv All rights reserved. Subject to change without notice. October 2009

Clean all Paint to Bare Metal from the Enclosure at the Points of Contact ...................... 5-2 Wiring of System Grounds ............................................................................................................ 5-3 Wiring Servo Amplifiers ................................................................................................................ 5-3 Isolation Transformer .................................................................................................................... 5-3

Compliance with the CE Directives .................................................................................................. 5-4 Guidelines for Construction of a CE-Compliant System ............................................................... 5-5

Major Assemblies Dimensional Data ................................................................................................ 5-6 LCD Console Mounting ................................................................................................................ 5-6

5000M Console and Manual Panel ................................................................................................ 5-11 OEM CNC Chassis ........................................................................................................................ 5-13 CAN I/O Boards, Mounting Locations ............................................................................................ 5-15 Digital Brushless Servo Amplifier ................................................................................................... 5-18 AC Brushless Servo Motors ........................................................................................................... 5-19

Section 6 - Connection Overview .......................................................................................................................................... 6-1 Power ............................................................................................................................................... 6-5

Connection ................................................................................................................................... 6-5 Fuses ............................................................................................................................................ 6-5

Amplifier Connectors ........................................................................................................................ 6-6 Motor Connectors ............................................................................................................................. 6-9 Console .......................................................................................................................................... 6-11

Power Requirements .................................................................................................................. 6-11 VGA to Single-Board Computer Connection............................................................................... 6-11 LCD Console Power Connection ................................................................................................ 6-12 LCD Setup and Adjustment Procedures ..................................................................................... 6-12

Connecting the OSD Board (P/N 33000486) ................................................................. 6-12 Disconnecting the OSD Board ....................................................................................... 6-13 Adjusting the On-Screen Display (OSD) Board Settings ............................................... 6-13

Keyboard Interface Board ........................................................................................................... 6-15 Keyboard Interface to External Keyboard Connection ................................................................ 6-17

Manual Panel Connections ............................................................................................................ 6-19 Remote Floppy Disk Drive Installation and Harnesses .................................................................. 6-22

Procedure ................................................................................................................................... 6-24 Control Axes (X, Y, Z, U, S, and W) ............................................................................................... 6-26

Single-Ended vs. Differential Axis (Jumper Settings) ................................................................. 6-27 Cable Specifications (Control Axes) ........................................................................................... 6-27

Handwheel or Readout Axes .......................................................................................................... 6-28 Cable Specifications (Readout Axes) ......................................................................................... 6-28

Printer Connection ......................................................................................................................... 6-29 COM2 Connection .......................................................................................................................... 6-29 Ethernet Network Connection ........................................................................................................ 6-30 Probe Connection .......................................................................................................................... 6-30 MBIO .............................................................................................................................................. 6-31

OEM Servo System Wiring ......................................................................................................... 6-31 Servo Control Board Use with MBIO (Option) ............................................................................ 6-33

Connectors ..................................................................................................................... 6-37 Controller Area Network (CAN) I/O Bus ......................................................................................... 6-39

Current Rating and Power Requirements ................................................................................... 6-39 Connections................................................................................................................................ 6-39 Mounting Additional CAN Boards Externally............................................................................... 6-43 CAN Bus Node Addressing (S1) ................................................................................................. 6-44 CAN Bus Termination ................................................................................................................. 6-45


All rights reserved. Subject to change without notice. v October 2009

Home Switch Inputs .................................................................................................................... 6-45 External Cabling and Connector Specifications ............................................................................. 6-46

Cables for Motors and Amplifiers ................................................................................................ 6-47 Mating Power and Encoder Connectors ..................................................................................... 6-51

Section 7 - Hardware Wiring Diagrams ............................................................................................................................... 7-1 Single-Board Computer .................................................................................................................... 7-5

Power Requirements .................................................................................................................... 7-6 VGA Connections ......................................................................................................................... 7-6 COM1 ........................................................................................................................................... 7-7 Keyboard ...................................................................................................................................... 7-7 Hard Drive .................................................................................................................................... 7-8 Printer ........................................................................................................................................... 7-9 COM2 ........................................................................................................................................... 7-9 Floppy Drive ............................................................................................................................... 7-10 Setting up the BIOS for the Single Board Computer ................................................................... 7-10 Restoring Factory Defaults ......................................................................................................... 7-11

Controller Area Network (CAN) Bus ............................................................................................... 7-12 Nodes ......................................................................................................................................... 7-13 Connections................................................................................................................................ 7-15 Analog Input Configuration ......................................................................................................... 7-15

DSP Board ..................................................................................................................................... 7-15 Encoder and Analog Power ........................................................................................................ 7-18 Machine Basic I/O ...................................................................................................................... 7-20 External START/STOP ............................................................................................................... 7-20 E-STOP and Manual Switches ................................................................................................... 7-20 CAN Bus Interface ...................................................................................................................... 7-21 Test Connection (P12) ................................................................................................................ 7-21 Probe (P15) ................................................................................................................................ 7-21 Jumpers ...................................................................................................................................... 7-22 Firmware .................................................................................................................................... 7-22

DSP2 Expansion ............................................................................................................................. 7-24 Encoder and Analog Power ........................................................................................................ 7-26 Jumpers ...................................................................................................................................... 7-26

Section 8 - Maintenance Balance and Signal Checks ............................................................................................................. 8-1 Hard Drive ........................................................................................................................................ 8-2 Filters ............................................................................................................................................... 8-2 Contamination .................................................................................................................................. 8-2 Cabling ............................................................................................................................................. 8-2 Fuses ............................................................................................................................................... 8-3 Console ............................................................................................................................................ 8-3

Keypad ......................................................................................................................................... 8-3 Filters ............................................................................................................................................ 8-3 Environment ................................................................................................................................. 8-3 Contamination .............................................................................................................................. 8-3 Cabling ......................................................................................................................................... 8-3

Preventive Measures........................................................................................................................ 8-4


vi All rights reserved. Subject to change without notice. October 2009

Section 9 - Troubleshooting Checking Voltages ........................................................................................................................... 9-1

Backplane LEDs ........................................................................................................................... 9-1 TB2 Terminal Block ...................................................................................................................... 9-2 DSP2 Board P12 ........................................................................................................................... 9-2

LCD Troubleshooting Suggestions ................................................................................................... 9-4 Amplifier Troubleshooting Suggestions ............................................................................................ 9-5 Index ...................................................................................................................................... Index-1

OEM CNC Installation P/N 70000506H - Introduction

All rights reserved. Subject to change without notice. 1-1 October 2009

Section 1 - Introduction

ANILAM's Commitment to You As part of our ongoing commitment to our OEM partners, ANILAM is pleased to introduce our latest line of PC-based OEM CNC products designed to keep you on top and in control.

Your new OEM product includes the following features:

Dual Processor Design in a Highly Integrated CNC Chassis common to all products

Color Liquid Crystal Display (LCD) Console

Remote Manual Panel (all except 3000M)

Distributed Controller Area Network (CAN) I/O System

Surface Mount Design to Enhance a Compact, Powerful System

At the core of the Computer Numerical Control (CNC) is a 100 MHz, 32-bit floating-point Digital Signal Processor (DSP) Motion Control Board called the DSP2 Board. The DSP2 Board will help you achieve an exponential increase in productivity. The DSP2 Board single-handedly performs all the motion control real-time computations required for optimal CNC performance. The PC processor controls the Human/Machine Interface (HMI). Together, the DSP2 Board and the PC processor provide the performance you need to meet the high-speed, high-accuracy demands of the modern machine tool market.

The modular LCD color-display console and remote manual panel gives you greater flexibility to build machines for specific applications. The distributed CAN I/O system allows you to install I/O modules anywhere you need them; for example, you can install a CAN I/O module in the electrical cabinet to provide I/O for various machine needs; or, you can install a CAN I/O module in the console enclosure to provide additional operator switches, which significantly reduce wiring. The reduction in wiring makes installation simpler and more reliable.

Models are available in either machinist language or ISO programming formats (G-codes) or both. ANILAM's built-in CAM system and advanced math calculators simplify programming at the control. It’s easy to run programs that are generated from an off-line CAD/CAM system directly from the CNC or via ANILAM's DNC feature. The CNC's program storage capacity is at least 8.0 GB.

OEM CNC Installation P/N 70000506H - Introduction

You can also connect the CNC to Ethernet-based networks. ANILAM offers off-line versions of all our CNC products. Use off-line versions to develop and test part programs on an off-line PC. For your convenience, the off-line software operates exactly like the CNC software. Off-line systems are compatible with **Microsoft® **MS-DOS® or Windows-based environments (including **Windows® 3.11, Windows for Workgroups, Windows 95, **Windows NT®, and **Windows XP®).

The initial connection of the CNC varies depending on the product line and its number of axes. Refer to Table 1-1 for product and port connection information.

Table 1-1, CNC Connection Ports

Product Port 0 1 2 3 4 5

3000M Systems X Y Z S 4200T Systems X C/S Z W 5000M Three-Axis Systems X Y Z S 5000M Four-Axis Systems X Y Z U S 5000M Five-Axis Systems X Y Z U S W

Effectivity Notation Some sections do not apply to all ANILAM OEM CNC products. In these sections, icons identify products to which the information applies. Refer to Table 1-2.

Table 1-2, Effectivity Notation

Icon Product

3300M

3000M Systems

4200T

4200T Systems

5300M

5000M Three-Axis Systems

5400M

5000M Four-Axis Systems

5500M

5000M Five-Axis Systems

3000M

5000M-3X

5000M-4X

5000M-5X

- - - - -

** Microsoft®, MS-DOS®, Windows®, Windows NT®, Windows XP® are registered trademarks of Microsoft Corporation in the United States and/or other countries.

1-2 All rights reserved. Subject to change without notice. October 2009

OEM CNC Installation P/N 70000506H - Theory of Operation


Section 2 - Theory of Operation

Closed-Loop System The Computer Numerical Control (CNC) is a closed-loop system that performs the following functions: • Receives positioning information from highly accurate measurement

transducers • Compares the actual position against the programmed positions • Adjusts for detected errors

Simultaneously, the CNC regulates the speed and position of the controlled axis until each command is completed.

Isolated Input/Output Each CAN board is an I/O node. (Refer to “Section 7, Nodes” for details.) Multiple CAN nodes provide I/O. Two CAN I/O nodes are supplied with the standard system; up to six nodes can be implemented. Each node supports up to 10 inputs and 6 outputs, for a total I/O capacity of 60 inputs and 36 outputs. I/O signals are connected via the P5 DB-25 connector on each node.

Inputs and outputs are optically isolated to prevent transmission of machine electrical noise to the processor circuits.

You can configure inputs to activate functions in the CNC. Machine codes (M-codes) are normally used to control outputs. You can use an M-code to turn some outputs on and other outputs off. Outputs turned ON via an M-code can remain ON for a specified duration (pulse width) or indefinitely. Refer to the appropriate CNC Setup Utility Manual for details on I/O interface.

For more advanced capability, use the ANILAM Integral Programmable Interface (IPI) feature to create a logic program that runs in the CNC. IPI accesses CNC registers and system flags to create sophisticated programs that control all types of machine functions. For example, you can use IPI to control the turret on a turning center or to control a tool changer on a machining center. Refer to the Integral Programmable Intelligence User's Guide, P/N 70000416, for details.

Overview

The Closed-Loop System

The Closed-loop System consists of a velocity loop and a positioning loop. The velocity loop, or the velocity-controlled servo drive, maintains a constant velocity at a constant input. A transducer, such as a tachometer, must be input directly to the servo system. In contrast, a torque-controlled system maintains a constant torque. Refer to Figure 2-1, Closed-Loop System.


CN

C

Enco

der

Serv

o M

otor

Serv

o D

rive

Balls

crew

Belt

Tabl

e

Arm

atur

e Vo

ltage

Velo

city

(Tac

hom

eter

) Fee

dbac

k

Velo

city

Loo

p

Posi

tion

Feed

back

Posi

tion

Loop

Com

man

d Si

gnal

CO

NTR

OLO

OP

Figure 2-1, Closed-Loop System




The positioning loop controls command signals and all position-sensing devices as follows:

1. The CNC sends a command signal of –10 to +10 V DC to the servo drive.

2. The servo drive amplifies the signal to power the servo motor. The servo motor typically consists of a DC motor, a rotary encoder, and a tachometer, all on the same shaft. The servo motor can use motors without rotary encoders if a linear encoder or an externally mounted rotary encoder supplies feedback. Refer to Figure 2-2, Closed-Loop System with Linear Encoder.

3. The tachometer feeds a DC signal proportional to the motor velocity back to the servo drive.

4. The servo drive, in turn, continuously compares the command signal to the tachometer feedback signal and adjusts the output to the motor accordingly.

5. The servo motor mechanically drives a belt that turns a ballscrew. The ballscrew converts rotary motion to linear mechanical motion. During this process, the encoder outputs incremental position information to the CNC.

6. The CNC reads and accumulates information on the known location of the workpiece relative to the tool. It uses the positional information and the part program to compute a tool path. The CNC derives command signals for cutting and sends them to the servo drive. The CNC also corrects for geometrical and mechanical imperfections.


CN

C

Serv

o M

otor

Serv

o D

rive

Balls

crew

Belt

Tabl

e

Arm

atur

e Vo

ltage

Vel

ocity

(Tac

hom

eter

) Fee

dbac

k

Velo

city

Loo

p

Posi

tion

Feed

back

Posi

tion

Loop

Com

man

d S

igna

l

Rea

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ead

Line

ar E

ncod

er

CN

TLO

OPS

CAL

E

Figure 2-2, Closed-Loop System with Linear Encoder



CNC System Overview

This section provides an overview of the CNC system. Refer to Figure 2-3, 3000M CNC System Overview. Refer to Figure 2-4, 4200T CNC System Overview, and Figure 2-5, 5000M CNC System Overview, for more details. A typical CNC system consists of the following hardware:

1. The chassis, which consists of the following equipment: • A single-board computer (SBC), an industrial PC that provides all

PC functions • A DSP2 Motion Board that controls all machine motion, readout

axes, and handwheels • A 3-slot ISA backplane • Two CAN I/O nodes • Power supplies. Multiple power supplies prevent cross talk • A hard drive

2. The console, which consists of the following equipment: • A color VGA monitor • The CNC keyboard • The E-STOP switch (3000M only) • FEEDRATE OVERRIDE switch (3000M only) • A connector port for a PC keyboard (optionally provided by the

builder)

4200T

5000M-3X

5000M-4X

5000M-5X

3. An external floppy drive

4. A manual panel provides handwheel control (option), axis selection, feedrate override, manual jog, E-STOP switch, and manual spindle control.

5. The OEM system is configurable to connect to each customer’s servo drives and external machine control electrics, such as safety switches and machine functions.



CRT/LCD

Floppy DiskDrive

SingleBoard

Computer

+5, +

/-12D

VC

Com

pute

r P/S

DSP2

MotionControlBoard

CAN 1

CAN 0

MBIO

3 Sl

ot P

assi

ve B

ackp

lane

Motor

EncoderMachineControlElectrics

Motor

CNC Chassis

Optional External QWERTY Keyboard

VGA Signals

Keyboard Data

E-Stop Datato MBIO

CO

M1

VG

A

KY

BD

Flop

py

CO

M2

Par

alle

l

Readout Axis Encoder Data

Flop

py P

ower

Inpu

t

Har

d D

rive

Pow

er In

put

Flop

py D

ata

Data

Handwheel

Axe

s D

AC

Com

man

d S

igna

ls

Encoder

Axes Position Encoder Data

Spindle DAC andEncoder Signals

Network

Motor

Encoder

External ParallelPrinter Port

COM2 ExternalRS-232 Comm Port


+5,+/-15VDCMotion P/S

CNCConsole

Keyboard

GeneralPurposeOpto I/O

Opto I/OIncluding

Limits

+24VDCI/OP/S

AmpAmpAmp

Optional NetworkConnection

Har

d D

isk

Driv

e

HandwheelEncoder Data

Probe

3000MSYSOVERVIEW

Figure 2-3, 3000M CNC System Overview



CRT/LCD

Floppy Disk Drive

SingleBoard

Computer

Har

d D

isk

Driv

e


DSP2

MotionControlBoard

CAN 1

CAN 0

External CAN

MBIO

3 Sl

ot P

assi

ve B

ackp

lane

MachineControlElectrics

Motor

CNC Chassis

Optional External QWERTY Keyboard


External Parallel

COM1 ManualPanel RS-232 Data

VGA Signals

Keyboard Data

E-Stop Datato MBIO

CO

M1

VG

A

KY

BD

Flop

py

CO

M2

Par

alle

lHandwheel Encoder Data


Flop

py P

ower

Inpu

t

Har

d D

rive

Pow

er In

put

Flop

py D

ata

Data

Handwheel

Axe

s D

AC

Com

man

d S

igna

ls

Encoder


Manual Panel


Network

4200TSYSOVERVIEW

Motor

Encoder

CNCConsole

Keyboard

+24VDCI/OP/S


Opto I/OIncluding

Limits

Amp Amp


+5, +

/-12V

DC

Com

pute

r P/S


Printer Port

Probe

Figure 2-4, 4200T CNC System Overview



CNCConsole

KeyboardFloppy Disk Drive

SingleBoard

Computer

Har

d D

isk

Driv

e


+5, +

/-12V

DC

Com

pute

r P/S

DSP2

MotionControlBoard

CAN 1

CAN 0

+24VDCI/OP/S

MBIO

3 Sl

ot P

assi

ve B

ackp

lane

MachineControlElectrics

CNC Chassis

Optional ExternalQWERTY Keyboard


External ParallelComm Port

COM1 ManualPanel RS-232 Data

VGA Signals

Keyboard Data

E-Stop Datato MBIO

CO

M1

VG

A

KY

BD

Flop

py

CO

M2

Par

alle

l

Handwheel Encoder Data



Opto I/OIncluding

Limits


Flop

py P

ower

Inpu

t

Har

d D

rive

Pow

er In

put

Flop

py D

ata

Data

Handwheel

Axe

s D

AC

Com

man

d S

igna

ls


Manual Panel


Network


5000MSYSOVERVIEW

Motor

Amp

Motor

Amp

Encoder

Motor

Amp

Motor

Amp

Encoder

Motor

Amp

5000M-4X5000M-5X

LCD

Encoder

ExternalCAN

Encoder Encoder

Probe

Figure 2-5, 5000M CNC System Overview




CNC Spindle Control

CNCs can control various types of spindle drives. The CNC provides DC and/or logic outputs to run the drive and can receive RPM and I/O information. The application determines the requirements of the spindle drive; the more sophisticated the application, the more intelligent the spindle drive required. The following subsections describe the CNC’s outputs and inputs and spindle drive requirements.

Outputs • DC analog command-signal output either unipolar (0V DC to +10V

DC) or bipolar (-10V DC to +10V DC) dependant on spindle drive hardware requirements. In bipolar mode, positive voltage is always forward rotation.

• Logical outputs are either +24V DC (source) or 24COM (sink) signals. I/O boards are either sink- or source-boardtype determined by spindle drive hardware requirements. If you require conditional logic, you must use IPI. Basic I/O supports limited only on/off control of outputs.

Inputs • Requires TTL quadrature with zero marker signals for RPM display

and control. Maximum input speed is one million counts per second. For tapping and orientation, spindle encoder must be 1:1 with spindle. For threading, spindle to encoder ratio must be 1:1 or higher (whole number ratios only).

Spindle Drive Requirements • For rigid tapping and orientation, the spindle must be capable of

closed-loop (servo) mode operation. IPI is required to program conditional logic. Tapping requires a floating tap head unless you use rigid tapping.

• For safety requirements, the spindle should have at speed and zero speed outputs. IPI is required to program conditional logic. The outputs are used by the resultant IPI program to determine: − When the drive has reached speed and the machine can continue

the program, and − When the drive has stopped and it is safe to remove power.

• Some spindle drives require a braking resistor. Some braking resistors have over-heat sensors, which require IPI to detect. For cooling purposes, mount the braking resistors outside the equipment enclosure and use guarding per relevant safety codes.

OEM CNC Installation P/N 70000506H - Specifications and Power Requirements


Section 3 - Specifications and Power Requirements

Power Requirements Refer to Table 3-1 for the required input power for Liquid Crystal Display (LCD) based systems.

Table 3-1, LCD Power Requirements

Device Power Requirement Computer 90–260 VAC, 1 Phase, 2 A to 1 A SVGA LCD Monitor 12 VDC, 2 A provided by computer power

supply.

CAUTION: The CNC must be plugged into a dedicated line. Voltage rating: 90–260 VAC (Dedicated, no other devices attached to the line.)

Power Supplies The CNC has three internal power supplies. Voltage inputs are required to meet the specifications listed in Table 3-2.

Table 3-2, Power Supplies

Power Supply Power Current Function Computer Power Supply P/N 90600342

100 W +5 V ±12 V 6 A Supplies power to SBC, disk drives, and logic power to DSP motion control board

Motion Power Supply P/N 90600341

25 W +5 V ±15 V 1 A Supplies 5 V to encoders, ±15 V to the DSP Motion Board

I/O Power Supply P/N 90600344

24 V 2 A**1 Supplies power to I/O

**1 Required amperage determined by number and types of external devices connected to the system. When specific equipment requires more than 2 A, customers must use their own external power supply.

OEM External Servo Power Supply for ANILAM Amplifiers A 160 VDC source is required for main power to the amplifiers. A schematic is shown in Figure 3-1, External Servo Power Supply. This supply will support one to five amplifiers. Because of the high current involved, #12 AWG wire should be used for all parts of this circuit except the control voltage for the Solid State Relay. For safety, the machine tool should be wired so that this voltage is removed during emergency conditions.


Figure 3-1, External Servo Power Supply

Environmental Requirements

Maintain the environmental constraints listed in Table 3-3 to ensure that the CNC performs to specification.

Table 3-3, Environmental Constraints

Parameter Environmental Constraints Ambient Temperature Operating 0 °C to 50 °C Storage and Transportation -3 °C to 65 °C Rise in internal temperature 10 °C above ambient, maximum Humidity Operating 10% to 90% RH, non-condensing Storage and Transportation 95% RH, non-condensing for one

month, maximum Shock Operating 30 g for 11-ms duration, half-sine

shock pulse, maximum Storage and Transportation 50 g for 11-ms duration, half-sine

shock pulse, maximum Vibration Operating 1.5 g acceleration over 5- to

300-Hz sine wave (P-P), I oct/min sine sweep.

Storage and Transportation 5 g acceleration over 5- to 300-Hz sine wave (P-P), I oct/min sine sweep.

Air Pressure Operating 0–10,000 ft. Storage and Transportation 0–40,000 ft.




The Servo System All ANILAM CNCs require velocity-controlled servo motors and feedback devices. Typically, this would include a motor with a built-in tachometer and a rotary encoder. An external rotary encoder or linear encoder can also be used.

The CNC uses feedback from either rotary encoders or linear encoders to provide the closed-loop positioning for the system. Refer to Setup Utility for details on setting each axis for the type of feedback device used. Axis resolution is set via the Machine Axis Setup.

The maximum display resolution is 0.5 microns.

The maximum number of line counts is 1,000,000 (one million) counts per second.

NOTE: If a higher line count frequency is required, contact ANILAM Sales.

Feedback The OEM CNC chassis supports both single-ended and differential feedback devices. The default configuration is single ended.

NOTE: ANILAM recommends that you use differential encoders in potentially noisy environments.

Encoder inputs should be TTL quadrature signals with a zero cross marker. Encoder inputs are fed to ANILAM custom ASIC counters. Counter inputs are filtered via a passive, two-stage capacitive network, and then pulled high with a 1 K resistor. The ASIC counter also incorporates an on-chip Schmidt trigger at each input to correct for input signal distortion. The input current is rated at 0.18 mA. The low input threshold is 0.8 V; the high input threshold is 2.0 V.

OEM Console with Liquid Crystal Display (LCD) Flat Panel Display The Liquid Crystal Display (LCD) Console includes a color-active matrix, Thin Film Transistor (TFT) LCD panel, Analog to Digital (A/D) Controller board, On-Screen Display (OSD) board (for factory adjustments only), and Inverter. The LCD panel is a low-reflection, high-color saturation, color-active matrix display.



LCD Specifications and Power Requirements Table 3-4 lists the LCD specifications.

Table 3-4, LCD Specifications

Description Specifications Display Diagonal 12.1 inches (31 cm) Display Format Super VGA (800 x 600) Dimensions (L x W x H) 5.12 inches (130 mm) x 0.79 inches (20 mm)

x 0.04 inches (13.5 mm) Active Area (W x H) 9.68 inches (240 mm) x 7.26 inches (184.5

mm) Dot Pitch (W x H) 0.012 inches (0.3075 mm) x 0.012 inches

(0.3075 mm) Response Time (TYP) 60 ms Contrast Ratio 300:1 Bits per Color 6 Power Panel 7.2 Backlight Power 6.6 W Brightness 250 nits

Table 3-5 lists the LCD inverter specifications.

Table 3-5, LCD Inverter Specifications

Description Specifications Input Voltage 9.6 VDC – 14.4 VDC Startup Voltage 1,500 Vrms (50–70 kHz) Power Requirements 9.6 VDC – 14.4 VDC Output Current 6.3 mArms Minimum

7.0 mArms Typical 7.7 mArms Maximum

Power Output 7.8 W (3.9 W x 2)



LCD Environmental Requirements Maintain the environmental conditions described in Table 3-6 to ensure that the LCD console performs to specification.

Table 3-6, Environmental Requirements

Parameter Environmental Requirements Ambient Temperature

Operating 0° C to 50° C Storage and Transportation

-25° C to +60° C

Humidity Operating, Storage, and Transportation

95% RH, noncondensing

Shock Operating 30 g for 11-ms duration, half-sine shock pulse, max.

Storage and Transportation

50 g for 11-ms duration, half-sine shock pulse, max.

Vibration Operating 1.5 g acceleration over 5–300 Hz sine wave (P-P).

Storage and Transportation

5 g acceleration over 5–300 Hz sine wave (P-P).

Air Pressure Operating 0–10,000 ft. Storage and Transportation

0–40,000 ft.

Handling the LCD Console

CAUTION: To prevent electrical shock or damage to the electrical components, turn the power off before connecting or disconnecting the cable to the LCD console. Because the connector area contains ESD-sensitive electronic components, avoid touching components. When you handle the LCD console, use all ESD precautionary measures.

CAUTION: The Backlight Inverter Board operates at high voltage. To prevent electrical shock or damage to the components on the board, avoid touching any electronic components.

VGA to OEM CNC Chassis Connection Use the P/N 33000188 harness to connect the 15-pin connector on the back of the LCD Console labeled VGA to the labeled 15-pin VGA connector on the CNC chassis.



Amplifier Refer to Table 4-1, Amplifier Specifications and Features, P/N 33001279.

Motors Refer to Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications and Features and Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features.

OEM CNC Installation P/N 70000506H – Amplifiers and Motors


Section 4 - Amplifiers and Motors

Digital Brushless Servo Amplifier The amplifier is illustrated in Figure 5-15, Digital Brushless Servo Amplifier, P/N 33001279. It has the same footprint as earlier DC amps and should be mounted in the same orientation. It accepts a +/- 10 Volt analog signal from the motion board in the kit console or OEM chassis and drives a 3-phase AC brushless servo motor. The analog input may be either single ended or differential. The amplifier has an input connector for encoder signals from the motor. These are used for commutation and can also be fed back to the motion board for position information. Various control and status signals to communicate with the CNC are described below. The amplifier requires 160 VDC for main power. For safety, the machine tool should be wired so that this voltage is removed during emergency conditions. The amplifier also requires +5 VDC at 300mA for onboard logic. This voltage should always be present to avoid loss of position. There is a host port to connect the amplifier to the RS232 serial port of either the CNC or an external computer. This is used to upload / download parameters and for tuning and troubleshooting. Red and green LED indicators display the functional status of the unit. The amplifier has an onboard FLASH memory that stores a large number of parameters even during complete power down. This replaces the trim pots of earlier generation equipment. It is critical that the amplifier have continuous forced air cooling. Refer to Table 4-1, Amplifier Specifications and Features, P/N 33001279.

See “Section 6, Amplifier Connectors” for connector pinouts and LED indicator information:

Table 6-3, Amplifier Mating Connectors

Table 6-4, Amplifier – J1 Host Connector Pinout Table 6-5, Amplifier – J2 Signal Inputs (from Motion Board to

machine interface) Connector Pinout Table 6-6, Amplifier – J3 Signal Inputs (from Rotary Encoder on

Motor) Connector Pinout Table 6-7, Amplifier – J7 External +5 V Connector Pinout Table 6-8, Amplifier – TB1 Terminal Block Connector Pinout Table 6-9, Amplifier – LED Indicators



Table 4-1, Amplifier Specifications and Features, P/N 33001279

Feature Specification Supply voltage 100–370 VDC (typical 160 VDC) +5 volt logic keep alive 500 mA (includes: 200 mA encoder power) Peak current output ± 30 A maximum Continuous current output ± 15 A maximum (with forced air cooling) Switching frequency 25 KHz Heatsink (base) temperature –25 °C to +70 °C (latches disabled >+70 °C)

–77 °F to +158 °F (latches disabled >+158 °F) Current loop bandwidth (programmable) 3 KHz Amplifier type (programmable) Velocity or Current mode Amplifier isolation Bus & Phase completely isolated from Low

signal Input command signal (programmable gain) ± 10 V maximum Hall U, V, W Pull up to 5 V logic levels Encoder feedback Accept encoder signals up to 4.3 MHz Fault out (programmable level) TTL and 24 V compatible Current monitor out 7.5 A/V, absolute value (30 A maximum) Encoder out Can be divided from the input frequency by

any integer 1–8 Low speed electronic circuit breaker (LS/ECB)

Latches when maximum programmable current and time exceed limits

Bus over voltage Trips nominally at 10% above maximum rated supply voltage

Bus under voltage Trips nominally at 10% below minimum rated supply voltage

Amplifier over temperature Amplifier faults and is inhibited if the heatsink temperature reaches 70 °C (158 °F)

Green LED indicator Run-Amplifier enabled, normal operating condition

Red LED indicator Fault-Amplifier over temperature or LS/ECB (latched condition)

Operating temperature 0 °C to +70 °C 32 °F to +158 °F

Storage temperature –40 °C to +80 °C –104 °F to +176 °F

Humidity 5% to 95% non-condensing Dimension (L +x H x W – mm) Dimension (L x H x W – inches)

181.1 x 152.4 x 35.05 7.13 x 6.00 x 1.38



AC Brushless Servo Motors The following AM series motors topics are described:

AM 96 Series – Motor Specifications AM 96 Series – Torque Characteristic Graphs AM 130 Series – Motor Specifications AM 130 Series – Torque Characteristic Graphs AM Series Cables and Connectors AM Series Motors Nameplate Conventions

AM 96 Series – Motor Specifications The motor is illustrated in Figure 5-16, AM 96 Series AC Brushless Servo Motors. Axis motors (synchronous motors) fulfill all requirements of a Numerical Control (NC) machine tool. The B in the model number indicates that the motor has a brake. They are 3-phase, AC brushless induction servo motors with built in optical encoders. Three AM 96 Series sizes are available: 1.5 Nm, 3.3 Nm, and 5.8 Nm (refer to Table 4-2). Units with and without internal brakes are available. When fitted, the brake operates on 24 VDC and is fail-safe (that is, with no power applied, the shaft is stopped).

Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications and Features

Motor Without Brake AM 96A AM 96C AM 96E Motor P/N Without Brake 37000330 37000331 37000332

Motor With Brake AM 96AB AM 96CB AM 96EB Motor P/N With Brake 37000340 37000341 37000342

Feature Units

Continuous stall torque when fitted to heatsink (Size 300 x 300 x 12 mm) (Size 12 x 12 x 0.5 in)

Nm lb-in

1.5 13.3

3.3 29

5.8 51

Motor weight without brake with brake

kg (lb) kg (lb)

3.8 (8.4) 4.6 (10.15)

5.0 (11.0) 5.8 (12.8)

7.2 (16.0) 8.0 (17.64)

Voltage gradient No Load V/1000 RPM**1 64 44 64

Maximum motor EMF Volts 380 260 380

Maximum speed RPM 6000 6000 6000

Insulation class F F F

Maximum ambient temperature °C (°F) 40 (104) 40 (104) 40 (104)

Thermal time constant Minutes 30 50 70

Static friction torque Nm (lb-in) 0.07 (0.62) 0.07 (0.62) 0.07 (0.62)

Peak stall torque**2 Nm (lb-in) 5.5 (49) 11.1 (98) 22 (200)

(Continued) **1 At 25 °C (77 °F) **2 Note that Kt is shown as a combined value for all three phases.



Table 4-2, AM 96 Series AC Brushless Servo Motor Specifications & Features (Continued) Motor Without Brake AM 96A AM 96C AM 96E Motor P/N Without Brake 37000330 37000331 37000332


Feature Units

Continuous stall current rms**3 Amps 1.9 5.8 7.3

Rotor polar moment of inertia kgcm2 2 3.3 6.3

(inclusive of resolver inertia) lb-in sec2 0.0018 0.0029 0.0056

Maximum current (peak) Amp 12.2 36 50

Cogging torque (no shaft seal fitted)

Nm 0.07 0.088 0.16

lb-in 0.62 0.78 1.4

Torque constant Kt Nm/Amp lb-in/Amp

0.75 6.6

0.51 4.5

0.75 6.6

Stator Winding

Resistance Line-Line**4 Ohms 11.2 1.6 1.16

Inductance Line-Line**4 MilliHenrys 18 3.5 3.3

Thermal resistance °C/Watt °F/Watt

1.25 2.3

0.92 1.70

0.75 1.34

**3 The temperature rise DT on the windings is 110K and applies to all continuous torque values. The maximum ambient temperature is 40 °C (104 °F) and therefore, the temperature on the windings should not be more than 150 °C (302 °F). A value higher than 150 °C (302 °F) would exceed the class “F” insulation temperature specification.

**4 At 25 °C (77 °F)

AM 96 Series – Torque Characteristic Graphs The following AM 96 Series torque characteristic graphs are illustrated:

Figure 4-1, AM 96A, AM 96AB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph

Figure 4-2, AM 96C, AM 96CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph

Figure 4-3, AM 96E, AM 96EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph


AM 96A, AM 96AB - Torque Characteristic Graph Refer to Figure 4-1.

AM96ATORQUE Figure 4-1, AM 96A, AM 96AB - Torque Characteristic on 250 V,

64 Voltage Gradient Graph

AM 96C, AM 96CB - Torque Characteristic Graph Refer to Figure 4-2.

AM96CTORQUE Figure 4-2, AM 96C, AM 96CB - Torque Characteristic on 250 V,




AM 96E, AM 96EB - Torque Characteristic Graph Refer to Figure 4-3.

AM96ETORQUE Figure 4-3, AM 96E, AM 96EB - Torque Characteristic on 250 V,


AM 130 Series – Motor Specifications The motor is illustrated in Figure 5-17, AM 130 Series AC Brushless Servo Motors. Axis motors (synchronous motors) fulfill all requirements of a Numerical Control (NC) machine tool. The B in the model number indicates that the motor has a brake. They are 3-phase, AC brushless induction servo motors with built in optical encoders. Three sizes are available: 3.3 Nm, 4.6 Nm, and 6.3 Nm (refer to Table 4-3, AM 130 Series AC Brushless Servo Motor Specifications and Features). Units with and without internal brakes are available. When fitted, the brake operates on 24 VDC and is fail-safe (that is, with no power applied, the shaft is stopped).





Motor Without Brake AM 130A AM 130C AM 130E Motor P/N Without Brake 37000300 37000301 37000302


Feature Units

Continuous stall torque when fitted to heatsink (Size 400 x 400 x 6 mm) (Size 16.75 x 16.75 x 0.24 in)

Nm lb-in

3.3 29

4.6 41

6.3 56

Motor weight without brake with brake

kg (lb) kg (lb)

6.1 (13.5) 7.7 (17.0)

7.0 (15.0) 8.6 (19.0)

7.9 (17.0) 9.5 (21.0)

Voltage gradient No Load (Peak)/1000 RPM 44 44 64

Maximum motor EMF Line – Line Volts 180 180 260

Maximum speed RPM 4000 4000 4000

Insulation class F F F

Maximum ambient temperature °C (°F) 40 (104) 40 (104) 40 (104)

Thermal time constant Minutes 40 40 50

Static friction torque Nm (lb-in) 0.14 (1.24) 0.14 (1.24) 0.14 (1.24)

Peak stall torque Nm (lb-in) 8.6 (76) 13.1 (116) 17 (150)

Continuous stall current rms**1 Amps 5.4 8.2 7.67

Rotor polar moment of inertia kgcm2 10.2 13 16

(inclusive of resolver inertia) lb-in sec2 0.009 0.0115 0.014

Maximum current (peak) Amp 25 38 34

Cogging torque (no shaft seal fitted)

Nm 0.28 0.3 0.3

lb-in 2.5 2.7 2.7

Torque constant Ktrms**2 **3 Nm/Amp

lb-in/Amp 0.51 4.5

0.51 4.5

0.75 6.6

Stator Winding

Resistance Line-Line**2 Ohms 1.6 0.77 0.91

Inductance Line-Line MilliHenrys 4.0 2.2 3.4

Thermal resistance °C/Watt °F/Watt

1.09 2.00

0.94 1.70

0.89 1.60

**1 The temperature rise DT on the windings is 110K and applies to all continuous torque values. The maximum ambient temperature is 40 °C (104 °F) and therefore, the temperature on the windings should not be more than 150 °C (302 °F). A value higher than 150 °C (302 °F) would exceed the class “F” insulation temperature specification.

**2 At 25 °C (77 °F) **3 Note that Kt is shown as a combined value for all three phases.


AM 130 Series – Torque Characteristic Graphs The following AM 130 Series torque characteristic graphs are illustrated:

Figure 4-4, AM 130A, AM 130AB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph

Figure 4-5, AM 130C, AM 130CB - Torque Characteristic on 250 V, 44 Voltage Gradient Graph

Figure 4-6, AM 130E, AM 130EB - Torque Characteristic on 250 V, 64 Voltage Gradient Graph

AM 130A, AM 130AB - Torque Characteristic Graph Refer to Figure 4-4.

AM130ATORQUE Figure 4-4, AM 130A, AM 130AB - Torque Characteristic on 250 V,




AM 130C, AM 130CB - Torque Characteristic Graph Refer to Figure 4-5.

AM130BTORQUE Figure 4-5, AM 130C, AM 130CB - Torque Characteristic on 250 V,


AM 130E, AM 130EB - Torque Characteristic Graph Refer to Figure 4-6.

AM130CTORQUE Figure 4-6, AM 130E, AM 130EB - Torque Characteristic on 250 V,





AM Series Cables and Connectors For AM 96 Series and AM 130 Series motors see “Section 6, Cables for Motors and Amplifies” for:

Figure 6-37, AC Brushless Motor (without Brake) Power Cable

Figure 6-38, AC Brushless Motor (with Brake) Power Cable

Figure 6-39, AC Brushless Motor Encoder Cable

Figure 6-40, Test Cable, P/N 33001389

For motor connectors, refer to the following tables:

Table 6-10, Power Connector, Non-Brake Motor, MS3102E-18-10P Pinout

Table 6-11 Power Connector, Brake Motor, MS3102E-20-15P Pinout

Table 6-12 Encoder Connector, MS3102E-20-29P Pinout

For mating power and encoder connectors, see “Section 6, Mating Power and Encoder Connectors.”


AM Series Motors Nameplate Conventions For AM Series AC brushless motors, the nameplate is a foil/metallic label. Refer to Figure 4-7.

C. STALL TORQUE

Jamestown, NY USA

www.acu-rite.com

PN:XXXXXXXX

MOTOR NAME SERIAL NO.

Manufactured by SEM Ltd in EnglandBRAKE DETAILS WHEN USED

MONTH & YEAR OF SHIPPINGEXAMPLE: A2006 JANUARY 2006

AMNAMEPLATE

TYPE

MANUFACTURER TECHNICALMOTOR DATA

MAX

FEEDBACKMOTOR PARTNUMBER

A

No

RPM V

IP IC

Tel: 716-661-1700

Fax: 716-661-1888

A

YXXXX

Figure 4-7, AM Series AC Brushless Motor Nameplate

For correct manufacturer technical motor data information on the nameplate for motor models, refer to:



For Type and Part Number, refer to Table 4-4.

Table 4-4, TYPE and Part Number (PN)

Type PN Type PN

AM 96A 34100330 AM 130A 34100300

AM 96C 34100331 AM 130C 34100301

AM 96E 34100332 AM 130E 37000302

AM 96AB 34100340 AM 130AB 34100310

AM 96CB 34100341 AM 130CB 34100311

AM 96EB 34100342 AM 130EB 37000312



OEM System Interconnect Refer to Figure 4-8.

INTERCONNECT

Figure 4-8, OEM System Interconnect Diagram


OEM CNC Installation P/N 70000506H - Dimensions and Installation


Section 5 - Dimensions and Installation

Wiring Guidelines and Grounding Concepts

General Wiring Guidelines

IMPORTANT: For safe operation, ensure that wiring conforms to all local and national codes.

IMPORTANT: The CNC, other control devices, and the enclosure must be properly grounded. An authoritative source on grounding requirements for most installations is the National Electrical Code (NEC).

Follow these general wiring guidelines:

1. Do not run the signal wire and the power wire in the same conduit. Where paths must cross, make intersections perpendicular.

2. Segregate I/O wires by signal types. Route wires with different signal characteristics along separate paths whenever possible. To prevent cross talk, avoid running harnesses containing different signal types parallel to one another.

3. Establish a low-impedance, single-point ground. All noise reduction techniques depend upon proper grounding.

4. Proper routing and grounding are more important than servo wire length.

5. Make signal wiring as short and direct as possible.

CAUTION: You must install E-STOP switches in the system. Make certain that the relay contacts have a sufficient rating for the application.

6. The E-STOP button and travel limit switches are wired in series. When any of them opens, the servos are de-energized. This will remove power from the machine. Ensure that they are correctly installed for safety purposes.

WARNING: Never alter these circuits to defeat their function. Serious injury or machine damage could result. Observe all applicable codes as to the placement and labeling of E-STOP switches.



General Grounding Guidelines This subsection contains procedures for proper system grounding during installation. Proper grounding is the foundation of all noise control techniques. It helps limit the effects of noise due to electromagnetic interference (EMI) and is essential to proper CNC operation.

WARNING: The CNC must be properly grounded. All applicable codes and ordinances must be observed when wiring the CNC.

In addition to the grounding required for the CNC and its electrical cabinet, you must provide proper grounding for all controlled devices in the application. Make sure to provide each device with an acceptable grounding path.

Establish Bonding Points on the Machine To establish a proper ground, remove all anodizing, paint, and other coatings down to the bare metal. Do this at points where mounting holes have been drilled into the machine to mount the electrical cabinets. A threaded hole drilled into the machine is not a proper ground. Remove the paint (or coating) around the hole, exposing bare metal. If you cannot use the mounting holes for electrical bond points, establish suitable bond points elsewhere.

Use Interior or Exterior Tooth Lock Washers Between Points of Contact To ensure a good electrical path, use interior or exterior tooth star washers between each point of metal-to-metal contact. Choose interior or exterior star washers based only on mechanical concerns.

Clean all Stand-Off and Mounting Assemblies to Bare Metal at Points of Contact The goal is to create a continuous metal-to-metal surface contact from the machine to the electrical cabinet. The machine builder decides which points are best suited for this task.

Threaded holes are not proper grounds; just as the threads of the mounting bolts are not proper ground paths. The best path is between two bare metal surfaces, with the proper star washer between them. The closer the installation is to this model, the better the ground.

Clean all Paint to Bare Metal from the Enclosure at the Points of Contact Once the bond point locations are determined, remove the paint at these points to allow bare metal-to-metal contact via internal or external tooth star washers.



Wiring of System Grounds

Verify that building grounds adhere to local codes at the time of the installation.

NOTE: If you suspect that there is no proper ground in the building, consult a qualified electrician.

Wiring Servo Amplifiers

Electrical equipment inherently generates radio-frequency interference (RFI) and wires act as antennae that transmit this interference. Motors inherently generate electromagnetic interference (EMI). Unless the wiring is very short, shielding on the motor wires is necessary to meet FCC RFI/EMI guidelines and to protect other equipment from the adverse effects of RFI/EMI.

Always use shielded wire or run the wires in a metal conduit. The shield or conduit must be connected to an earth-grounded amplifier base plate.

In order to decrease shock hazard and comply with electrical codes, run a conductor of the same gauge as the motor wires (or make a direct metal-to-metal connection) from the motor case to the amplifier baseplate.

Earth grounding is required to meet NEC regulations and to suppress RFI/EMI.

IMPORTANT: The signal wiring to the tachometer and the signal inputs to the amplifier are susceptible to noise. Excessive noise will cause erratic amplifier operation. Run each signal-input line in a separate, twisted-pair, shielded cable for optimal performance.

Terminate the shield only at the amplifier end to a common terminal. Keep signal lines as far as possible from any power or motor wires.

Isolation Transformer

An isolation transformer is sometimes used in the AC line to the controller. This type of transformer provides isolation from the power distribution system and is often used as a step-down transformer to reduce line voltage. Any transformer used with the CNC must have a sufficient power rating for its load. This power rating is typically expressed in volt-amperes (VA). Two guidelines when determining the correct transformer and its size are as follows:

ANILAM recommends an electrostatic-shielded isolation transformer rated at .5 KVA.

If output devices are connected through the transformer, add their maximum VA requirements to determine the correct transformer size.



Compliance with the CE Directives The 3000M, 4200T, and 5000M are OEM products and must be installed by qualified technicians. Compliance with CE directives and the attachment of the CE mark is the responsibility of the machine builder, who assumes all liability.

ANILAM has had the CNC components described herein tested for electromagnetic compatibility per the CE directives listed in Table 5-1.

Table 5-1, CE Directives

Directive Description EN 50081-1 Electromagnetic compatibility – Generic emissions

standard Part 1. Residential, commercial, and light industrial, 1992.

EN 50082-2 May 1995: Generic immunity standard for industrial environment.

EN 55011 Limits and methods of measurement of electromagnetic disturbance characteristics of industrial, scientific, and medical (ISM) radio-frequency equipment, Second Edition 1990-09.

EN 61000-4-2 Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 2: Electrostatic discharge immunity test, 1995.

ENV 50140 Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 3: Radiated radio frequency electromagnetic field immunity test, 1993.

EN 61000-4-4 Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 4: Electrical fast transient/burst immunity test, 1995.

ENV 50141 Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques, Section 6: Continuous conducted interference, 1993.

EN 61000-4-11 Electromagnetic compatibility (EMC) Part 4: Voltage Dips, short interruptions, and voltage variations, 1994.

EN 55022 (CISPR 22) Limits and methods of measurement techniques of radio disturbance characteristics of information technology equipment.

An NRTL-certified laboratory performed CNC electromagnetic compatibility testing. Test results are chronicled in EMC test reports EMI689 and EMI621A. In accordance with the CE directives, these reports are kept on file in the USA and UK offices of ANILAM, Inc.



Guidelines for Construction of a CE-Compliant System The following guidelines can aid in the design and construction of a CE-compliant system that uses ANILAM components. Primary consideration should be given to compliance with directive EN 60204-1, Safety of Machinery. Also, consult Wiring Guidelines and Grounding Concepts, preceding this subsection.

ANILAM CNC systems were tested according to stringent specifications for emissions and immunity. Electrostatic and radiated emissions were tested to light industrial standards. Electrostatic discharge and radiated electromagnetic field immunity were tested to heavy industrial standards. To ensure the repeatability of “passing” test results, ANILAM recommends that the machine builder adhere to the following guidelines:

• Follow good grounding techniques. Always keep grounds as short as possible. High-frequency noise grounding requires as much surface area metal-to-metal contact as possible to combat skin effect. ANILAM recommends use of star washers or similar products.

• Ferrous enclosures are preferred to aluminum enclosures because of their superior magnetic properties. Make the minimum number of outlets, preferably grouped together, in the enclosure. The enclosure and its conduits should form a single Faraday cage (metallically bonded). The door(s) should use clamps or cables to ensure conductivity.

• Where required, use liquid-tight, flexible metal conduit. Where a conduit’s fittings enter the enclosure, remove all paint or coatings to bare metal, especially around the nut that fastens the fitting to the enclosure.

• PWM amplifiers and switching power supplies are typical sources of emissions. Shield them in grounded metal enclosures, if necessary.

• Segregate cabling from known noise sources from other wiring. Place split ferrites at the noise source and where the cabling leaves the enclosure to aid in noise reduction.

• Use shielded cabling and ground the shields at one end only. Ground shields to the enclosure directly upon entry, not by “pigtails” or indirect methods.



Major Assemblies Dimensional Data The drawings listed in Table 5-2, provide dimensions, mounting hole patterns, and clearance requirements for ANILAM monitors, chassis, and CAN I/O boards.

Table 5-2, Dimensional Drawings Component Figure Reference

4200T LCD Console, Front View Figure 5-1, 4200T LCD Console, Front View

4200T LCD Console, Top View Figure 5-2, 4200T LCD Console, Top View

4200T LCD Console, Side View Figure 5-3, 4200T LCD Console, Side View

3000M Console Figure 5-4, 3000M Monitor, Ref. Dwg. D000591

4200T Manual Panel with Handwheel

Figure 5-5, 4200T Manual Panel with Handwheel, Ref. Dwg. D000595

4200T Manual Panel with no Handwheel

Figure 5-6, 4200T Manual Panel with No Handwheel, Ref. Dwg. D000594

5000M Console Figure 5-7, 5000M Monitor, Ref. Dwg. D000593

5000M Manual Panel with Handwheel

Figure 5-8, 5000M Manual Panel with Handwheel, Ref. Dwg. D000597

5000M Manual Panel with no Handwheel

Figure 5-9, 5000M Manual Panel with No Handwheel, Ref. Dwg. D000596

OEM CNC Chassis Figure 5-10, OEM CNC Chassis, Ref. Dwg. D000589

CAN I/O, Source In/Out Figure 5-11, CAN I/O, Source In/Out, OEM, P/N 33001503

CAN I/O, Sink In/Out Figure 5-12, CAN I/O, Sink In/Out, OEM, P/N 33001504

Phoenix Module Figure 5-13, Phoenix Modules

Phoenix DB-25 to terminal adapter Figure 5-14, Phoenix DB-25 to Terminal Adapter, Phoenix P/N 2281209

Amplifier Figure 5-15, Digital Brushless Servo Amplifier, P/N 33001279

Motors Figure 5-16, AM 96 Series AC Brushless Servo Motors Figure 5-17, AM 130 Series AC Brushless Servo Motors

The CNC chassis is common to all OEM products. All LCD consoles and manual panel assemblies have the same mounting characteristics.

LCD Console Mounting Figure 5-1, 4200T LCD Console, Front View shows a front view of the LCD console and its dimensions. Figure 5-2, 4200T LCD Console, Top View shows a top view of the LCD console. Figure 5-3, 4200T LCD Console, Side View shows a side view of the LCD console.

3000M and 5000M LCD consoles have the same dimensions as the 4200T.


Figure 5-1, 4200T LCD Console, Front View

Figure 5-2, 4200T LCD Console, Top View



Do not use DVI connector.

Figure 5-3, 4200T LCD Console, Side View



3000M Console

Figure 5-4, 3000M Console, Ref. Dwg. D000876



Dimensions in parenthesis ( ) aremillimeters (mm).

Side View D000595

0.187 (4.7) DIA. THRUTYP. 6 PLACESUSE #8-32 PAN HD.SCREWS OREQUIVALENT

Figure 5-5, 4200T Manual Panel with Handwheel, Ref. Dwg. D000595



Side View D000594

Figure 5-6, 4200T Manual Panel with No Handwheel, Ref. Dwg. D000594



5000M Console and Manual Panel

Figure 5-7, 5000M Console, Ref. Dwg. D000877




Side View


D000597

Figure 5-8, 5000M Manual Panel with Handwheel, Ref. Dwg. D000597


Side View


D000596

Figure 5-9, 5000M Manual Panel with No Handwheel, Ref. Dwg. D000596




OEM CNC Chassis Refer to Figure 5-10, OEM CNC Chassis, Ref. Dwg. D000589. The illustration shows the chassis mounted in a standing position. If you are mounting the chassis likewise, ANILAM recommends that you mount the chassis in the orientation shown in the illustration. The ANILAM logo will be located at the top of the chassis; the power supply terminal blocks will be located at the bottom.

The illustration also shows the locations of two standard CAN I/O boards, mounted inside the chassis. Mount any additional CAN I/O boards on the outside of the CNC chassis, via the provided mounting holes.


D000589

Figure 5-10, OEM CNC Chassis, Ref. Dwg. D000589



CAN I/O Boards, Mounting Locations The standard CNC chassis includes two CAN Source I/O boards. In a typical OEM system, these correspond to CAN0 and CAN1 on the OEM chassis. CAN Sink I/O boards are also available.

Refer to Figure 5-11 and Figure 5-12, CAN I/O, Sink In/Out, OEM, P/N 33001504. You can purchase additional boards.

Refer to Figure 5-10, OEM CNC Chassis, Ref. Dwg. D000589 for the location of the two standard boards and instructions on where to mount additional CAN I/O boards.

Figure 5-11, CAN I/O, Source In/Out, OEM, P/N 33001503



Figure 5-12, CAN I/O, Sink In/Out, OEM, P/N 33001504

Refer to Figure 5-14, Phoenix DB-25 to Terminal Adapter, Phoenix P/N 2281209 for the Phoenix components required to mount a single CAN board on a DIN rail.

PHOENIX1

Phoenix ContactTyp UMK-SE 11, 25-1

(End Cap)

Phoenix ContactTyp UMK-SE 11, 25-1

(End Cap)

Phoenix ContactTyp UMK-BE 45

Phoenix ContactTyp UMK-BE 45

Phoenix ContactTyp UMK-BE22,5

Use these Phoenix componentsto accommodate additional CAN I/O Boards mounted onDIN rails.

Use these endcaps on both ends of the CAN I/O board chain when multiple boardsare mounted on DIN rails.

Figure 5-13, Phoenix Modules



The Phoenix components are modular and can be used in combinations to mount additional CAN I/O boards. Depending on the number of boards, determine which components are required to hold all the boards. Place an endcap at each end of the chain of boards.

Use Phoenix components (Phoenix P/N UMK-FE) to secure the boards to the DIN rail. Refer to Figure 5-14. Connections to the CAN I/O boards are via the P5 DB-25 connector. Use the Phoenix Adapter, Phoenix P/N 2281209, if terminal blocks are required. The pins, labeled on the DB-25 and terminal blocks, are wired one-to-one. For example, Pin 1 on the DB-25 connector corresponds to Pin 1 on the terminal blocks. The adapter can be mounted on a DIN rail.

PMBPM

B

12

34

56

78

910

1112

13

1415

1617

1819

2021

2223

2425

PHNXADPT

Figure 5-14, Phoenix DB-25 to Terminal Adapter, Phoenix P/N 2281209

Install a flat-ribbon cable from the Phoenix terminal adapter to the CAN Node DB-25 P5 connector to connect the adapter to the CNC chassis.



Digital Brushless Servo Amplifier Refer to Figure 5-15.

AMPLIFIER

J7 J1 J2 J3 TB1

ACU-RITE COMPANIES INC.

+ -

J7 J1 J2 J3 TB

GENERAL NOTES1. Dimensions are in inches / (MM)2. Requires firmware 3.10 REV. C or newer

Figure 5-15, Digital Brushless Servo Amplifier, P/N 33001279



AC Brushless Servo Motors Refer to Figure 5-16 and Figure 5-17, AM 130 Series AC Brushless Servo Motors.

FOR DIM. SEE DETAIL "A"

DETAIL "A"

AM96Dim

GENERAL NOTES1. Dimensions are in inches (MM)

MotorAM 96AAM 96ABAM 96CAM 96CBAM 96EAM 96EB

P/N370003303700034037000331370003413700033237000342

DIM "A" 7.60 (193) 9.14 (232) 8.58 (218)10.12 (257)10.55 (268)12.09 (307)

Figure 5-16, AM 96 Series AC Brushless Servo Motors



AM130Dim

GENERAL NOTES1. Dimensions are in inches (MM)

MotorAM 130AAM 130ABAM 130BAM 130BBAM 130CAM 130CB

P/N370003003700031037000301370003113700030237000312

DIM "A"7.68 (195)7.68 (195)8.09 (205)8.09 (205)8.51 (216)8.51 (216)

Figure 5-17, AM 130 Series AC Brushless Servo Motors


OEM CNC Installation P/N 70000506H - Connection

Section 6 - Connection Overview

This section explains the interconnection of ANILAM's OEM components. This includes connection information for pre-assembled harnesses or cables fabricated by the machine builder.

NOTE: Shell size (DB, DA, and DE); number of pins (25, 15, and 9); and type of connector (F for female socket, M for male plug) are provided for connectors. Example: DB-25F refers to a DB shell size, 25-pin female connector. DA-15M refers to a DA shell size, 15-pin male connector.

The CNC chassis is common to all systems. Refer to Figure 6-1.

COM1

Ethernet Network

VGA

Keyboard

CO

M2

PR

INTE

R

FLO

PP

Y D

ATA

FLO

PP

Y P

OW

ER

Ref. Dwg. 23000031

Figure 6-1, Side View of CNC Chassis with Connections

Refer to Table 6-1 to determine the figure that contains the appropriate connection diagram for your system.

Table 6-1, Interconnection Wiring Diagrams System Reference Figure

3000M LCD Console Figure 6-2, 3000M LCD Console Connection Diagram, Ref. Dwg. 30100289

4200T/5000M (without handwheel) LCD Console

Figure 6-3, 4200T/5000M (without Handwheel) LCD Connection Diagram, Ref. Dwg. 30100287

4200T/5000M (with handwheel) LCD Console

Figure 6-4, 4200T/5000M (with Handwheel) LCD Connection Diagram, Ref. Dwg. 30100288



30100289

3/4Probe

Figure 6-2, 3000M LCD Console Connection Diagram, Ref. Dwg. 30100289



30100287

Probe

Figure 6-3, 4200T/5000M (without Handwheel) LCD Console Connection Diagram,

Ref. Dwg. 30100287



30100288

Probe

Figure 6-4, 4200T/5000M (with Handwheel) LCD Console Connection Diagram, Ref.

Dwg. 30100288



Power

Connection

Connect the input power (TB1) and output power (TB2) for the CNC to the terminal blocks on the side of the CNC chassis. Refer to Figure 6-5. The system requires an input power of 110 V AC single-phase at 2 A. Refer to Table 6-2 for the pinouts.

Figure 6-5, Input and Output Power Terminal Blocks

Table 6-2, Input and Output Power Connections

TB1 (INPUT) TB2 (OUTPUT) Pin Signal Pin Signal 1 LINE 1 +5 V 2 NEUTRAL 2 5 COM 3 GROUND 3 +12 V 4 12 COM 5 +24 V 6 24 COM

Fuses The input AC (TB1, Pin 1) connects to a dedicated fuse rated at 10 A at 250 V. The 24 V power supply (TB2, Pin 5) connects to a dedicated fuse rated at 2 A at 250 V.



Amplifier Connectors For amplifier connectors, refer to the following tables:


Table 6-4, Amplifier – J1 Host Connector Pinout Table 6-5, Amplifier – J2 Signal Inputs (from Motion Board to

machine interface) Connector Pinout Table 6-6, Amplifier – J3 Signal Inputs (from Rotary Encoder on

Motor) Connector Pinout Table 6-7, Amplifier – J7 External +5 V Connector Pinout Table 6-8, Amplifier – TB1 Terminal Block Connector Pinout Table 6-9, Amplifier – LED Indicators


Connector Description Input mating connector (J1) Molex part number: 22-01-3047 Input mating connector (J2) Molex part number: 22-01-3167 Input mating connector (J3) T & B part number: 622-2041 Input mating connector (J7) Molex part number: 22-01-3027

Table 6-4, Amplifier – J1 Host Connector Pinout

Pin Signal Description

1 4

J1 - HOST

4-pin single row header

1 GND Signal common 2 RX RS232 data into amplifier 3 TX RS232 data from amplifier 4 n/c no / connect



Table 6-5, Amplifier – J2 Signal Inputs (from Motion Board to machine interface) Connector Pinout


6


J2 - SIGNAL INPUTS

1 1 16-pin single row header

1 SIG 1+ Signal input, plus 2 SIG 1– Signal input, minus 3 COMMON Signal common 4 ABS CURRENT Analog motor current monitor output 5 ANALOG OUT Programmable analog output 6 +LIMIT Plus direction limit input, active low 7 –LIMIT Minus direction limit input, active low 8 INHIBIT Inhibit input, active low 9 FAULT OUT Fault output, open drain, active low 10 ENC A+ OUT Encoder phase A+ output 11 ENC A– OUT Encoder phase A– output 12 ENC B+ OUT Encoder phase B+ output 13 ENC B- OUT Encoder phase B– output 14 ENC Z+ OUT Encoder phase Z+ output 15 ENC Z– OUT Encoder phase Z– output 16 COMMON Signal common


Table 6-6, Amplifier – J3 Signal Inputs (from Rotary Encoder on Motor) Connector Pinout


9

0


J3 - SIGNAL INPUTS

1 1

2 2

20-pin double row header

1 +5 V ENC Power for encoder 2 COMMON Signal common 3 +5 V ENC Power for encoder 4 COMMON Signal common 5 ENC A+ Encoder Phase A+ 6 ENC A– Encoder Phase A– 7 ENC B+ Encoder Phase B+ 8 ENC B– Encoder Phase B– 9 ENC Z+ Encoder Phase Z+ 10 ENC Z– Encoder Phase Z– 11 HALL U Commutation Track Phase U 12 HALL U– Commutation Track Phase U– 13 HALL V Commutation Track Phase V 14 HALL V– Commutation Track Phase V– 15 HALL W Commutation Track Phase W 16 HALL W– Commutation Track Phase W– 17 n/c No connect 18 COMMON Signal common 19 COMMON Signal common 20 COMMON Signal common

Table 6-7, Amplifier – J7 Ext +5 V Connector Pinout


J7 - EXT +5V

2-pin single row header

1 EXT +5V External power for amplifier

2 GND Common Table 6-8, Amplifier – TB1 Terminal Block Connector Pinout

Pin Signal Description 1 – Negative main bus power 2 + Positive main bus power 3 T To pin C, V phase, of motor power connector 4 S To pin A, U phase, of motor power connector 5 R To pin B, W phase, of motor power connector


Table 6-9, Amplifier – LED Indicators

Red Green Condition Off Off No power Off On Enabled On Off Fault On On Inhibit

Motor Connectors For motor connectors, refer to the following tables:


Table 6-11 Power Connector, Brake Motor, MS3102E-20-15P Pinout




MS3102E-18-10P

A Motor U To pin 4, S phase, of amplifier terminal block

B Motor V To pin 5, R phase, of amplifier terminal block

C Motor W To pin 3, T phase, of amplifier terminal block

D Earth Safety earth

Table 6-11, Power Connector, Brake Motor, MS3102E-20-15P Pinout


MS3102E-20-15P

A Motor U To pin 4, S phase, of amplifier terminal block

B Motor V To pin 5, R phase, of amplifier terminal block

C Motor W To pin 3, T phase, of amplifier terminal block

D Earth Safety earth E Brake B+ Brake power + F Brake B– Brake power – G n/c no / connect





MS3102E-20-29P

A ENC A+ Encoder phase A+ B HALL V- Commutation track phase V– C ENC A– Encoder phase A– D HALL V Commutation track phase V E ENC B+ Encoder phase B+ F ENC B– Encoder phase B– G ENC Z+ Encoder phase Z+ H ENC Z– Encoder phase Z– J GND Common K HALL U Commutation track phase U L HALL W– Commutation track phase W– M HALL U– Commutation track phase U– N +5V Encoder power P HALL W Commutation track phase W R n/c S n/c T n/c



Console

Power Requirements

The SVGA LCD monitor requires 12 V DC at 2 A input power. The computer provides the power to the LCD monitor.

A constant voltage transformer can further isolate the CNC and servo from input voltage irregularities. The control alone requires a 0.5 KVA transformer. ANILAM also recommends that you similarly protect the servo system.

CAUTION: You must plug the CNC into a dedicated line. Failure to do so could lead to improper operation.

VGA to Single-Board Computer Connection

NOTE: The standard length of all interconnecting harnesses is 15 feet (4.57 M). Custom lengths are available upon request.

Refer to Figure 6-6. The VGA harness connects the 15-pin connector on the back of the color screen to the labeled 15-pin VGA connector on the side of the CNC chassis. Refer to Figure 6-1, Side View of CNC Chassis with Connection.

Figure 6-6, VGA Harness, P/N 33000188

Refer to Figure 5-3, 4200T LCD Console, Side View. Do not use DVI connector.




LCD Console Power Connection Use a two-position terminal block (.2 center), ANILAM P/N 80900128 and Phoenix P/N 1757019, and a 20-AWG, two-conductor wire to connect the LCD console to the +12-V connector and the COM connector on the OEM CNC chassis.

Refer to Figure 6-2, 3000M LCD Console Connection Diagram, P/N 30100289, Figure 6-3, 4200T/5000M (without Handwheel) LCD Console Connection Diagram, Ref. Dwg. 30100287, and Figure 6-4, 4200T/5000M (with Handwheel) LCD Console Connection Diagram, Ref. Dwg. 30100288.

LCD Setup and Adjustment Procedures

If you’re using a board with a handwheel, refer to Figure 6-4, 4200T/5000M (with Handwheel) LCD Console Connection Diagram, Ref. Dwg. 30100288. If you’re using a board without a handwheel, refer to Figure 6-3, 4200T/5000M (without Handwheel) LCD Console Connection Diagram, Ref. Dwg. 30100287.

Connecting the OSD Board (P/N 33000486)

CAUTION: To avoid possible electrical shock or damage to the OSD board or LCD console, turn OFF the power to the OEM CNC system before you connect or disconnect the OSD board.

The On-Screen Display (OSD) board is normally not connected during operation. However, when it is not connected, jumpers must be inserted between pins 1 and 2 and pins 3 and 4 on console connector labeled OSD.

To connect the OSD board to the OSD connector on the console, perform the following steps:

1. Turn OFF the power to the OEM CNC system.

2. Remove the jumpers from pins 1 and 2 and pins 3 and 4 on the OSD connector on the console.

3. Plug the OSD board connector to the OSD connector on the console.

4. Turn on the power to the OEM CNC system.

5. Perform the necessary adjustments to the LCD.


Disconnecting the OSD Board

CAUTION: To avoid possible electrical shock or damage to the OSD board or LCD console, turn OFF the power to the OEM CNC system before you connect or disconnect the OSD board.

To disconnect the OSD board from the OSD connector on the console, perform the following steps:

1. Turn off the power to the OEM CNC system.

2. Unplug the OSD board connector from the OSD connector on the console.

3. Reinstall the jumpers between pins 1 and 2 and pins 3 and 4.

4. Turn on the power to the OEM CNC system.

Adjusting the On-Screen Display (OSD) Board Settings If the LCD requires any adjustments, perform them after you install the LCD console.

The OSD board uses the OSD Menu to allow On-Screen Display adjustment of the LCD console display. Refer to Figure 6-7. The OSD board contains a variable resistor and four buttons to adjust the following settings:

• On/Off - Power toggle switch.

• Brightness - Controls backlight brightness.

• Contrast - Adjusts color saturation.

• Phase - Adjusts data sampling position.

• Size - Adjusts the image size for SVGA resolutions. While using this setting, you may need to adjust the image horizontal position.

• Vert - Adjusts the vertical position.

• Horiz - Adjusts the horizontal position.

Menu Select

+

-ON/Off/Brightness

Figure 6-7, On-Screen Display (OSD) Board Settings Adjustments

The OSD board allows you to adjust the LCD console display OSD settings using the OSD Menu.




To adjust any OSD setting, perform the following steps:

1. Press Menu on the OSD board. The LCD console displays the OSD Menu.

2. Press Select to select the setting you wish to adjust.

3. Press + to increase the selected setting.

– or –

1. Press – to decrease the selected setting.

2. Repeat steps 2 and 3 to adjust another setting.

3. When all adjustments are complete, press Menu on the OSD board. The LCD console turns off the OSD Menu.

4. To reset all settings to the default settings, press Select, +, and – at the same time.


Keyboard Interface Board Refer to Figure 6-8 and Figure 6-9, 4200T/5000M Keyboard Interface Board, P/N 33000977.

33000976

Figure 6-8, 3000M Keyboard Interface Board, P/N 33000976



33000977

Figure 6-9, 4200T/5000M Keyboard Interface Board, P/N 33000977




Keyboard Interface to External Keyboard Connection

Refer to Figure 6-10, Keyboard Interface Harness. Use these harnesses to connect an external keyboard to the system. The cable with the 6-pin socket, P/N 33001057, plugs into the side of the CNC chassis at the 6-pin, mini-DIN connector labeled KEYBOARD. Connect the other end to P9 on the Keyboard Interface PCB on the front panel. The 6-pin header P10 on the keyboard interface PCB of OEM consoles, made since 1 January 2003, allows the connection of both an external PC PS/2 keyboard and a PS/2 style mouse. Use wiring harness 33001092 (3 feet) or 33001093 (6 feet) to provide a standard 6-pin mini-DIN socket. A PS/2 style keyboard with a 6-pin mini-DIN connector can be plugged directly into the socket. A mouse, with or without an external keyboard, requires a PS/2 Y-splitter cable. A mouse is required to use the DXF Converter feature. Refer to the DXF Converter section in the CNC Programming and Operations Manual. Refer to Figure 6-1, Side View of CNC Chassis with Connections.

In certain installations, it may be necessary to run the keyboard cable through areas where there exists significant electronic “noise.” In this case, this noise may adversely affect keyboard operation. A pigtail connection to the cable’s shield is provided for these circumstances. The pigtail should be attached to a convenient chassis ground point in the console to eliminate the noise, if required.


Figure 6-10, Keyboard Interface Harnesses

Tabulation Block

PART NO. DIM T NO. DIM. A . A PAR33001057 15 feet 33001067 50 feet 33001058 400 inch 33001068 55 feet 33001059 33 feet 33001069 60 feet 33001060 23 feet 33001070 65 feet 33001061 25 feet 33001071 70 feet 33001062 20 feet 33001072 75 feet 33001063 30 feet 33001073 9 feet 33001064 35 feet 33001074 4 feet 33001065 40 feet 33001075 10 feet 33001066 45 feet



Manual Panel Connections

C11

R4 R5

P5R1 D

1

U10

C10

C13

C12

U7 R3

U8

R6

P3P4R2R1

3

U6

C17

C16

C9

C1

C15 C

8U9

R11

R10

R12

R9R8

R7

U3

C14

U1 C3

C2

27C

256

W/S

OC

KET

78C

10W

/SO

CKE

T74

ALS5

73

74LS

138

MAX

233

U2

U11

U5

C6 C5

Q1

P2

X1

U4

C7

C19

JW2

JW1

P1R1

4

4.7

TAN

T

TAN

T4.

710

00pF

1000

pF

.01

.01

.01

3.3K 10K

10K

10K

10K

.1 .01

.01

7705

A

10K

100

010

0 0

100

010

0 0

100

0

11.0

592

MHZ

10K

.01

.01

TANT

4.7

10pF

10pF

.1

C18

11

1

11

1P6

R15

P7

C4

1K

.47

100

HCTL

2016

1N41

481M

F

10 W

74LS

541

74LS

541

74LS

541

74LS

541

TAN

T

TAN

T22

MF

1416

1K

.1C20

9010

0295

RE

V A

LM34

OT-5

3190

0541

BYE

AR/W

EEK

GN

D+1

5

CO

M

3109

0054

1

4200T

5300M5000M-3X

5400M5000M-4X5500M5000M-5X

Figure 6-11, 4200T/5000M Manual Panel Interface Board, P/N 31900541



The COM1 connector on the side of the CNC chassis is a 9-pin, RS-232 port that connects to the Manual Panel Interface Board (P2 connector). Refer to Table 6-13 and Figure 6-12.

Table 6-13, COM1 Pinout

Pin Signal 1 N/C 2 RXD 3 TXD 4 N/C 5 GND 6 N/C 7 N/C 8 N/C 9 N/C

RED

BLK

P2

TO MANUAL PANEL

3" TYP.

BRN

TO KEYBD INTFC

(RXD)

(TXD)

(COM)4

321

56

33000187

15 FT

SHLD

4(GND) BLK9

5

(RXD) BRN(TXD) RED

6

87

321

CHASSIS-COM1TO OEM CMPTR

Ref. Dwg. P/N 33000187 Figure 6-12, Manual Panel to COM1 Harness, P/N 33000187



Connect the manual panel handwheel, if present, to CTR 0 on the CNC chassis. Refer to Table 6-14 and Figure 6-13.

Table 6-14, Manual Panel Handwheel (CTR0) Pinout

Pin Signal 1 PHASE A SIGNAL 2 N/C 3 N/C 4 N/C 5 PHASE B SIGNAL 6 N/C 7 +5 8 GND 9 N/C

Figure 6-13, Manual Panel Handwheel to CTR0 Harness, P/N 33000204



Remote Floppy Disk Drive Installation and Harnesses This section describes how to install the floppy disk drive in a remote location. Refer to Table 6-15 for required parts, Figure 6-14, and Figure 6-15, Remote Floppy Disk Drive Dimensions.

Table 6-15, Floppy Disk Drive Installation Components

Hardware Kit, P/N 33000199 Item Part

Number Description Quantity

1 21900413 Sheet Metal, Floppy Drive Flush Mounting Bracket 1 2 31300204 Disk Drive, 3.5” Floppy 1 3 21900784 Sheet Metal, Floppy Disk Drive Cover 1 4 86100030 Machine Screw, #4-40 × 1/4” LG 4 5 86100166 Machine Screw, #6-32 × 3/4” LG PHL PAN HD 4

33000199

Figure 6-14, Remote Floppy Disk Drive Illustration, P/N 33000199



33000199DIM

(100.08)

(146.3)

(114.3)

(149.35)

0.12"(3.05)

0.22(5.59)

(37.34)

(32.0)

(50.04)

(65.02) (65.02)

3.94"

5.88" 5.76"

4.50"

1.47"

2.56"2.56"

1.97"

1.26"

Figure 6-15, Remote Floppy Disk Drive Dimensions

For floppy disk drive harness components, refer to Table 6-16, Figure 6-16, and Figure 6-17, Remote Floppy Disk Drive Signal Harness, P/N 36000371.

Table 6-16, Floppy Disk Drive Harness Components Harnesses

Part Number

Description Quantity

33000203 12 and 5 V Computer Power Supply/Remote Floppy Disk Drive Power Supply Harness, 15 FT. Refer to Figure 6-16.

1

36000371 OEM Floppy Disk Drive Signal Extension, 15 FT. Refer to Figure 6-17, Remote Floppy Disk Drive Signal Harness, P/N 36000371.

1

Figure 6-16, Remote Floppy Disk Drive Power Supply Harness, P/N 33000203



Figure 6-17, Remote Floppy Disk Drive Signal Harness, P/N 36000371

Procedure

To install the floppy disk drive in a remote:

1. Drill four holes and make a rectangular cutout for the floppy disk drive. Refer to Figure 6-18.

5.12"(130.05)

3.94"(100.08) FDCUTOUT

1.26"(32)

0.59"(14.98)

0.17" (4.32) DIA.,4 PLACES

Figure 6-18, Floppy Drive Drilled Hole and Rectangular Cutout Dimensions

2. Mount the floppy disk drive to the provided bracket, P/N 21900413, with the four 4-40 X 1/4” Phillips screws, P/N 86100030. Refer to Figure 6-19, Floppy Disk Drive Mounting Bracket, P/N 21900413 and Figure 6-14, Remote Floppy Disk Drive Illustration, P/N 33000199.



Figure 6-19, Floppy Disk Drive Mounting Bracket, P/N 21900413

3. Plug the remote, floppy disk drive signal harness, P/N 36000371, into the 37-pin, D-sub connector, labeled FLOPPY DATA, on the chassis. Refer to Figure 6-20.

COM1

Ethernet Network

VGA

Keyboard

CO

M2

PR

INTE

R

FLO

PP

Y D

ATA

FLO

PP

Y P

OW

ER

Ref. Dwg. 23000031 Figure 6-20, Backplane Connection Points

4. Plug the remote floppy disk drive power supply harness, P/N 33000203, into the computer’s +5/+12 V power supply, labeled FLOPPY POWER, on the chassis.

5. Attach the power cable and data cable to the floppy disk drive. 6. Use the 6-32 X 3/8” flat head screw, P/N 86100150, to mount the

floppy disk drive bracket to the cutout. Align the four mounting holes. 7. Attach the flip-top cover, P/N 21900784, to the floppy disk drive

bracket with the four provided 6-32 X 3/4” Phillips screws, P/N 86100123.



Control Axes (X, Y, Z, U, S, and W)

The CNC interfaces to the controlled axes using labeled ports on the cover of the CNC chassis (Axes X, Y, Z, U, S, and W correspond to Ports 0, 1, 2, 3, 4, and 5, respectively). The port numbers are silk-screened on the chassis top cover. The encoder input and analog output signals for the controlled axes are received using a DA-15M connector for each axis. OEM configurations usually include mating connectors. The pinouts for these connectors (Ports 0–5) are the same. Refer to Figure 6-21, for axis pin assignments. Refer to Table 6-17, for connector assignments.

Table 6-17, Control Axes Connections

Product Port 0 1 2 3 4 5

3000M Systems X Y Z S 4200T Systems X C/S Z 5000M Three-Axis Systems X Y Z S 5000M Four-Axis Systems X Y Z U S 5000M Five-Axis Systems X Y Z U S W

A Phase A Phase *

B Phase

Index B Phase *

Index *Encoder +5VDC

Encoder +5VDCEncoder GND

Encoder GND

10

11

12

DAC Command Signal COMChassis GND

1

2

3

4

5

6

7

8

9

13

14

15

Chassis GND

DAC Command Signal

Figure 6-21, Control Axes Pinouts (Ports 0 to 5)




Single-Ended vs. Differential Axis (Jumper Settings)

Refer to Table 6-18 and Table 6-19 to configure the required switch and jumper settings for single-ended or differential input/output.

NOTE: The factory default for encoder inputs and analog outputs on all axes is single-ended.

Table 6-18, Switch Settings for Encoder Inputs Axes Switch Signal Type

0 Axis Encoder SW1-1, 2, 3 ON Single-Ended Input SW1-1, 2, 3 OFF Differential Input 1 Axis Encoder SW1-4, 5, 6 ON Single-Ended Input SW1-4, 5, 6 OFF Differential Input 2 Axis Encoder SW1-7, 8, 9 ON Single-Ended Input SW1-7, 8, 9 OFF Differential Input 3 Axis Encoder SW1-10, 11, 12 ON Single-Ended Input SW1-10, 11, 12 OFF Differential Input

Table 6-19, Jumper Settings for Analog Outputs Axes Jumpers Signal Type

0 Axis Analog Output J10, J11 2-3 Single-Ended Output J10, J11 1-2 Differential Output

1 Axis Analog Output J12, J13 2-3 Single-Ended Output J12, J13 1-2 Differential Output 2 Axis Analog Output J14, J15 2-3 Single-Ended Output J14, J15 1-2 Differential Output 3 Axis Analog Output J16, J17 2-3 Single-Ended Output J16, J17 1-2 Differential Output

Cable Specifications (Control Axes)

Use the following guidelines when you wire the control axes:

• Use shielded wire on all axes.

• For differential axes, use shielded double-twisted pair wire.

• The maximum cable length between an encoder and the OEM CNC chassis is 50 feet (15.24 M).


Handwheel or Readout Axes

Connect the readout/handwheel axes to the cover of the CNC chassis. (Use CTR 0, 1, or 2. CTR stands for Counter.) The port names are silk-screened on the chassis cover. Connection is through a DE-9M connector (one for each axis). Refer to Figure 6-22, for readout axis pin assignments.

A Phase

Index Encoder +5VDC

Encoder GND

ShieldB Phase

7

8

9

1

2

3

4

5

6 N.C.N.C.

N.C.

CTR0CTR1 Figure 6-22, CTR0/CTR1 Pinout

Cable Specifications (Readout Axes)

Use the following guidelines when you wire the handwheel/readout axes:

• Use shielded wire on all axes.

• The maximum cable length between an encoder and the OEM chassis is 50 feet (15.24 M).




Printer Connection

Refer to Figure 6-20, Backplane Connection Points. The labeled DB-25F printer connector is located on the backplane of the CNC chassis. Refer to Table 6-20.

Table 6-20, Printer Connector Pinout

Pin Signal Pin Signal 1 -Strobe 10 -Acknowledge 2 +Data Bit 0 11 +Busy 3 +Data Bit 1 12 +P. End (out of paper) 4 +Data Bit 2 13 +Select 5 +Data Bit 3 14 -Auto Feed 6 +Data Bit 4 15 -Error 7 +Data Bit 5 16 -Initialize Printer 8 +Data Bit 6 17 -Select Input 9 +Data Bit 7 18–25 Ground

COM2 Connection

Refer to Figure 6-20, Backplane Connection Points. The labeled COM2 connector located on the backplane of the CNC chassis is a DE-9M, RS-232 port. It is an IBM PC AT 9-pin serial port. Refer to Table 6-21.


Pin Signal

1 N/C 2 RXD 3 TXD 4 N/C 5 GND 6 N/C 7 N/C 8 N/C 9 N/C


Ethernet Network Connection Refer to Figure 6-1, Side View of CNC Chassis with Connections. Make network connections using the single-board computer. Refer to Table 6-22. Locate the RJ-45, mini-modular, 10BaseT Ethernet, twisted-pair connection on the SBC mounting bracket. (Refer to “Section 7, Single-Board Computer.”)

Table 6-22, Ethernet Connector Pinout

Pin Signal 1 TPT+ 2 TPT- 3 TPR+ 4 N/C 5 N/C 6 TPR- 7 N/C 8 N/C

Probe Connection Locate the single-row header for the Probe. Use harness P/N 33000973 to the 16-pin Probe P15 connector on the back of the chassis. Refer to Table 6-23 and Figure 6-23.

Table 6-23, Probe Header Pinout

Pin Signal 1 24V Common 2 READY Input 3 START Output 4 +24V Power 5 BATTERY LOW Input 6 TOUCH Input 7 24V Common

33000973PINOUT Figure 6-23, Probe Pinout



MBIO

OEM Servo System Wiring

Refer to Figure 6-2, Top View of CNC Chassis Cover with Connections. The Machine Basic input/output (MBIO) DA-15F connector on the CNC chassis cover receives machine basic input and output signals. Refer to Figure 6-24.

10

11

12

1

2

3

4

5

6

7

8

9

13

15

E-Stop SW

+24VDC

+24VDC

AUTO/MANUAL

+24VDC

24COM

SVOON*

RESET2

RESET1

SVOEN

SVO RST IN*

RESET COM

+24VDC

EXT START

14

EXT STOP

Figure 6-24, MBIO Mating Connector

The MBIO connector receives the signals for the E-STOP, Auto Manual Select, and External Stop/Start functions. Refer to Table 6-24, for the illustrations that describe these functions.

Table 6-24, MBIO Functions

Function Reference Figure E-STOP (Turn-On circuit) Figure 6-25, MBIO Turn-On Circuit AUTO/MANUAL SELECT Figure 6-26, MBIO AUTOMANUAL Select Circuit EXTERNAL STOP/START Figure 6-27, External STOP/START Circuit

NOTE: In the following illustrations, the numbers on the left followed by descriptions are pin numbers that correspond to the MBIO connector.



SVOON

1- E-STOP SW

2- +24VDC

10- SVOEN

9- RESET1

8- RESET2

7- SVOON*

5- + 24VDC

12- COM

11- SVO RST IN*

E-STOPLOGIC CIRCUIT

E-STOPSWITCH

SVOON

SVOON

DEAD STOPLIMIT

SWITCHES

RESETSWITCH

MANUAL PANEL P7- OR-KEYBOARD INTERFACE P7- OR-

USER SUPPLIED SWITCHP7-P1P7-P2

Figure 6-25, MBIO Turn-On Circuit

3- +24VDC

4- MAN

AUTO

MAN

ENERGIZINGSIGNAL (USER) USER'S MACHINE

ELECTRICS

SVOON

OPTIONAL AUTO/MANUALSWITCHING CIRCUIT

Figure 6-26, MBIO AUTO/MANUAL Select Circuit

13- EXT STOP

15- EXT START

14- +24VDC

OPTIONAL EXTERNALSTOP/START CIRCUIT

STARTSWITCH

STOPSWITCH

Figure 6-27, External STOP/START Circuit



Servo Control Board Use with MBIO (Option)

An ANILAM Servo Control Board (SCB), P/N 33001521, can be installed on OEM configurations. Refer to Figure 6-28. The board is the junction point of the E-STOP, dead-stop limit inputs, auto/manual select, spindle motor control, and coolant signals.

CAN Address J2CAN Terminating Board J1

33001521

Figure 6-28, Servo Control Board, P/N 33001521



The board controls the servo turn-on loop that powers the servos. As part of the safety loop, the Solid State Relay turns on power to the servo drive. Refer to Figure 6-29.

Figure 6-29, Servo Control and M-Function Simplified Schematic, Ref. Dwg. KS6302BF

The relay is rated at 250 V AC at 25 A. The signals pick-up voltage is 3 V DC (32 V DC allowed), and the operating voltage range is 24-280 V AC.

When the board receives a servo enable signal from the CNC, it sends the signal through the dead-stop limits string. If none of the dead stop limits are tripped and the E-STOP and Servo Reset contactors are closed, the board transmits the servo enable signal that energizes the servos and turns on the servo and solid state relays.




You can connect an optional AUTO/MANUAL switch to the board using P15 Pins 3 and 4. If you set the switch to AUTO, the solid-state relay that powers the drives turns on.

The board is a CAN Node. The CAN Node number depends on the setting of jumper J2. Refer to Table 6-25.

Table 6-25, Setting Board as CAN 0 or CAN 1

CAN Node Address Jumper Setting CAN 0 Jumper J2 PRESENT CAN 1 Jumper J2 ABSENT

Function signals from the CNC are sent to the SCB (using CAN Bus protocol) to activate the required output ports. User-configured wiring on the P3 connector receives and transmits I/O signals.

The servo control board provides six outputs and ten inputs. Normally, three outputs are used to power three drive relays on the board. These outputs switch AC power to the P13 connector, which contains the spindle functions (forward and reverse), coolant control, and an optional thermal overload switch. If the thermal overload switch is turned on, the servo relays will not switch on.

Additional I/O is available using CAN bus nodes mounted within the CNC chassis or mounted externally. You must place a terminating jumper on J1 of the servo control board if you are not installing additional CAN Nodes. If the system contains additional CAN nodes, do not place a jumper across J1; place the terminating jumper on the last board in the chain.

The board provides the interface circuitry for all signals that connect to the system using the MBIO connector on the CNC chassis cover (with the exception of the Remote Start/Stop option). These signals include the Auto/Manual select switch and the servo enable and E-STOP switch. The board receives the signals through its P15 connector.

P2 and P17 are output Clamp circuits from the Servo Control Board. P17 can be normally open or normally closed, depending on the pin used. Refer to Table 6-26, Servo Inhibitor (P2) Pinout and Table 6-27, Servo Inhibitor (P17) Pinout. Both connectors contain pins that you can use for connection to chassis ground, as required.

Refer to Figure 6-30, Pinout for Servo Board, P/N 33001521. or to an external signal • K1: 4PDT 24 V DC socket mount relay • K2: SPDT DC actuated chassis mount solid-state relay • K3 to K5: 2PDT 24 V DC socket mount relays. • K3 and K4 are electrically interlocked for use with reversing contactor

sets. You can disable the interlock function using the J4 and J5 jumpers.


33001521PINOUT Figure 6-30, Pinout for Servo Control Board, P/N 33001521




Connectors

Table 6-26 through Table 6-31 provide the servo control board connector pinouts.

Table 6-26, AC Power (P1) Pinout

Pin Signal 1 LINE 2 NEUT IN 3 NEUT OUT 1 4 LINE OUT 1 5 NEUT OUT 2 6 LINE OUT 2

Table 6-27, Servo Inhibitor (P2) Pinout

Pin Signal 1 N.C. 2 N.C. 3 N.C. 4 COM 5 CHASSIS GND

Table 6-28, Servo Control Board CAN I/O (P3) Pinout

Pin Signal Pin Signal 1 IN0 11 OUT0 2 IN1 12 OUT1 3 IN2 13 OUT2 4 IN3 14 OUT3 5 IN4 15 OUT4

6 IN5 16 OUT5

7 IN6 17 +24 V

8 IN7 18 +24 V

9 IN8 19 24 COM

10 IN9 20 24 COM



Table 6-29, Servo Control Board (P13) Pinout

Pin Signal 1 OVERLOAD 1 2 OVERLOAD 2 3 SPINDLE FWD 4 SPINDLE REV 5 COOLANT 6 NEUTRAL

Table 6-30, Servo Control Board Console (P15) Pinout

Pin Signal 1 +24 V DC 2 24 COM 3 ONAUTO2 4 ONAUTO1 5 SVOON* 6 RESET2 7 RESET1 8 SVOEN 9 ESTOP2

10 ESTOP1

Table 6-31, Servo Inhibitor (P17) Pinout

Pin Signal 1 N.C. 2 N.O. 3 COM 4 CHASSIS GND


Controller Area Network (CAN) I/O Bus

Current Rating and Power Requirements

The board contains ten opto-isolated inputs, six isolated relay driver outputs, and one 10-bit A/D converter for an optional analog input. The board uses 5 V DC at 80 mA, 24 V DC at 40 mA, and the current drawn by the external relays. The output current of the relay drivers on the board is 250 mA. Refer to Figure 6-31.

33001503

Figure 6-31, CAN I/O Board, P/N 33001503 Connections

Connectors P1 and P2 have the same pin assignments. P1 transmits the CAN high and low signals to the DSP2 P11 connector and connects to the computer's +5 V power supply. Use P2 to connect additional boards in a chain or to connect externally mounted CAN boards using the CAN expansion connector on the CNC chassis. Refer to Table 6-32.

Table 6-32, CAN Connector Pinouts

P1 CAN P2 CAN BUS Pin Signal Pin Signal 1 +5 V 1 +5 V 2 GND 2 GND 3 CAN HIGH 3 CAN HIGH 4 CAN LOW 4 CAN LOW 5 GND 5 GND 6 +5 V 6 +5 V

(Continued…)




Table 6-32, CAN Connector Pinouts (Continued)

P3 CAN P4 CAN BUS Pin Signal Pin Signal 1 24 COM 1 24 COM 2 +24 V 2 +24 V 3 24 COM 3 24 COM

P5 CAN Pin Signal Pin Signal 1 IN0 14 OUT0 2 IN1 15 OUT1 3 IN2 16 OUT2 4 IN3 17 OUT3 5 IN4 18 OUT4 6 IN5 19 OUT5 7 IN6 20 ADC 8 IN7 21 (not used) 9 IN8 22 (not used) 10 IN9 23 24COM 11 24 COM 24 +24 V DC 12 +24 V DC 25 (not used) 13 (not used)

P6 CAN Pin Signal 1 +5 V 2 GND 3 CAN HIGH 4 CAN LOW

Connectors P3 and P4 have the same pin assignments and provide the 24 COM and +24 V power to the CAN board.

The DB-25 P5 connector controls 10 inputs, 6 outputs, 1 (optional) analog input and the 24 V DC signal. Refer to Figure 6-32, CNC Chassis CAN/I/O Connection.


15

16

17

1

2

3

4

5

6

7

8

14

18

20

INPUT 0OUTPUT 0INPUT 1OUTPUT 1INPUT 2OUTPUT 2INPUT 3OUTPUT 3INPUT 4OUTPUT 4INPUT 5OUTPUT 5

ADCINPUT 7

19

INPUT 6

22

9

10

11

12

13

23

25

N.C.INPUT 8N.C.INPUT 924COM24COM+24VDC

N.C.N.C.

24

+24VDC

21

Figure 6-32, CNC Chassis CAN I/O Connection

If a CAN I/O board is selected using jumper and Setup utility as having an analog input, that input will be applied to Pin 20 of the P5 DB-25 connector. If jumpered as an analog board, that board’s OUTPUT5 is disabled. Input is referenced to the system’s +5 V DC computer power supply, which is available at the CAN I/O board P6, pins 1 and 2.

Figure 6-33, CAN I/O ADC Variable Register Input Connection, shows the connection of a variable resistor using the +5 V DC source as a reference voltage.

Figure 6-34, CAN I/O ADC External Device Input Connection, shows the connection of an external device that has an analog output. Such outputs are typically used to provide amperage, temperature, and speed. The external device must be referenced to the CAN I/O board and via P6, pin 2. The voltage input to P6, pin 20 must always be positive in reference to +5 COM. If the external device’s analog output never exceeds +5 V DC the potentiometer is not required.

IMPORTANT: The input voltage to the CAN I/O board must never exceed +5 V DC.



10 K Ohm

P6

P5

4 3 2 1

Pin 20: ADC

5 V Common

+5 VDC

Figure 6-33, CAN I/O ADC Variable Resistor Input Connection

10 K Ohm

P6

P5

4 3 2 1

Pin 20: ADC

5 V Common

External Device with AnalogOutput Greater than 5VDC

Output

OutputCommon

NOTE: Set the variableresistor so that the input tothe CAN I/O board ADCinput is never greater than5VDC.

Figure 6-34, CAN I/O ADC External Device Input Connection



Mounting Additional CAN Boards Externally

Connect the first external CAN I/O Board to the CNC chassis using the P6 CAN Connector located on top of the chassis. Refer to Figure 6-35. Refer to Table 6-33, for the P6 CAN Connector pinouts. When ordering external CAN I/O boards, use P/N 33000332 and P/N 33000333. These boards are the same as P/Ns 33001503 and 33001504 but have mating connectors.

P6 CANConnector

D0005891 Figure 6-35, Top View of Computer Cover with Connections

Table 6-33, P6 CAN Connector Pinouts

Pin Signal 1 +5 V 2 GND 3 CAN HIGH 4 CAN LOW



You can connect additional CAN nodes to the system using either of the following two methods:

Method 1, Daisy Chain Refer to Figure 6-36. The board connects to 5-V power and the CAN data bus using two 6-pin headers (P1 and P2) and to 24-V power using two 3-pin headers (P3 and P4). All four headers are female. You can daisy chain multiple boards using 6-pin and 3-pin double male plugs with long pins. The two boards mounted inside the CNC chassis are daisy-chained. You can also daisy chain additional boards mounted externally.

Method 2, Phoenix Terminal Method

Refer to Figure 6-36. If you cannot daisy chain the external boards, you must connect them using the P5 and P6 connectors on each board. Connect 5-V power and the CAN data bus to P6. Connect 24-V power and the machine inputs and outputs to P5. Refer to Table 6-33, P2 CAN Connector Pinouts for the pinouts.

CAN Bus Node Addressing (S1)

EXTERNALCANIO

Method 1P1, P2, P3, and P4 are female connectors thatallow you to daisy-chain CAN boards together.

The S1 AddressSwitch used totrack Node numbersfor all installed CANboards.

Place Jumperacross J1 on theterminating board.

Method 2Use P6 to connectmultiple boards.

Callout of S1

Callout of J1

J1

S1

Figure 6-36, External Mounting of Additional CAN I/O Boards

Refer to Figure 6-36. The four-pole, two-position S1 switch selects the board address (node). The illustration shows all four poles in the OFF position. You can mount a maximum of six boards (nodes) in a system. Each board must have a different address. Refer to Table 6-34, CAN Bus Address to set the required address. Node numbers, in conjunction with bit numbers, identify an input or output.

CAN nodes have opto-isolators that isolate noise from the machine electronics from the CNC chassis.




Table 6-34, CAN Bus Address

Bus Address (Node) S1-1 S1-2 S1-3 S1-4 0 ON ON ON ON 1 ON ON ON OFF 2 ON ON OFF ON 3 ON ON OFF OFF 4 ON OFF ON ON 5 ON OFF ON OFF

CAN Bus Termination

To identify the last board in the chain as the terminating board, you must insert a jumper across J1. Refer to Table 6-35.

Table 6-35, CAN Bus Termination Signal Jumper

Bus Terminated J1 PRESENT Bus NOT Terminated J1 ABSENT

Home Switch Inputs Home switches are wired to the same CAN Node 0 ports as the vector limits. Wire the home switch to the input that corresponds to the direction that you select for each axis.

Home Switches restrictions follow:

• Must be normally closed switches. • Must be on CAN Node 0 • Are hard-coded • Cannot be used as general purpose I/O • Selected direction only must be wired for assigned axes • Can also be used as Vector Limit Switches See the CNC Setup Utility Manual for Vector Limit Port Assignments. Refer to:

4200T CNC Setup Utility Manual, P/N 70000414

“Section 2, Enabling Vector Limits”

Table 2-2, CAN Bus Node 0 Vector Limit Input Port Assignments

3000M CNC Setup Utility Manual, P/N 70000499

“Section 2, Vector/Home Limit Switch Connections”

Table 2-10, CAN I/O Systems Vector/Home Limit Switches

5000M CNC Setup Utility Manual, P/N 70000509

“Section 2, Enabling Vector Limits”

Table 2-2, CAN Bus Node 0 Vector Limit Input Port Assignments and Table 2-3, Vector Limit Inputs for 5000M 4-Axes and 5000M 5-Axes



External Cabling and Connector Specifications

The machine builder is responsible for assembling the necessary cables and connectors for external connectors located on the cover of the CNC chassis. The mating connectors are included in the CNC package. Refer to Table 6-36.

Table 6-36, Recommended External Cabling and Connector Guidelines

Connector

Mating Connector: Type,

ANILAM P/N, AMP specification

Cable Specifications

Pinout/Wire Color Ports 0-5 (Encoder Controlled Axes)

DA-15M ANILAM P/N 80300212 AMP-747908-2

To encoder: 24 AWG, foil-shielded, 8 conductor To servo: 22GA, Foil-shielded, 2 conductor (Suggested manufacturer/model: Carol CO744)

Refer to Figure 6-21, Control Axes Pinouts (Ports 0 to 5).

CTR 0 thru 2 (DRO Axes)

DE-9M ANILAM P/N 80300210 AMP-747904-2

22 AWG, foil-shielded, 5 conductor (Suggested manufacturer/model: Comtram 4571)

Refer to Figure 6-22, CTR0/CTR1 Pinout.

MBIO DA-15F ANILAM P/N 80300213 AMP-747909-2

22-24 AWG (Machine builder determines other specifications.)

Refer to Figure 6-24, MBIO Mating Connector.

CAN I/O 0 and 1

DB-25M ANILAM P/N 80300037 AMP-747912-2

22-24 AWG (Machine builder determines other specifications.)

Refer to Figure 6-32, CNC Chassis CAN I/O Connection.


Cables for Motors and Amplifiers Standard cables are available in a variety of lengths to connect the amplifier to the motor. The Motor (without Brake) Power Cable is shown in Figure 6-37, the Motor (with Brake) Power Cable is shown in Figure 6-38, AC Brushless Motor (with Brake) Power Cable, and the Motor Encoder Cable is shown in Figure 6-39, AC Brushless Motor Encoder Cable. The Test Cable connects the host port on the amplifier to a standard DE9 RS232 serial port for testing and setup. Refer to Figure 6-40, Test Cable, P/N 33001389.

See Table 6-37ToGND

ToServoAmplifier

POWERCABLE

4 X 14 Gauge

Figure 6-37, AC Brushless Motor (without Brake) Power Cable

Table 6-37, AC Brushless Motor (without Brake) Power Cable Lengths

Part Number Description Length 36001310 Cable, Motor 10 ft 10 ft 36001315 Cable, Motor 15 ft 15 ft 36001320 Cable, Motor 20 ft 20 ft 36001325 Cable, Motor 25 ft 25 ft 36001330 Cable, Motor 30 ft 30 ft 36001335 Cable, Motor 35 ft 35 ft



For the Motor (with Brake) Power Cable, refer to Figure 6-38 and Table 6-38.

See Table 6-38

ToServoAmplifier

ToGND

POWERWBRAKE

Figure 6-38, AC Brushless Motor (with Brake) Power Cable

Table 6-38, AC Brushless Motor (with Brake) Power Cable Lengths

Part Number Description Length 36001510 Cable, Motor (with Brake) 10 ft 10 ft 36001515 Cable, Motor (with Brake) 15 ft 15 ft 36001520 Cable, Motor (with Brake) 20 ft 20 ft 36001525 Cable, Motor (with Brake) 25 ft 25 ft 36001530 Cable, Motor (with Brake) 30 ft 30 ft 36001535 Cable, Motor (with Brake) 35 ft 35 ft



ToServoAmplifier

ENCODERCABLE

See Table 5-38

Figure 6-39, AC Brushless Motor Encoder Cable

Table 6-39, AC Brushless Motor Encoder Cable Lengths

Part Number Description Length 36001410 Cable, Encoder, Servo DR, 10 ft 10 ft 36001415 Cable, Encoder, Servo DR, 15 ft 15 ft 36001420 Cable, Encoder, Servo DR, 20 ft 20 ft 36001425 Cable, Encoder, Servo DR, 25 ft 25 ft 36001430 Cable, Encoder, Servo DR, 30 ft 30 ft 36001435 Cable, Encoder, Servo DR, 35 ft 35 ft



Cable Length - 12 feet

TESTCABLE

Figure 6-40, Test Cable, P/N 33001389




Mating Power and Encoder Connectors This information is for OEMs building their own cables.

Table 6-40, Mating Power and Encoder Connectors

Description Manufacturer, Specification Mating power connector for motor without brake

**Amphenol®, MS 3106A, 18-10S, 4 Socket

Mating power connector for motor with brake Amphenol, MS 3106A, 20-15S, 7 Socket Mating encoder connector for motor Amphenol, MS 3106A, 20-29S, 17 Socket Mating encoder connector to servo amplifier AMP, 102387-4

-----

** Amphenol® is a registered trademark of Amphenol Corporation.

OEM CNC Installation P/N 70000506H - Hardware

Section 7 - Hardware

Wiring Diagrams Figure 7-1, Figure 7-2, Figure 7-3, and Figure 7-4 illustrate the OEM CNC chassis system wiring diagrams for various axes and spindle combinations. The components for these diagrams are described in detail later in this section.

Ref. Dwg. D000709 Figure 7-1, Two Axes and One Spindle OEM CNC Chassis System Wiring Diagram



Ref. Dwg. D000710

Figure 7-2, Three Axes and One Spindle OEM CNC Chassis System Wiring Diagram



Ref. Dwg. D000711 Figure 7-3, Four Axes and One Spindle OEM CNC Chassis System Wiring Diagram



Ref. Dwg. D000712

Figure 7-4, Five Axes and One Spindle OEM CNC Chassis System Wiring Diagram



Single-Board Computer The IHV-745E is a single-board computer based on the Pentium 166 MHz MMX processor and the ALI chip set. Refer to Figure 7-5. The board meets stringent safety and low EMI standards (UL-1950).

Ref. Dwg. 91400301 Figure 7-5, IHV-745E Single-Board Computer

The IHV-745E supports two banks of 60ns fast-page mode DRAM installed in 72-pin SIMM sockets. The SIMM parts are the 5V versions of sizes 2Mx32 (8MB), 4Mx32 (16MB), and 8Mx32 (32MB). The standard configuration uses 8MB DRAM for 3000M and 4200T and 16MB DRAM for 5000M. The IHV-745E does not use parity DRAM.

The DRAM controller is set to map addresses in the region from 0x000C8000 to 0x000EFFFF to the AT-bus. You can use the area from 0x000C8FFF to 0x000DFFFF as shadow areas configured through setup. The DRAM controller automatically sends memory accesses beyond the installed DRAM and not overlapping the 1MB video memory at 0x2000000 to 0x20FFFFF to the AT-bus. The video memory is above the system memory.

To improve the performance of the BIOS that is initially contained in an 8-bit wide Flash EPROM, the BIOS is shadowed in the DRAM at address 0x000FXXXX after power-on reset. The VGA BIOS is shadowed in the region 0x000C0000 to 0X000C7FFF.



Power Requirements The single-board computer operates on 5V power only. The required voltage range is 4.75V to 5.25V. Supply +12V via the ISA-bus or the power connector to erase or program the FLASH devices, including the BIOS. Refer to Table 7-1 for the reference numbers used for various board components.

Table 7-1, Board Components and Reference Numbers Reference Number

Component

CN30 Ethernet CN27 COM1 CN36 Keyboard CN21 Hard Disk Drive (IDE) CN3 Flat Panel CN28 COM2 CN26 Printer CN25 Floppy Diskette Drive CN29 VGA connector

VGA Connections The 15-pin VGA connector on the back of the monitor connects to the single-board computer using harness P/N 33000188. Refer to Table 7-2.

Table 7-2, VGA Pinout Pin Signal 1 RED

1

5

6

15

11

10

2 GREEN 3 BLUE 4 NOT USED 5 GND 6 GND 7 GND 8 GND 9 NOT USED

10 GND 11 NOT USED 12 DDDA 13 H SYNC 14 V SYNC 15 DDCK



COM1 The COM1 connector is an RS-232 port that connects to serial port 1. Refer to Table 7-3.


Pin Signal

1 CD 2 RXD 3 TXD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI

Keyboard The single-board computer connector connects to the user keyboard (rather than the CNC keyboard). Refer to Table 7-4.

Table 7-4, Keyboard Pinout

Pin Signal 1 KEYBOARD DATA

3

4

1

2 6

5

2 MOUSE DATA 3 GND 4 +5VDC 5 KEYBOARD CLK 6 MOUSE CLK



Hard Drive The single-board computer connector connects to the hard drive. Refer to Table 7-5.

Table 7-5, EIDE Hard Drive Connector Pinout

Pin Signal Pin Signal 1 IDERST/ 2 GND 3 IDED7 4 IDED8 5 IDED6 6 IDED9 7 IDED5 8 IDED10 9 IDED4 10 IDED11

11 IDED3 12 IDED12 13 IDED2 14 IDED13 15 IDED1 16 IDED14 17 IDED0 18 IDED15 19 GND 20 NOT USED 21 NOT USED 22 GND 23 IDEIOW/ 24 GND 25 IDEIOR/ 26 GND 27 NOT USED 28 IDEALE 29 NOT USED 30 GND 31 IRQ 32 IOCS16/ 33 IDESA1 34 NOT USED 35 IDESA0 36 IDESA2 37 HDCS0/ 38 HDCS1/ 39 IDEACT/ 40 GND



Printer The single-board computer connector connects to the printer. Refer to Table 7-6.

PRINTER

Table 7-6, Printer Pinout

Pin Signal Pin Signal 1 STROBE/ 14 AUTOFD/ 2 PDAT0 15 ERROR/ 3 PDAT1 16 INIT/ 4 PDAT2 17 SLCTIN/ 5 PDAT3 18 GND 6 PDAT4 19 GND 7 PDAT5 20 GND 8 PDAT6 21 GND 9 PDAT7 22 GND

10 ACK/ 23 GND 11 BUSY 24 GND 12 PE 25 GND 13 SLCT 26

COM2 The COM2 connector connects to serial port 2. Refer to Table 7-7.

COM2


Pin Signal Pin Signal 1 DCD 2 DSR 3 RXD 4 RTS 5 TXD 6 CTS 7 DTR 8 RI 9 GND 10 NOT USED



Floppy Drive The single-board computer connector connects the computer to the back of the remote floppy disk drive, P/N 33000199. Refer to Table 7-8.

PIN 1Floppy Disk Drive

Table 7-8, Floppy Disk Drive Pinout Pin Signal Pin Signal 1 GND 2 RPMLC 3 GND 4 NOT USED 5 GND 6 NOT USED 7 GND 8 INDEX/ 9 GND 10 MOTOR0/

11 GND 12 DRIVE SELECT1/ 13 GND 14 DRIVE SELECT0/ 15 GND 16 MOTOR1/ 17 GND 18 DIRECTION 19 GND 20 STEP/ 21 GND 22 WRITE DATA/ 23 GND 24 WRITE GATE/ 25 GND 26 TRACK0/ 27 GND 28 WRITE PROTECT/ 29 GND 30 READ DATA/ 31 GND 32 HEAD SELECT/ 33 GND 34 DISK CHANGE/

Setting up the BIOS for the Single Board Computer The Single Board Computer (SBC) uses the latest AMI “Plug-n-Play” BIOS, which contains a Setup Utility for configuring the system. A Lithium battery backs up the on-board CMOS memory, which stores the system configuration settings. If you experience unusual errors while you run programs, your CMOS may be corrupted. This could occur during loss of battery power or an accidental power hit.




Restoring Factory Defaults

NOTE: Your system must have an external keyboard to perform the following procedures.

To restore the BIOS setup values to their factory default settings, initiate a cold boot (Reset) or a warm boot (Ctrl + Alt + Del). When the software prompts you, press Del to abort the memory diagnostics and display the Setup Utility MAIN SETUP MENU.

CAUTION: Improper settings of certain values in the CHIPSET, POWER MANAGEMENT, and PNP/PCI BIOS menus can cause unpredictable results. Do NOT change factory default settings.

1. Press the appropriate ARROW key(s) to highlight the AUTO-CONFIGURATION WITH OPTIMUM SETTINGS line, and then press Enter to select it.

2. Press Y and then press Enter again to accept it.

NOTE: To scroll through the choices for a selected setting, press either the PgUp or PgDn key as needed. You can also press PgUp to decrease the setting or PgDn to increase the setting.

3. To select the colors used in the setup screens, in the MAIN SETUP MENU, press F2.

4. To save the changes before you exit the Setup Utility, press F10.

5. To exit the Setup Utility without saving the changes press Esc.

6. After you complete all changes in the Setup Utility, press F10 or select the appropriate selection from the MAIN SETUP MENU to save the changes.



Controller Area Network (CAN) Bus The CAN bus is a fast, efficient serial data communications bus for real-time applications. Data can travel across transmission lines at speeds of up to 1Mb/sec. To maximize machine control, the CNC’s DSP2 Board includes a CAN controller on the ISA bus. This controller is the interface between the CNC and the CAN bus.

Because of its content-oriented nature, the CAN protocol enables a high degree of convenience and flexibility. You can add new nodes to the network without having to reconfigure existing hardware or software.

ANILAM uses shielded twisted-pair cable for its two-wire bus. Twisted-pair cable provides better immunity from external noise, such as EMI, than does flat-pair (telephone type) cable.

The CAN I/O board contains one 82C150 Serial Linked I/O (SLIO) device. The SLIO connects to the CAN bus through an 82C250 CAN transceiver. You can configure four bits of the 11-bit CAN identifier using the DIP switch. The 10 inputs connect to opto-couplers, which in turn are connected to the SLIO.

Jumpers installed during PCB assembly configure for current sinking or current sourcing inputs. The SLIO connects to opto-couplers, which connect to transistors. Transistors drive the six outputs. The SLIO contains the A/D converter, which allows you to transfer from one of the outputs by using jumper settings.


Nodes Each CAN board is an I/O node. Nodes are numbered consecutively, beginning with 0 (zero). The system can accommodate a maximum of six nodes. Typically, the servo control board is set as Node 0. I/O boards can be either Source (output switches +24 V) or Sink (output switches 24 COM). The standard CNC chassis includes two source boards. Refer to Figure 7-6 and Figure 7-7.

S1 Address SwitchComponents unique

to Source In/Out CAN

Figure 7-6, CAN I/O, Source In/Out, OEM, Ref. Dwg. 33001503

Components uniqueto Sink In/Out CAN

Figure 7-7, CAN I/O, Sink In/Out, OEM, Ref. Dwg. 33001504




Refer to Figure 7-6, CAN I/O, Source In/Out, OEM, Ref. Dwg. 33001503. The four-pole, two-position S1 switch selects the board address (node). The illustration shows all four poles in the OFF position. You can mount a maximum of six boards (nodes) in a system. Each board must have a different address. Refer to Table 7-9 to set the required address. Node numbers, in conjunction with bit numbers, identify an input or output.

CAN nodes have opto-isolators that isolate noise from the machine electronics from the CNC chassis.

Table 7-9, CAN Bus Address

Bus Address (Node) S1-1 S1-2 S1-3 S1-4 0 ON ON ON ON 1 ON ON ON OFF 2 ON ON OFF ON 3 ON ON OFF OFF 4 ON OFF ON ON 5 ON OFF ON OFF

Each node has 16 bits, including six output bits and 10 input bits. Optionally, you can configure Output 5 as an analog rather than a digital output.

Data messages transmitted from a CAN node do not contain addresses of the transmitting node nor the receiving node.

A unique identifier labels the content of the message. Each node performs an acceptance test on the identifier and determines whether the message content is relevant to that particular node. If the message is relevant, the node processes it; otherwise, it ignores the message. This is “multi-cast” mode of operation.

To activate the I/O interface and assign M-functions to the CAN nodes’ input and output ports, refer to CNC Setup Utility Manual, “Section 2, Setting Basic I/O Interface” and the following subsections.

Connections Refer to “Section 6, Connections” for CAN node pinouts.



DSP Board The ANILAM DSP2 Motion I/O Board provides motion control, machine basic I/O, and interface to the Controller Area Network (CAN) industrial serial data bus. Firmware on the board provides all velocity and position-loop closure, machine geometry error correction for up to four controlled axes, and readout-only for two more axes.

A connector and mounting holes allow you to install a daughter card for two additional controlled axes and one additional readout-only axis. Surface mount construction and a high degree of integration result in a compact, powerful unit with a high level of reliability.

The DSP2 contains one **Texas Instruments™ TMS320C33 32-bit floating-point CPU operated at 100 MHz (P/N 33001102). The board contains 128K x 8 of FLASH memory for permanent firmware storage and 64K words of fast-static RAM. Refer to Figure 7-8, DSP Board, P/N 33001102. The board contains a FPGA chip, which provides digital filtering, phase detectors, marker latches, 16-bit bi-directional counters, and diagnostic functions for six axes. Line receivers and RC networks on the board allow a complete, switch-selectable interface for either differential or single-ended encoder signals.

The interface between the Digital Signal Processing (DSP) and the ISA bus occurs in the FPGA chip. The FPGA chip contains address latches and control circuits that allow the FLASH memory to be erased and then rewritten from the ISA bus. The FPGA chip also implements chip selects and other glue-logic functions for the rest of the board. An **ATMEL® AT17LV256 serial PROM loads the pattern for the FPGA chip at power up.

An AD7835 quad D/A converter with external reference provides analog output to axis servo amplifiers and spindle drives. Jumper-selectable buffer amplifiers on the board allow a choice of single-ended or differential outputs.

To interface to minimal machine electronics, the board has a parallel port on the ISA bus. This port has six opto-isolated inputs and one opto-isolated output, which connect to standard 24 V DC relay logic. The board has one opto-isolator drive transistor circuit used with a low-current membrane servo-reset button to drive a relay.

For additional machine control, the board has an **Intel® 82527 CAN controller on the ISA bus. This chip allows you to interface with a large number of input and output devices.

**Texas Instruments™ Texas Instruments™ is a trademark of Texas Instruments Incorporated

**ATMEL® ............................................... ATMEL® is a registered trademark of Atmel Corporation.

**Intel® ............................................................ Intel® is a registered trademark of Intel Corporation.


330011020 Figure 7-8, DSP Board, P/N 33001102




Encoder and Analog Power Refer to Table 7-11. A four-pin locking header supplies encoder and analog power for the controlled axes to the board.

Table 7-11, P3 Encoder and Analog Power

Pin Signal 1 +15 V 2 -15 V 3 Common 4 +5 V Encoder

Refer to Table 7-12. The encoder inputs and analog outputs for the four controlled axes are located on two 30-pin, double-row headers on the top edge of the board. Normally, 30-pin ribbon cables plug into each header. The ribbon splits into two DA-15 connectors (one for each axis) that interface to the machine.

Table 7-12, P4 and P5 to Axis Ports (0 to 4)

Header Pin

DA-15 Pin P4 Signal P5 Signal

1 1 2PHASEA+ 3PHASEA+ 2 9 2PHASEA- 3PHASEA- 3 2 2PHASEB+ 3PHASEB+ 4 10 2PHASEB- 3PHASEB- 5 3 2MARKER+ 3MARKER+ 6 11 2MARKER- 3MARKER- 7 4 +5 V +5 V 8 12 +5 V +5 V 9 5 COMMON COMMON

10 13 COMMON COMMON 11 6 EARTH GND EARTH GND 12 14 NOT USED NOT USED 13 7 EARTH GND EARTH GND 14 15 2ANALOG- 3ANALOG- 15 8 2ANALOG+ 3ANALOG+ 16 1 0PHASEA+ 1PHASEA+ 17 9 0PHASEA- 1PHASEA- 18 2 0PHASEB+ 1PHASEB+ 19 10 0PHASEB- 1PHASEB- 20 3 0MARKER+ 1MARKER+

(Continued…)



Table 7-12, P4 and P5 to Axis Ports (0 to 4) (Continued)

Header Pin

DA15 Pin P4 Signal P5 Signal

21 11 0MARKER- 1MARKER- 22 4 +5 V +5 V 23 12 +5 V +5 V 24 5 COMMON COMMON 25 13 COMMON COMMON 26 6 EARTH GND EARTH GND 27 14 NOT USED NOT USED 28 7 EARTH GND EARTH GND 29 15 0ANALOG- 1ANALOG- 30 8 0ANALOG+ 1ANALOG+

The two DRO encoder inputs are on separate ten-pin, double-row headers mounted on the top edge of the board. Normally, ten-pin ribbon cables plug into each header. The ribbon goes to DE-9 connectors (one for each axis) that interface to the machine. Refer to Table 7-13.

Table 7-13, P6 and P7 to Readout Axes

Header Pin

DE-9 Pin P6 Signal P7 Signal

1 1 0PHASEA 1PHASEA 2 6 NOT USED NOT USED 3 2 NOT USED NOT USED 4 7 +5 V +5 V 5 3 0MARKER 1MARKER 6 8 COMMON COMMON 7 4 NOT USED NOT USED 8 9 EARTH GND EARTH GND 9 5 0PHASEB 1PHASEB

10 NOT USED NOT USED



Machine Basic I/O Machine I/O output, two of the inputs, and the servo reset switch input and output are on an eight-pin, single-row header on the opposite end of the board from the mounting bracket. This connector normally connects to the servo enable wiring and safety loop. Refer to Table 7-14.

Table 7-14, P8 Machine Basic I/O

Pin Signal 1 +24 V 2 24 V COMMON 3 SVO ON* 4 RESET2 5 RESET1 6 SVO EN 7 SERVO RESET IN 8 5 V COMMON

External START/STOP Two more of the inputs are on a three-pin, single-row header. The header is available for an external Start/Stop switch. Refer to Table 7-15.

Table 7-15, P9 External START and STOP Switches

Pin Signal 1 EXTERNAL STOP 2 +24V 3 EXTERNAL START

E-STOP and Manual Switches The last two inputs are on a four-pin, single-row header. The header normally connects to the E-Stop and Auto/Manual switches in the console. Refer to Table 7-16.

Table 7-16, P10 E-STOP and Manual Switches

Pin Signal 1 E STOP SWITCH 2 +24 V 3 +24 V 4 MANUAL SWITCH


CAN Bus Interface The CAN Bus interface is on a three-pin, single-row header. Refer to Table 7-17.

Table 7-17, P11 CAN BUS Interface Pin Signal 1 CAN HIGH 2 CAN LOW 3 NOT USED

Test Connection (P12) Using a 3.5-digit DVM or better, attach leads to the P12 test points to monitor 5 V and ±15 V signals coming from the DSP Board. Refer to Table 7-18.

Table 7-18, P12 Test Connection Pin Signal 1 -15 V 2 COM 9 5 V

10 15 V

Probe (P15) The 15-pin Probe P15 connector on the back of the chassis connects to the single-row header using harness P/N 33000973. Refer to Table 7-19.

Table 7-19, P15 Probe Pinout Pin Signal 1 BLK 2 ORNG 3 GRN 4 RED 5 LT BLUE 6 BRN 7 WHT 8 NOT USED 9 NOT USED

10 NOT USED 11 NOT USED 12 NOT USED 13 NOT USED 14 NOT USED 15 NOT USED




Jumpers Table 7-20 and Table 7-21 describe switch and jumper settings.

Table 7-20, Encoder Input Axes Switch Signal Type

0 Axis Encoder SW1-1, 2, 3 ON Single-Ended Input SW1-1, 2, 3 OFF Differential Input 1 Axis Encoder SW1-4, 5, 6 ON Single-Ended Input SW1-4, 5, 6 OFF Differential Input 2 Axis Encoder SW1-7, 8, 9 ON Single-Ended Input SW1-7, 8, 9 OFF Differential Input 3 Axis Encoder SW1-10, 11, 12 ON Single-Ended Input SW1-10, 11, 12 OFF Differential Input

Table 7-21, Analog Output Axes Jumpers Signal Type

0 Axis Analog Output

J10, J11 2-3 Single-Ended Output

J10, J11 1-2 Differential Output 1 Axis Analog Output






J16, J17 1-2 Differential Output

Firmware The DSP2 program reads the delta position data from the ASIC chip, accumulates absolute position and velocity error over time, executes the PID algorithm, and outputs motor velocity information to the D/A converter. Refer to Figure 7-9.

The firmware also applies corrections for several forms of geometric error caused by mechanical imperfections. The firmware includes commands to assist in testing the board, adjusting the board, and adjusting the servo system. Communication with the software running on the ISA bus takes place using the bi-directional latched port.


64K X 32 SRAM2 X IDT71016

128K X 8 FLASH29F010

DSP CPUTMS320C31

4 AXISAD7835

GLUE LOGIC,6 AXIS COUNTERS,DUAL PORT RAM,

BUFFERS,ADDRESS LATCHXCS30-4PQ208C

P1 ISA BUS

P40,2

ENCODER,SERVO

30 PIN D/R

P6V AXIS

ENCODER10 PIN D/R

P7W AXIS

ENCODER10 PIN D/R

P5PROBE

5 PIN S/R

P8MACH.BASIC

I/O8 PINS/R

P10ESTOP

4 PIN S/R

CAN BUSCONTROLLER

82527

P11CAN BUS3 PIN S/R

P9REMOTE3 PIN S/R

2

2

2

SPROM,XC17S30V08C

P51,3

ENCODER,SERVO

30 PIN D/R

P3POWER

4 PIN .156

+/- 2.5VRef

Figure 7-9, DSP Block Diagram



DSP2 Expansion

3000M-4X

5000M-4X

5000M-5X

The DSP2 Expansion provides two additional control axes and one additional readout axis. Refer to Figure 7-10.

33000816

Figure 7-10, DSP2 Expansion, Ref. Dwg. 33000816




Refer to Table 7-22. The encoder inputs and analog outputs for the DSP2 Expansion’s controlled axis are located on one 30-pin, double-row header on the top edge of the board. Normally, a 30-pin ribbon cable plugs into the header. The ribbon splits into two DA-15 connectors connect to the machine.

Table 7-22, P1 to Axis Ports (4 and 5)

Header Pin DA-15 Pin Signal 1 1 4PHASEA+ 2 9 4PHASEA- 3 2 4PHASEB+ 4 10 4PHASEB- 5 3 4MARKER+ 6 11 4MARKER- 7 4 +5 V 8 12 +5 V 9 5 COMMON

10 13 COMMON 11 6 EARTH GND 12 14 NOT USED 13 7 EARTH GND 14 15 4ANALOG- 15 8 5ANALOG+ 16 1 5PHASEA+ 17 9 5PHASEA- 18 2 5PHASEB+ 19 10 5PHASEB- 20 3 5MARKER+ 21 11 5MARKER- 22 4 +5 V 23 12 +5 V 24 5 COMMON 25 13 COMMON 26 6 EARTH GND 27 14 NOT USED 28 7 EARTH GND 29 15 5ANALOG- 30 8 5ANALOG+



Refer to Table 7-23. The single DRO encoder input is on a separate ten-pin, double-row header mounted on the top edge of the board. Normally, a ten-pin ribbon cable plugs into the header. The ribbon goes to a DE-9 connector that interfaces to the machine.

Table 7-23, P2 to Readout Axis Header Pin DE-9 Pin Signal

1 1 2PHASEA 2 6 NOT USED 3 2 NOT USED 4 7 +5 V 5 3 2MARKER 6 8 EARTH GND 7 4 NOT USED 8 9 COMMON 9 5 2PHASEB

10 NOT USED

Encoder and Analog Power Refer to Table 7-24. A four-pin locking header supplies encoder and analog power for the controlled axis to the DSP2 Expansion.

Table 7-24, P3 Encoder and Analog Power Pin Signal 1 +15 V 2 -15 V 3 Common 4 +5 V Encoder

Jumpers Table 7-25 and Table 7-26 describe the Jumpers for the DSP2 Expansion.

Table 7-25, Encoder Input Axes Jumpers Signal Type

4 Axis Encoder J1, J2, J3 PRESENT Single-Ended Input J1, J2, J3 ABSENT Differential Input 5 Axis Encoder J12, J13, J14 PRESENT Single-Ended Input J12, J13, J14 ABSENT Differential Input

Table 7-26, Analog Output Axes Jumpers Signal Type

4 Axis Analog Output J5, J9 2-3 Single-Ended Output J5, J9 1-2 Differential Output 5 Axis Analog Output J4, J8 2-3 Single-Ended Output J4, J8 1-2 Differential Output

OEM CNC Installation P/N 70000506H - Maintenance


Section 8 - Maintenance

Balance and Signal Checks Refer to the CNC Motion Setup/Testing Utility manual included in the OEM manual package. Refer to Table 8-1, for the applicable manual and P/N. The MST, a function of the control software, provides commands that carry out motion-specific setup and testing by generating the signals required to balance the outputs. A basic knowledge of machine operation and programming is required. Refer to the appropriate programming manual for details on how to program and operate the CNC.

Table 8-1, MST Utility Manual Reference

Product MST P/N 3000M 70000498 4200T 70000419 5000M 70000510

Setup includes the following procedures:

• Servo Board Balancing • Servo Board Signal Gain Setting (motor step response is displayed in

open loop)

The CNC provides the following troubleshooting tools:

• Detection of Index Pulse • Detection of Counts between Index Pulses (actual resolution) • Tuning for the Optimal Filter Parameters

The General Status displays the following information:

• Display of active CNC status codes • Display of machine position, feedrates, RPM, dwell, and override



Hard Drive The control software includes a disk optimization utility to “defrag” the hard drive. ANILAM recommends that you optimize your disk every six months.

Refer to the Setup Utility. To optimize your hard drive, perform the following steps:

1. Highlight Control Software in the Software Options Menu.

2. Press ENTER.

3. Press PROGRAM (F2).

4. Press Utility (F9).

5. Highlight More… .

6. Press ENTER. Disk Optimizer is automatically highlighted.

7. Press ENTER to begin disk optimization. When optimization is complete, the system prompts to exit.

8. Press ENTER to return to the PROGRAM screen.

9. Press Exit (F10) to exit the Control Software.

Filters ANILAM recommends that you install air filters wherever the chassis vents to open air and wherever a fan pulls air from outside the chassis. Depending upon the level of dust and other airborne contaminants in the particular shop environment, replace the following filters as indicated below:

• All fan filters every three months or sooner.

• All vent filters every year or sooner.

NOTE: Use appropriate filters for systems required to machine graphite or cast iron.

Contamination To prevent dust, chips, coolant, and other airborne contaminants from entering the system, keep the doors to the computer cabinet and the chassis closed at all times, unless performing maintenance procedures. Never operate the CNC unless all doors are closed.

Cabling ANILAM recommends that customers check their systems’ cabling annually. Tighten all loose cables and replace any damaged or frayed cables. Ensure that all cabling is secured and out of the way of moving parts.



Fuses The CNC is equipped with two universal input fuses. The fuse dedicated to Input AC is rated at 10 A at 250 V. The fuse dedicated to the 24 V power supply is rated at 2 A at 250 V. Replace fuses as required.

Console

Keypad Wipe the keypad with a paper towel or soft cloth weekly to prevent the accumulation of fine airborne chips, which could damage the plastic keypad cover and cause shorts.

Filters ANILAM recommends that you install air filters wherever the console vents to open air and wherever a fan pulls air from outside the console. Depending upon the level of dust and other airborne contaminants in the particular shop environment, replace the following filters as indicated below:

• All fan filters every three months or sooner. • All vent filters every year or sooner.

NOTE: Use appropriate filters for systems required to machine graphite or cast iron.

Environment Store and operate the monitor within the environmental parameters specified in “Section 3, Environmental Requirements.”

Contamination To prevent dust, chips, coolant, and other airborne contaminants from entering the system, keep the console and the sheet metal housing closed at all times, unless performing maintenance procedures. Never operate the CNC unless all doors are closed.

Cabling ANILAM recommends that customers check their systems’ cabling annually. Tighten all loose cables and replace any damaged or frayed cables. Ensure that all cabling is secured and out of the way of moving parts.



Preventive Measures ANILAM recommends that the machine builder implement the preventive measures described in Table 8-2 to minimize environmental damage to the CNC and ensure maximal performance.

Table 8-2, Preventive Measures

Dangerous Condition

Cause(s) Preventive Measure(s)

Chips invade cabinet Improperly sealed cabinet Seal all openings. Dust on components, insulation degrades

Improperly sealed cabinet, fan blowing directly on PCB

Seal all openings, install fan filters where cabinet vents to open air, ensure that fan does not blow directly on PCBs, apply packing to surface mounts, install fan filters where cabinet vents to open air.

Coolant mist invades cabinet

Improperly sealed cabinet, cabinet located too close to source of coolant

Seal all openings, locate cabinet away from source of coolant, and install fan filters where cabinet vents to open air.

Excessive internal temperature rise

Restricted air flow inside the chassis

Leave sufficient space between the cabinet wall and the components.

Display fluctuates EMI around display caused by switches, solenoid valves, and cables

Ensure that all components generating EMI are installed away from display.

Excessive noise Lack of proper shielding, improper grounding, unit too close to noise emitter

Ensure that parts/cables supplied with 50 V DC or more or AC power are not near the display. Use shielded cables, or cables enclosed in flexible metal conduit.

Shorts in keypad or damage to keypad

Flying chips cut the plastic keypad.

Keep keypad out of the range of flying chips, or fabricate a shield for the keypad. Wipe the keypad clean frequently to avoid accumulation of chips.

Dust from graphite or cast iron invades the system.

Tiny airborne particles pass through conventional filtering media.

Install filters designed to be used with graphite and cast iron.

OEM CNC Installation P/N 70000506H - Troubleshooting

Section 9 - Troubleshooting Checking Voltages

This section describes how to check voltages across various test points in the ANILAM CNC system. You can check voltages at the following locations:

Backplane LEDs TB2 Power Supply Terminal Block on the side of the chassis DSP2 Motion Control Board P12 connector

These components are located inside the CNC chassis. To open the chassis, loosen the thumbscrews at each end. Make sure you close the chassis and tighten the thumbscrews at the end of the procedure.

Backplane LEDs

The backplane LEDs monitor power supply voltages to the computer (100 W). As indicated in Figure 9-1, the LEDs monitor +12 V, -12 V, -5 V, and +5 V signals. An LED lights when the indicated voltage is present. If an LED is not lit, the indicated voltage is not present. The +5 V and +12 V voltages are the same as those present on the TB2 terminal block.

Figure 9-1, Backplane of CNC Computer Chassis

NOTE: The –5 V LED is normally not lit. The system does not use or supply a –5 V voltage.




TB2 Terminal Block Refer to Figure 9-1, Backplane of CNC Computer Chassis, for the location of the TB2 terminal block. Refer to Table 9-1 for a list of the TB2 pinout signal names. The computer (100 W) power supply voltages are present at Pins 1 to 4. The +24 V DC power supply is present at Pins 5 and 6.

Attach leads to the appropriate pin to monitor voltages. Use a DVM with a resolution of 3.5 digits or better.

Table 9-1, TB2 Pinout

Pin No. Signal Name 1 +5 V 2 5COM 3 +12 V 4 12COM 5 +24 V 6 24COM

DSP2 Board P12

Attach leads to the P12 test points to monitor the (25 W) 5 V and ±15 V signals from the DSP Board. Use a 3.5-digit DVM or better. Refer to Table 9-2. Refer to Figure 9-2, DSP2 Board, P/N 33000413, P12 Connector.

Table 9-2, P12 Test Point

Test Point Pin Signal 1 -15 V 2 COM 9 5 V

10 15 V


33001102-P12

Figure 9-2, DSP2 Board, P/N 33001102, P12 Connector




LCD Troubleshooting Suggestions After you resolve common-sense issues, ANILAM recommends that you follow the suggestions in Table 9-3 to isolate and correct any problem that you encounter.

Table 9-3, LCD Troubleshooting Suggestions

Problem Possible Cause(s) No image A lack of image is most likely caused by a loose

or incorrect connection, lack of power, failure to provide a signal, or incorrect graphics card setting. Check all connections and the +12-V input. If possible, check the OEM CNC VGA output using a working display. If the panel backlight is not working, you may still see some images on the Flat Panel Display. If the OSD board is not connected, make sure the jumpers are inserted between pins 1 and 2, and pins 3 and 4 on the OSD connector on the console.

Image is out of position

If you are unable to position the image correctly (i.e., the image adjustment controls will not move the image far enough), verify that the OSD board is properly connected.

Image Appearance is Poor

A faulty Flat Panel Display can have blank lines, failed sections, flickering, or flashing display.



Amplifier Troubleshooting Suggestions After you resolve common-sense issues, ANILAM recommends that you follow the suggestions in Table 9-4 to isolate and correct any problem that you encounter.

Table 9-4, Amplifier Troubleshooting Suggestions

Problem Possible Cause(s) Both LEDs OFF No logic power. Check pins 1 & 2 on J7.

Should be +5 -0.1 +0.2 VDC. Red ON Green OFF Amplifier Fault. Check pins 1 & 2 on terminal block.

Should be 160–170 VDC. Check both cables between amplifier and motor.

Red ON Green ON Amplifier Inhibit. Check J2 pin 8, should be high to run.

Axis will not move Check cable between amplifier and CNC, check CNC Builder Setup, and restore default amplifier parameters.

Axis runs away Check cable between amplifier and CNC, in CNC Builder Setup, change encoder phase or DAC Invert.

Fault out (active low voltage) J2 pin 9 Low with no fault

Amplifier parameters corrupted. Restore default amplifier parameters.

OEM CNC Installation P/N 70000506H - Index

All rights reserved. Subject to change without notice. Index-1 October 2009

100W power supply, 9-2 10BaseT Ethernet, 6-30 25W power supply, 9-2 3000M

CNC system overview, illustration, 2-6 console, illustration, 5-9 E-STOP switch, 2-5 FEEDRATE OVERRIDE switch, 2-5 keyboard interface board, illustration, 6-15 LCD connection, illustration, 6-2 systems, icon, 1-2

3000M CNC Setup Utility Manual, P/N 70000499, referenced, 6-45

33001389, test cable, illustration, 6-50

4200T CNC system overview, illustration, 2-7 LCD

(with handwheel) connection, illustration, 6-4

(without handwheel) connection, illustration, 6-3

console front view, illustration, 5-7 side view, illustration, 5-8 top view, illustration, 5-7

manual panel with handwheel, illustration, 5-10 with no handwheel, illustration, 5-10

systems, icon, 1-2 4200T CNC Setup Utility Manual,

P/N 70000414, referenced, 6-45

4200T/5000M keyboard interface board, illustration, 6-16 manual panel interface board, illustration,

6-19 5000M

CNC system overview, illustration, 2-8 console, illustration, 5-11 five-axis systems, icon, 1-2 four-axis systems, icon, 1-2 LCD

(with handwheel) connection, illustration, 6-4

(without handwheel) connection, illustration, 6-3

manual panel with handwheel, illustration, 5-12

with no handwheel, illustration, 5-12 three-axis systems, icon, 1-2

5000M CNC Setup Utility Manual, P/N 70000509, referenced, 6-45

82C150 serial linked I/O, 7-12 82C250 CAN transceiver, 7-12

A A/D converter, 6-39, 7-12 aborting, memory diagnostics,

7-11 AC brushless servo motor. See

motors AC power (P1) pinout, 6-37 accessing, setup utility, 7-11 accidental, power hit, 7-10 air pressure, 3-2 ALI chip set, 7-5 aluminum enclosures, 5-5 AM 130 series

description, 4-6 specifications & features, table, 4-7

AM 130A, AM 130AB specifications, table, 4-7 torque graph, illustration, 4-8

AM 130C, AM 130CB specifications, table, 4-7 torque graph, illustration, 4-9

AM 130E, AM 130EB specifications, table, 4-7 torque graph, illustration, 4-9

AM 96 series description, 4-3 specifications & features, table, 4-3 torque graphs, listed, 4-4, 4-8

AM 96A, AM 96AB specifications, table, 4-3 torque graph, illustration, 4-5

AM 96C, AM 96CB specifications, table, 4-3 torque graph, illustration, 4-5

AM 96E, AM 96EB specifications, table, 4-3 torque graph, illustration, 4-6

AM series, cables and connectors, listed, 4-10

AM series, nameplate, illustration, 4-11

ambient temperature, 3-2


Index-2 All rights reserved. Subject to change without notice. October 2009

AMI Plug-n-Play BIOS, 7-10 amperage, required, 3-1 amplifier

connectors, tables, listed, 4-1, 6-6 digital brushless servo

description, 4-1 referenced, 3-6

dimensions, illustration, 5-18 external, power supply kit, 3-1 external, schematic illustration, 3-1 features, table, 4-2 J1 host connector, pinout, 6-6 J1 host connector, pinout, referenced, 4-1 J2 signal inputs connector, pinout, 6-7 J2 signal inputs connector, pinout,

referenced, 4-1 J3 signal inputs connector, pinout, 6-8 J3 signal inputs connector, pinout,

reference, 4-1 J7 external +5 V connector, pinout, 6-8 J7 external +5 V connector, pinout,

referenced, 4-1 LED indicators

description, 4-2 table, 6-9 table, referenced, 4-1

mating connectors, table, 6-6 mating connectors, table, referenced, 4-1 operation, erratic, 5-3 specifications, table, 4-2 system interconnect diagram, illustration,

4-12 TB1 terminal block connector, pinout, 6-8 TB1 terminal block connector, pinout,

referenced, 4-1 troubleshooting, 9-5

analog input, 6-39 input configuration, 7-15 output, table, 7-22 outputs, 7-18 power, 7-18 power, description, 7-26

ANILAM, commitment, 1-1 ASIC chip, 7-22 ASIC counters, 3-3 AT-bus, 7-5 auto/manual select, 6-33 AUTO/MANUAL SELECT, 6-31 axis resolution, 3-3 axis selection, 2-5

B backplane

CNC computer console, illustration, 9-1 connection points, illustration, 6-25 LEDs, 9-1

balance and signal checks, 8-1 bi-directional latched port, 7-22 BIOS, 7-5 BIOS, for single-board computer,

7-10 bipolar, output, 2-9 board

address, 7-14 components and reference numbers, 7-6 setting, as CAN 0 or CAN 1, 6-35

bond points, establish, 5-2 brake motor, MS3102E-20-15P,

power connector pinout, 6-9 pinout, referenced, 4-10

braking resistor, 2-9 braking resistors, cooling, 2-9 brushless

amplifier, digital servo, dimensions, illustration, 5-18

motor, AC power cable with brake, illustration, 6-48 with break, referenced, 4-10 without brake, illustration, 6-47 without break, referenced, 4-10

motor, encoder cable illustration, 6-49 referenced, 4-10

motors, AC servo AM 130 series, dimensions, illustration,

5-20 AM 96 series, dimensions, illustration,

5-19

C cables

motor encoder illustration, 6-49 lengths, table, 6-49 referenced, 4-10

motor power with brake, lengths, table, 6-48 without brake, lengths, table, 6-47

motor power, AC brushless with brake, illustration, 6-48



with brake, referenced, 4-10 without brake, illustration, 6-47 without brake, referenced, 4-10

test, illustration, 6-50 twisted-pair, 7-12

cabling specifications CNC chassis connections, 6-46 control axes, 6-27 readout axes, 6-28 system, 6-46

cabling, in console, 8-3 cabling, maintenance, 8-2 CAM system, 1-1 CAN

board connections, 6-39 bus

address, table, 6-44, 7-14 description, 7-12 interface, description, 7-21 termination, table, 6-45

connector, pinouts, 6-39 controller, 7-12 defined, 6-39 expansion connector, 6-39 jumper J1 location, illustration, 6-42, 7-15 node, 6-35 node connections, 6-39 nodes, multiple, 2-1 sink I/O board, 5-15 transceiver, 7-12

CAN I/O ADC external device input connection,

illustration, 6-42 ADC variable resistor input connection,

illustration, 6-42 board, illustration, 6-39 board, jumpered as having analog input,

6-41 boards

dimensional data, 5-6 mounting, 5-15 mounting outside of CNC chassis, 5-13

bus, 6-39 nodes, CNC hardware, listed, 2-5 sink in/out, illustration, 5-16, 7-13 source in/out, illustration, 5-15, 7-13

CE compliance, 5-4 CE directives, listed, 5-4 CE-compliant system, 5-5 chassis, 5-6

CNC hardware, listed, 2-5

connection points, illustration, 6-1 mount solid state relay, 6-35 power connection, 6-5 side view, illustration, 6-1

checking, voltages, 9-1 clearance requirements, 5-6 closed-loop

(servo) mode operation, 2-9 positioning, 3-3 system

CNC, 2-1 description, 2-1 illustration, 2-2 with linear encoder, illustration, 2-4

CMOS memory battery backup, 7-10 corrupted, 7-10 system configuration settings, 7-10

CNC chassis

CAN I/O connection, illustration, 6-41 OEM, 5-13 side view, illustration, 6-1

computer console, backplane, illustration, 9-1

connection ports, table, 1-2 defined, 1-1 keyboard, 2-5 OEM chassis, illustration, 5-14 spindle control, description, 2-9 system overview

3000M, illustration, 2-6 4200T, illustration, 2-7 5000M, illustration, 2-8 description, 2-5

VGA connection, to OEM CNC, 3-5 CNC Motion Setup/Testing

Utility, referenced, 8-1 CNC Programming and

Operations Manual, referenced, 6-17

CNC Setup Utility Manual, referenced, 2-1

codes, machine, 2-1 color-display LCD console, 1-1 colors, screen, selecting, 7-11 COM1

harness, from manual panel, illustration, 6-20

pinout, 6-20 pinout, 7-7



COM2, pinout, 6-29, 7-9 command signals, 2-3 compatibility, testing results, 5-4 compliance, CE directives, 5-4 component testing, 5-4 computer

cover, with connections, top view, 6-43 numerical control. See CNC power supply, 3-1

conditional logic, 2-9 conduit, flexible metal, 5-5 connect

additional boards in a chain, 6-39 additional CAN nodes to the system, 6-44 CNC to Ethernet-based networks, 1-2 externally mounted CAN boards, 6-39

connection initial, 1-2 keyboard interface to external, 6-17 overview, description, 6-1 points, backplane, illustration, 6-25 to chassis ground, 6-35 to external signal, 6-35

connections manual panel, illustration, 6-19 P1 and P2, 6-39 readout axes, 6-28

connector description, 6-1, 6-46 port, PC keyboard, 2-5 servo control board, pinouts, 6-37 specifications, description, 6-46

connector, amplifier J1 host, illustration, 6-6 J1 host, illustration, referenced, 4-1 J2 signal inputs, illustration, 6-7 J2 signal inputs, illustration, referenced,

4-1 J3 signal inputs, illustration, 6-8 J3 signal inputs, illustration, referenced,

4-1 J7 external +5 V, illustration, 6-8 J7 external +5 V, illustration, referenced,

4-1 mating, table, 6-6 mating, table, referenced, 4-1 tables, listed, 4-1, 6-6 TB1 terminal block connector, pinout, 6-8 TB1 terminal block connector, pinout,

referenced, 4-1

connector, motor brake motor, illustration, 6-9 brake motor, illustration, referenced, 4-10 encoder

illustration, 6-10 illustration, referenced, 4-10

non-brake motor illustration, 6-9 illustration, referenced, 4-10

tables, listed, 4-10, 6-9 console

4200T, LCD front view, illustration, 5-7 side view, illustration, 5-8 top view, illustration, 5-7

cabling, maintenance, 8-3 contamination, maintenance, 8-3 environment, maintenance, 8-3 equipment listed, 2-5 filters, maintenance, 8-3 keypad, maintenance, 8-3 LCD

3000M connection, illustration, 6-2 4200T/5000M (with handwheel)

connection, illustration, 6-4 4200T/5000M (without handwheel)

connection, illustration, 6-3 color-display, 1-1 power requirements, 6-11

maintenance, 8-3 OEM, description, 3-3

constant voltage transformer, 6-11

contamination, in console, 8-3 contamination, prevent, 8-2 control axes

cabling specifications, 6-27 connections, table, 6-26 pinouts, ports 0 to 5, 6-26

Controller Area Network. See CAN

coolant signals, 6-33 correction, for geometric error,

7-22 counter inputs, 3-3 cross talk, prevent, 2-5, 5-1 CTR0/CTR1 pinout, 6-28 current

drawn by external relays, 6-39 rating, 6-39



sinking inputs, 7-12 sourcing inputs, 7-12

D DA-15 connectors, 7-18 DA-15M connector, 6-26 daisy-chaining, additional CAN

nodes to system, 6-44 dangerous conditions, 8-4 data cable, 6-25 DB-25 P5 connector, 6-40 DB-25F printer connector, 6-29 DE-9 connector, 7-19 DE-9M, RS-232 port, 6-29 dead-stop, limit inputs, 6-33 dead-stop, limits string, 6-34 defaults, restoring, factory, 7-11 detected, errors, 2-1 determining, correct transformer

size, 5-3 differential axis, input/output,

6-27 digital

amplifier, brushless servo description, 4-1 dimensions, illustration, 5-18 specifications, table, 4-2

signal processor. See DSP dimensional data, major

assemblies, 5-6 dimensional drawings, listed, 5-6 DIN rail connectors, 5-16 disabling the interlock function,

6-35 disclaimer, iii display

resolution, maximum, 3-3 RPM, 2-9 Setup Utility, 7-11

distributed, CAN I/O system, 1-1 DNC feature, 1-1 DRAM controller, 7-5 DRAM, installing, 7-5 DSP

block diagram, illustration, 7-22 board, 1-1 board, description, 7-15 board, illustration, 7-17 board, P12 connector, illustration, 9-3 defined, 7-16 motion test point (P12), 9-2

DSP2 board, 1-1, 7-12 expansion reference drawing, illustration,

7-24 expansion, description, 7-24 motion board, CNC hardware, listed, 2-5

D-sub connector, 6-25 dual processor design, 1-1

E effectivity notation, 1-2 EIDE hard drive, connector

pinout, 7-8 electrical codes, 5-1 electrical noise, machine, 2-1 electromagnetic

compatibility, 5-4 interference, 5-2, 5-3

electronic noise, keyboard, 6-17 electrostatic-shielded, isolation

transformer, 5-3 EMC test reports, 5-4 EMI, 5-3 EMI standards, 7-5 EMI, defined, 5-2 emissions, typical sources, 5-5 enclosures, aluminum, 5-5 enclosures, ferrous, 5-5 encoder

and analog power, description, 7-18, 7-26 cable

illustration, 6-49 lengths, table, 6-49 referenced, 4-10

connector, mating description, 6-51 referenced, 4-10

input, table, 7-22 inputs, 3-3, 7-18 inputs, switch settings, 6-27 MS3102E-20-29P, motor connector

pinout, 6-10 pinout, referenced, 4-10

ensuring conductivity, 5-5 environmental

parameters, console, 8-3 requirements, 3-2 requirements, LCD, 3-5

erratic, amplifier operation, 5-3



errors detected, 2-1 unusual, 7-10 while you run programs, 7-10

E-STOP button, 5-1 contactors, 6-34 function, description, 6-31 P10, manual switches, 7-20 switch, 3000M, 2-5

Ethernet based networks, connecting the CNC, 1-2 connector pinout, 6-30 network connection, 6-30

excessive, noise, 5-3 external

boards, wiring together using P6 connector, 6-44

cabling, description, 6-46 device, with analog output, 6-41 keyboard connection, 6-17 machine control electrics, 2-5 mounting, additional CAN I/O boards,

illustration, 6-44 noise, 7-12 power supplies, 3-1 rotary encoder, 3-3 START/STOP, 7-20 STOP/START, 6-31 STOP/START circuit, illustration, 6-32

F faraday cage, 5-5 feedback, description, 3-3 feedback, devices, 3-3 feedrate override, 2-5 FEEDRATE OVERRIDE switch,

3000M, 2-5 feedrate percentage control,

6-41 ferrous enclosures, 5-5 filters

console, maintenance, 8-3 installation, 8-2 replacement, 8-2

firmware, description, 7-22 FLASH devices, 7-6 Flash EPROM, 7-5 flat-pair cable, 7-12 flexible, metal conduit, 5-5 floating tap head, 2-9

floating-point, DSP motion control board, 1-1

floppy disk drive bracket, 6-25 connector pinout, 7-10 data cable, 6-25 external, 2-5 installation components, table, 6-22 mounting bracket, illustration, 6-25 power cable, 6-25 to install, in remote, 6-24

forward, rotation, 2-9 fuses, 8-3 fuses, description, 6-5

G G-codes, 1-1 grounding

concepts, 5-1 guidelines, description, 5-2 requirements, 5-1 techniques, 5-5

H handwheel

axes connections, 6-28 control, 2-5 ports, 6-28

hard drive CNC hardware, listed, 2-5 connector pinout, 7-8 maintenance, 8-2

hardware kit, P/N 33000199, 6-22

hardware, description, 7-1 harness

floppy disk drive, 6-23 keyboard interface, illustration, 6-18 remote floppy disk drive

drive signal, illustration, 6-24 power supply, illustration, 6-23

VGA, illustration, 6-11 high, input threshold, 3-3 high-frequency noise, 5-5 home switches

restrictions, listed, 6-45 wired to vector limit port, 6-45

humidity, 3-2



I I/O

capacity, total, 2-1 node, 2-1, 7-13 power supply, 3-1 signals, 2-1

IHV-745E, 7-5 improper, settings of certain

values in CHIPSET, 7-11 initial, connection, 1-2 input

CAN bus address, 7-14 description, 2-9 node supports, 2-1 power, 6-5 power (TB1), 6-5 power terminal blocks, 6-5 signal distortion, 3-3 speed, maximum, 2-9 threshold, 3-3 voltage irregularities, 6-11

installation, 5-1 installing, additional CAN nodes,

6-35 Integral Programmable

Intelligence User's Guide, P/N 70000416, referenced, 2-1

Integral Programmable Interface. See IPI.

interconnecting harnesses, length, 6-11

interconnection wiring diagrams, listed, 6-1

interface between CNC and CAN bus, 7-12 keyboard harness, illustration, 6-18

interference, 5-3 internal, power supplies, 3-1 introduction, 1-1 inverter, LCD, specifications, 3-4 IPI, defined, 2-1 IPI, program conditional logic,

2-9 ISA backplane, CNC hardware,

listed, 2-5 ISO programming formats, 1-1 isolated, input/output, 2-1 isolated, relay driver outputs,

6-39

isolating, noise from machine electronics, 6-44, 7-14

isolation transformer, description, 5-3

J jumper settings, 7-22 jumper settings, single-ended vs

differential axis, input/output, 6-27

jumpers analog output, table, 7-26 DSP2 expansion, 7-26 encoder input, table, 7-26 installed, 7-12

K K1: 4PDT 24 V DC socket mount

relay, 6-35 K2: SPDT DC actuated chassis

mount solid state relay, 6-35 K3 to K5: 2PDT 24 V DC socket

mount relays, 6-35 keyboard

connector pinout, 7-7 interface board

3000M, illustration, 6-15 4200T/5000M, illustration, 6-16

interface harness, illustration, 6-18 interface to external, 6-17 noise, electronic, shield, 6-17 pinout, 7-7

keypad, maintenance, 8-3

L LCD

3000M connection, illustration, 6-2 4200T

console front view, illustration, 5-7 side view, illustration, 5-8 top view, illustration, 5-7

4200T/5000M (with handwheel) connection,

illustration, 6-4 (without handwheel) connection,

illustration, 6-3 console

handling, 3-5 mounting, 5-6 power connection, 6-12



defined, 1-1 description, 3-3 environmental requirements, 3-5 inverter, specifications, 3-4 liquid crystal display, description, 3-1 monitor, specifications, 3-4 power requirements, table, 3-1 setup

OSD board, adjusting settings, 6-13 OSD board, connecting, 6-12 OSD board, disconnecting, 6-13

setup and adjustment, procedures, 6-12 SVGA, monitor, power requirements, 3-1 troubleshooting, 9-4

LED, amplifier, table, 6-9 LED, amplifier, table, referenced,

4-1 LEDs, backplane, 9-1 line counts, maximum, 3-3 line voltage, reduce, 5-3 linear encoder, 3-3 liquid crystal display. See LCD logic, conditional, 2-9 logical outputs, 2-9 loss of battery power, 7-10 low speed electronic circuit

breaker, LS/ECB, 4-2 low, input threshold, 3-3 LS/ECB, low speed electronic

circuit breaker, 4-2

M machine

basic I/O, description, 7-20 bonding points, establish, 5-2 codes, 2-1 control electrics, external, 2-5 electrical noise, 2-1

Machine Basic input/output. See MBIO

machinist language, 1-1 maintenance

balance and signal checks, 8-1 cabling, 8-2 console, cabling, 8-3 console, contamination, 8-3 console, environment, 8-3 console, filters, 8-3 contamination, prevent, 8-2 filters, 8-2 fuses, 8-3

hard drive, 8-2 keypad, 8-3

manual jog, 2-5 manual panel

4200T, with handwheel, illustration, 5-10 4200T, with no handwheel, illustration,

5-10 5000M, with handwheel, illustration, 5-12 5000M, with no handwheel, illustration,

5-12 connections, illustration, 6-19 description, 2-5 handwheel

(CTR0) pinout, 6-21 connection, 6-21 to CTR0 harness, illustration, 6-21

interface board, 4200T/5000M, illustration, 6-19

to COM1 harness, illustration, 6-20 manual, spindle control, 2-5 mating

connector specifications, 6-46 encoder connector for motor,

manufacturer P/N, 6-51 encoder connector to servo amplifier,

manufacturer P/N, 6-51 power connector for motor with brake,

manufacturer P/N, 6-51 power connector for motor without brake,

manufacturer P/N, 6-51 maximum

cable length, 6-27, 6-28 display resolution, 3-3 input speed, 2-9 line counts, 3-3

MBIO AUTO/MANUAL select circuit, illustration,

6-32 connector, 6-31 DA-15F connector, 6-31 defined, 6-31 functions, table, 6-31 mating connector, illustration, 6-31 turn-on circuit, illustration, 6-32 used with, servo control board, 6-33

M-codes, defined, 2-1 measurement transducers, 2-1 mechanical imperfections, 7-22 memory accesses, 7-5 monitor, LCD, specifications, 3-4 monitors, 5-6



motion control board, description, 1-1 power supply, 3-1 test point (P12), 9-2

motors AM 130 series

description, 4-7 referenced, 3-6 specification & features, table, 4-7 stator winding, 4-7

AM 96 series description, 4-3 referenced, 3-6 specification & features, table, 4-3 stator winding, 4-4

cables power

with brake, lengths, table, 6-48 without brake, lengths, table, 6-47

power, AC brushless with brake, illustration, 6-48 with brake, referenced, 4-10 without brake, illustration, 6-47 without brake, referenced, 4-10

connector, tables, listed, 4-10, 6-9 dimensions

AM 130 series, illustration, 5-20 AM 96 series, illustration, 5-19

encoder connector pinout, 6-10 pinout, referenced, 4-10

encoder connector, mating description, 6-51 referenced, 4-10

power connector brake motor

pinout, 6-9 brake motor, pinout, referenced, 4-10 mating


non-brake motor pinout, 6-9

non-brake motor, pinout, 4-10 system interconnect diagram, illustration,

4-12 mounting

CAN I/O boards, 5-15 external CAN I/O Board(s), 6-43 hole patterns, 5-6

MS3102E-18-10P, motor connector, non-brake motor illustration, 6-9 illustration, referenced, 4-10

MS3102E-20-15P, motor connector, brake motor illustration, 6-9 illustration, referenced, 4-10

MS3102E-20-29P, encoder connector, motor illustration, 6-10 illustration, referenced, 4-10

MS-DOS, 1-2 multi-cast mode, 7-14

N nameplate, AM series,

illustration, 4-11 National Electrical Code, 5-1 NEC regulations, 5-3 node, 7-14 nodes, CAN, 2-1 nodes, description, 7-13 noise

control, 5-2 electronic, keyboard, 6-17 excessive, 5-3 high-frequency, 5-5 reduction, 5-5

noisy environments, 3-3 non-brake motor, MS3102E-18-

10P, power connector pinout, 6-9 pinout, referenced, 4-10

O OEM

CNC chassis, 5-13 CNC chassis, illustration, 5-14 console, description, 3-3 external, servo power supply kit, 3-1 servo system wiring, 6-31 system interconnect diagram, illustration,

4-12 off-line software, 1-2 operating systems, compatibility

with off-line software, 1-2 operation, theory of, 2-1 optional, analog input, 6-39 opto-couplers, 7-12 opto-isolated inputs, 6-39



opto-isolators, 6-44, 7-14 orientation, spindle encoder

ratio, 2-9 OSD board

adjusting settings, 6-13 connecting, 6-12 disconnecting, 6-13

output bipolar, 2-9 CAN bus address, 7-14 clamp circuits, 6-35 current, of relay drivers, 6-39 description, 2-9 logical, 2-9 node supports, 2-1 power, 6-5 power (TB2), 6-5 power terminal blocks, 6-5 unipolar, 2-9

over-heat sensors, 2-9

P P/N 31900541, manual panel

interface board, illustration, 6-19

P/N 33000187, manual panel to COM1 harness, illustration, 6-20

P/N 33000199, hardware kit, 6-22

P/N 33000976, keyboard interface board, illustration, 6-15

P/N 33000977, keyboard interface board, illustration, 6-16

P/N 33001279, digital brushless servo amplifier description, 4-1 illustration, 5-18 referenced, 3-6 specifications, table, 4-2

P/N 33001503, CAN I/O board, illustration, 6-39

P/N 33001521, servo control board illustration, 6-33

P/N 70000414, 4200T CNC Setup Utility Manual, referenced, 6-45

P/N 70000416, Integral Programmable Intelligence User’s Guide, referenced, 2-1

P/N 70000499, 3000M CNC Setup Utility Manual, referenced, 6-45

P/N 70000509, 5000M CNC Setup Utility Manual, referenced, 6-45

P1 and P2, connections, 6-39 P1 to axis ports, table, 7-25 P10 E-STOP and manual

switches, table, 7-20 P11 CAN BUS interface, table,

7-21 P12 test connection, 7-21 P15 output/input, table, 7-15 P15 probe pinout, 7-21 P2 connector, 6-20 P2 to readout axis, table, 7-26 P3 encoder and analog power,

table, 7-18, 7-26 P4 and P5 to axis ports (0 to 4),

table, 7-18 P5 DB-25 connector, 2-1, 5-17,

6-41 P6 and P7 to readout axes,

table, 7-19 P6 CAN connector pinouts, 6-43 P6, pin 20, voltage input, 6-41 P8 machine basic I/O, table,

7-20 P9 external START and STOP

switches, table, 7-20 parity DRAM, 7-5 PC processor, 1-1 Pentium 166 MHz MMX, 7-5 Phoenix

adapter, 5-17 components, 5-16 modules, illustration, 5-16 terminal adapter, illustration, 5-17 terminal, method, 6-44

pigtails, 5-5 points of contact

clean assemblies, 5-2 clean, paint off, 5-2 use washers, 5-2

ports 0 to 5, control axes connections, 6-26

positioning loop, 2-1, 2-3



position-sensing devices, 2-3 potentiometer, spindle

percentage or feedrate percentage control, 6-41

power cable, 6-25 connection to chassis, 6-5 connections, input and output, table, 6-5 connector, mating


hit, accidental, 7-10 requirements, 6-39, 7-6

LCD, description, 3-1, 6-11 supplies

CNC hardware, listed, 2-5 external, 3-1 internal, table, 3-1 switching, 5-5

prevent, cross talk, 2-5, 5-1 preventive measures, table, 8-4 printer

connector, pinout, 7-9 connector, pinout, 6-29

probe connector pinout, 6-30 P15 pinout, 7-21

program storage capacity, 1-1 pulse width, 2-1 PWM amplifiers, 5-5

R radio-frequency interference, 5-3 readout axes, connections, 6-28 recommended, external cabling

and connector guidelines, table, 6-46

relay outputs, 7-15 remote floppy disk drive

dimensions, illustration, 6-23 harnesses, description, 6-23 installation, description, 6-22 power supply, harness, illustration, 6-23 signal, harness, illustration, 6-24

remote, manual panel, 1-1 remote, STOP/START, 6-31 required, voltage, 7-6 restoring, factory defaults, 7-11 reversing, contactor sets, 6-35 RFI, 5-3 rigid, tapping, 2-9

RJ-45 connection, 6-30 rotary encoder, 3-3 rotation, forward, 2-9 RPM display, 2-9 RS-232 port, COM1 connector,

7-7

S S1 switch, 6-44, 7-14 safety

codes, 2-9 loop, 6-34, 7-20 of machinery, 5-5 switches, 2-5

S-axis, control axis, 6-26 SBC, single-board computer,

7-10 Schmidt trigger, 3-3 screen, selecting colors, 7-11 serial port 1, 7-7 serial port 2, 7-9 servo

AC brushless motors AM 130 series, dimensions, illustration,

5-20 AM 96 series, dimensions, illustration,

5-19 amplifier, digital brushless

description, 4-1 dimensions, illustration, 5-18 specifications, table, 4-2

control and M-function simplified schematic, 6-34

drives, 2-5 enable, 6-34 enable, signal, 6-34 enable, wiring, 7-20 external, power supply kit, 3-1 inhibitor (P17) pinout, 6-38 inhibitor (P2) pinout, 6-37 reset switch, input, 7-20 reset switch, output, 7-20 system, description, 3-3 turn-on loop, 6-34

servo control board (P13) pinout, 6-38 CAN I/O (P3) pinout, illustration, 6-37 connections, 6-35 connector, pinouts, 6-37 console (P15) pinout, 6-38 description, 6-35



illustration, 6-33 nodes, illustration, 7-13 operating voltage, range, 6-34 pinout, illustration, 6-36 relay, rating, 6-34 signal pick-up, voltage, 6-34 use, with MBIO, 6-33

servo motor. See motors Servo Reset contactors, 6-34 setting, board as CAN 0 or

CAN 1, 6-35 setup screens, selecting colors,

7-11 Setup Utility, 7-11 Setup Utility, for configuring the

system, 7-10 shadow areas, 7-5 shield, electronic noise,

keyboard, 6-17 shields, 5-5 shock, 3-2 signal checks, 8-1 SIMM sockets, 7-5 single-board computer

CNC hardware, listed, 2-5 Ethernet connector, 6-30 illustration, 7-5 SBC, 7-10 setting up the BIOS, 7-10

single-ended axis, input/output, 6-27

sink-board, 2-9 SLIO, 7-12 socket mount relay, K1, 6-35 socket mount relays, K3 to K5,

6-35 solid state relay, 6-34 source-board, 2-9 specifications, 3-1 spindle

drive, requirements, 2-9 drives, CNC, 2-9 motor control, 6-33 percentage, potentiometer, 6-41

START/STOP switches, table, 7-20

stator winding, AM 130 motors, 4-7

stator winding, AM 96 motors, 4-4

step-down transformer, 5-3

surface mount design, 1-1 SVGA, LCD, monitor, power

requirements, 3-1 switch settings, 7-22 switching, power supplies, 5-5 system interconnect diagram,

illustration, 4-12 system memory, 7-5 system overview

3000M, illustration, 2-6 4200T, illustration, 2-7 5000M, illustration, 2-8

system wiring diagram five axes and one spindle, 7-4 four axes and one spindle, 7-3 three axes and one spindle, 7-2 two axes and one spindle, 7-1

T tapping, requirements, 2-9 tapping, spindle encoder ratio,

2-9 TB1, 6-5 TB1 (input power), 6-5 TB2, 6-5 TB2 (output power), 6-5 TB2 power supply, 9-2 techniques, grounding, 5-5 temperature, ambient, 3-2 terminal adapter, illustration,

5-17 terminate, CAN bus, table, 6-45 terminating jumper, 6-35 test cable, illustration, 6-50 test connection (P12, 7-21 test points, 9-1 threading, spindle to encoder

ratio, 2-9 torque graph, illustration

AM 130 series, listed, 4-8 AM 130A, AM 130AB, 4-8 AM 130C, AM 130CB, 4-9 AM 130E, AM 130EB, 4-9 AM 96 series, listed, 4-4 AM 96A, 96AB, 4-5 AM 96C, AM 96CB, 4-5 AM 96E, AM 96EB, 4-6

torque-controlled system, 2-1 transducer, 2-1



transformer isolation, description, 5-3 size, determining correct, 5-3

transistors, 7-12 travel limit, switches, 5-1 troubleshooting

amplifier, 9-5 checking voltages, 9-1 LCD, 9-4

turn-on circuit, 6-31 twisted-pair cable, 7-12 twisted-pair connection, 6-30

U U-axis, control axis, 6-26 UL-1950, 7-5 unipolar, output, 2-9 unpredictable, results, 7-11 unusual, errors, 7-10 user keyboard, connector pinout,

7-7

V velocity loop, 2-1 velocity-controlled

feedback devices, 3-3 servo drive, 2-1 servo motors, 3-3

VGA BIOS, 7-5 connection, 3-5, 6-11 connector pinout, 7-6 harness, illustration, 6-11 monitor, 2-5

to single-board computer connection, 6-11

vibration, 3-2 video memory, 7-5 voltage

checking, 9-1 input to P6, pin 20, 6-41 inputs, 3-1 required, 7-6

W W-axis, control axis, 6-26 Windows 3.11, 1-2 Windows 95, 1-2 Windows for Workgroups, 1-2 Windows NT, 1-2 Windows XP, 1-2 wiring

control axes, 6-27 diagrams, 7-1 diagrams, listed, 6-1 guidelines, 5-1 OEM servo system, 6-31 servo amplifiers, 5-3 system grounds, 5-3

X X-axis, control axis, 6-26

Y Y-axis, control axis, 6-26

Z Z-axis, control axis, 6-26

70000506H · 1 · 10/2009 · Printed in USA

333 East State ParkwaySchaumburg, IL 60173-5337 USA

HEIDENHAIN CORPORATION

+1 (847) 490-1191+1 (847) 490-3931

E-Mail: [email protected]

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