Applied Robotics Torchmate 401A Installation instructions

Computer Numerical Control for Windows
Model 401A
Signal Generator
Hardware Guide
Applied Robotics, Inc.
4719 17th Street, North
Arlington, VA 22207
[phone]

Table of Contents
GETTING STARTED ......................................................................................................................................................................1
ABOUT THIS MANUAL.................................................................................................................................................................1
SAFETY AND USAGE GUIDELINES..............................................................................................................................................2
HARDWARE GUIDE.......................................................................................................................................................................3
OVERVIEW OF THE SIGNAL GENERATOR.................................................................................................................................3
FRONT PANEL...............................................................................................................................................................................3
REAR PANEL..................................................................................................................................................................................3
OUTPUT SIGNAL SCHEMATIC....................................................................................................................................................7
TURNING OFF THE CONTROLLER..............................................................................................................................................7
SAMPLE WIRING DIAGRAMS ...................................................................................................................................................9
TYPICAL MOTOR SIGNAL CIRCUIT.........................................................................................................................................10
TYPICAL MOTOR SIGNAL CIRCUIT WITH AN EXTERNAL 5V POWER SUPPLY...............................................................12
TYPICAL MOTOR SIGNAL CIRCUIT WITHOUT PULL-UP RESISTORS.................................................................................13
TYPICAL OUTPUT LINE CIRCUIT............................................................................................................................................14
TYPICAL INPUT LINE CIRCUIT ................................................................................................................................................16
SIGNAL GENERATOR BOARD LAYOUT ...................................................................................................................................17
I/O CONNECTOR SCHEMATIC ..................................................................................................................................................19

Torchmate Section 1Getting Started 1
1. Getting Started
About this Manual
Torchmate is a unique application involving hardware and software, so you’ll need some
instruction to get started.
Since automated machining is potentially dangerous, please take
the time to completely read through this manual and the
software User’s Guide to understand the operation of the
electronics, software and machine before cutting a part.
Section

Torchmate Section 1Getting Started2
Safety and Usage Guidelines
When running an automated machine tool, safety is of utmost importance.
For proper and safe use of the Torchmate program and your CNC machine,
the following safety guidelines must be followed:
1. Never let the machine tool run unattended.
2. Require any person in the same room as a running machine tool to wear
safety goggles, and to stay a safe distance from the machine.
3. Allow only trained operators to run the machine tool. Any operator must
have:
Knowledge of machine tool operation.
Knowledge of personal computer operation.
Knowledge of Microsoft Windows.
Good common sense.
4. Place safety guards around the machine to prevent injury from flying
objects. It is highly recommended that you build a safety shield around
the entire tool envelope.
5. Never place any part of your body within the tool envelope while the
machine is online, since unexpected machine movement can occur at any
time.
6. Always keep the tool envelope tidy and free of any loose objects.
7. Be on alert for computer crashes at all times.
Applied Robotics, Inc. is not responsible for the safe installation and use of
this product. You and only you are responsible for the safety of yourself and
others during the operation of your CNC machine tool. Applied Robotics
supplies this product but has no control over how it is installed or used.
Always be careful!
Applied Robotics, Inc. is not responsible for damage to any equipment or
workpiece resulting from use of this product.
If you do not understand and agree with all of the above safety guidelines, do
not use this product.

Torchmate Section 2Hardware Guide 3
2. Hardware Guide
Overview of the Signal Generator
The Signal Generator provides a flexible interface that controls up to 4 stepper or digital
servo motor drivers, 8 output lines and 8 input lines. It works in conjunction with the
Torchmate software. Please note that there are several software and hardware settings
that affect the use of the Signal Generator. These settings are described in this manual
and the software User’s Guide.
Front Panel
The front panel of the signal generator has the power on/off switch and 8 LED’s with
the following functions:
Limit - Turns red when any limit/input switch is open (using normally closed
switches).
X, Y, Z, Α- Turns green when the respective motor is stepping. Note that the
polarity of these lights will be reversed if the Park Signal is set to Low in the
Motor Signals Setup dialog box.
RXD - Turns yellow when receiving data from the host PC.
TXD - Turns yellow when transmitting data to the host PC.
Power - Turns green when the power switch is turned on.
On/Off Switch - Turns the unit on and off. If there is ever a communications
error while running Torchmate, turn the switch off and on to reset the internal
microprocessor.
Rear Panel
The rear panel has connectors for input and output signals as described below.
Section

Torchmate Section 2Hardware Guide4
DC IN - Receptacle for the power supply. The unit is shipped with a 9V DC,
800-1000mA wall transformer power supply.
Fuse - Cartridge for the fuse. If the fuse blows, replace it with a 3AG, 1.5A
slow-blow fuse.
RS-232 - Serial port connector for communication with the host PC (9 pin
female). Most PC’s have 9 pin male or 25 pin male. Use either a 9 Pin Male -
9 Pin Female or a 9 Pin Male - 25 Pin Female cable depending on the serial
port on your PC.
INPUT - The connector for up to 8 input lines. The most common use of the
input lines is for limit or safety switches. These lines are all TTL level inputs.
When a switch is open, its input signal is high (+5V). When the switch is
closed, its input signal is grounded low (0V).
The 401A is wired for normally closed (NC) switches. Each line that is not
connected to a switch must be wired directly to its ground. When any of the
input lines are open the red Limit light will illuminate and a signal will be sent to
the host PC to indicate which input line(s) went high. You can use normally
open (NO) switches, however the red Limit light will always be on. Note that
all 8 input lines must be normally open, or all 8 input lines must be normally
closed. If you are not using the input lines, the Limit light will always be
illuminated.
If you are using normally closed switches, make sure the Signal Generator
Model 401A option is selected in the System Options Setup dialog box. If you
are using normally open switches, make sure the Signal Generator Model 401
option is selected in the System Options dialog box. All input lines must be
properly defined in the Input Lines Setup dialog box.
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE SIGNAL GENERATOR.
Limit lines 5, 6, 7 & 8 are also connected through pins 5, 6, 7 & 8 respectively
of the Motor Signal connector. This makes it convenient to send any signals
from your motor driver box, such as a servo position error signal, back to the
Signal Generator. Note that if the signal is being used through the Motor Signal
connector, that line must remain open in the Input connector. Also, if the Input
connector is wired as normally closed, then the signal coming in through the

Torchmate Section 2Hardware Guide 5
Motor Signal connector must be normally LOW. Alternatively, if the Input
connector is wired as normally open, then the signal coming in through the
Motor Signal connector must be normally HIGH. If you are not using input
signals through the Motor Signal connector, then don’t connect them to
anything.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr.
Series 16 pin receptacle (part number 39-01-2160), with female pins (part
number 39-00-0039). The input lines as seen from the back of the box are
arranged as follows:
G G G G
GGG G
86 4 2
7 5 3 1
OUTPUT - The connector for up to 8 output lines. These lines are all optically
isolated, TTL level outputs. Low is 0V and high is +5V.
Two input pins are provided for optical ground and optical +5V. You
must connect these pins to ground and +5V from an external power
supply for the output signals to operate. Note that these pins are
internally connected to the optical ground and optical +5V pins on the
Motor Signal connector. Therefore, if you are connecting a power
supply to the optical ground and optical +5V pins on the Motor Signal
connector, do not connect an external power supply here.
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE SIGNAL GENERATOR.
The output lines are all initialized to low (0V) when you turn on the Signal
Generator. If you are using an external supply, the output lines will go
high if the Signal Generator is turned off and the external power supply
is still on. THIS WILL CAUSE ANY DEVICE CONNECTED TO THE
OUTPUT LINES TO TURN ON.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr.
Series 10 pin receptacle (part number 39-01-2100), with female pins (part
number 39-00-0039). The output lines as seen from the back of the box are
arranged as follows:

Torchmate Section 2Hardware Guide6
GND
+5V
86 4 2
753 1
OPT
OPT
MOTOR SIGNALS - The DB-25 male connector for all signals going out to
the stepper or digital servo motor driver(s). If you are using one of the
Torchmate motor drivers, connect this to the DB-25 female connector on the
motor driver using a DB25 M-F interface cable.
The cable used must be a DB-25 Interface Cable with all 25-pins wired
straight through.
The motor signal lines are all optically isolated, TTL level outputs.
Two input pins are provided for optical ground and optical +5V. You
must connect these pins to ground and +5V from an external power
supply or the internal power supply for the output signals to operate.
Note that these pins are internally connected to the optical ground and
optical +5V pins on the 10-pin Output connector. Therefore, if you are
connecting an external power supply to the optical ground and optical
+5V pins on the 10-pin Output connector, do not connect an external
power supply here.
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE MOTOR SIGNAL GENERATOR.
Two pins are directly connected to ground and +5V from the internal power
supply. These are provided for convenience as a source for the optical ground
and optical +5V if there is no external power source available. Using the
internal supply to power the optical isolators will negate most of the isolation
provided by the optical isolators. To use the internal supply, directly connect
Motor Signal connector pin 24 to 25 and pin 22 to 23.
The motor signal lines as seen from the back of the box are arranged as follows:

Torchmate Section 2Hardware Guide 7
113
14 25
DB25
Pin Signal DB25 Pin Signal
1NC 14 ENABLE ALL
2NC 15 Α PARK
3NC 16 Z PARK
4NC 17 Y PARK
5INPUT 5 18 X PARK
6INPUT 6 19 ΑDIRECTION
7INPUT 7 20 Z DIRECTION
8INPUT 8 21 Y DIRECTION
9X DIRECTION 22 Internal VCC +5V
10 ΑSTEP 23 OPT VCC (INPUT)
11 Z STEP 24 Internal GND
12 Y STEP 25 OPT GND (INPUT)
13 X STEP
Output Signal Schematic
The output signals are all optically isolated using a series of PS2501-4 optical couplers.
The strength of the output signal can be controlled by changing the value of resistors
RP4, RP5 and RP6. These resistors come shipped as 470Ω. In some applications, it is
best to remove the resistor altogether. Please consult the user’s manual for your
stepper motor drive or any other output device for the strength of this signal. The end of
this manual contains some sample wiring diagrams for different types of drives. Below
is a schematic for the typical output signal:
Turning off the Controller
Always turn off the Signal Generator when it is not in use.
CPU Signal
+5V Output Signal
OPT GND
OPT VCC
390ΩRP4, 5, 6 (Normally 470Ω) PS2501-4

Torchmate Section 2Hardware Guide8

Torchmate Section 3Sample Wiring Diagrams 9
3. Sample Wiring DiagramsSection

Torchmate Section 3Sample Wiring Diagrams10
Typical Motor Signal Circuit
The above schematic shows a typical connection of a motor driver to the motor signals of the Signal Generator.
Signal Generator Model 401 A
5V
OPT-VCC DB25-22
DB25-23
DB25-24
DB25-25
VCC OPT-VCC
OPT-GND
Step Clock
Logic
Ground
Enable
Half/Full
CW/CCW
0.
1F µ
0.
1F µ
OPT-GND
Phase A
Phase A~
Phase B~
Phase B
V+
Ground 40VDC
S h
i
e
l
d e
d
C a b l
e
Current
Adjust
2K Ω

Torchmate Section 3Sample Wiring Diagrams 11
Since the Motor Signal lines are run off the optical couplers (PS2501-4) there must be an optical power source. In this example we
have bridged the optical power source with the internal power source of the Signal Generator by connecting lines 22 to 23 and 24 to 25
of the DB25 Motor Signal connector.
Alternatively, we could have connected an external 5V power supply to pins 23 and 25 of the DB25 or the OPT GND and OPT +5V
pins of the Output connector. Note that if an external power supply is used, the load on any output signal will get powered on if the
Signal Generator is turned off while the external 5V power supply is still on.
Also note that RP4 and RP6 are socketed 470 ohm pull-up resistors. These resistors can be changed or removed depending on
current requirements for the input signal of the motor driver. The resistor is an 8 pin 7 resistor package. For the Torchmate Servo
Drive, this resistor value should be 4.7Kohm
In this example a 0.1uF capacitor was placed between the step signal and ground and between the direction signal and ground. This
filters out any transient noise in the signals. It’s better to place these capacitors on the drive unit rather than the Signal Generator.

Torchmate Section 3Sample Wiring Diagrams12
Typical Motor Signal Circuit With an External 5V Power Supply
Signal Generator Model 401 A
OPT-VCC DB25-23
DB25-25
VCC OPT-VCC
OPT-GND
Step Clock
Logic
Ground
Enable
Half/Full
CW/CCW
0.
1F µ
0.
1F µ
OPT-GND
Phase A
Phase A~
Phase B~
Phase B
V+
Ground 40VDC
S h
i
e
l
d e
d
C a b l
e
Current
Adjust
2K Ω
5VDC
+
-

Torchmate Section 3Sample Wiring Diagrams 13
Typical Motor Signal Circuit Without Pull-up Resistors
Signal Generator Model 401 A
5V
OPT-VCC DB25-22
DB25-23
DB25-24
DB25-25
VCC
OPT-GND
Step Pulse
Opto In
Direction
0.
1F µ
0.
1F µ
OPT-GND
Phase A
Phase A~
Phase B~
Phase B
V+
Ground 40VDC
S h
i
e
l
d e
d
C a b l
e

Torchmate Section 3Sample Wiring Diagrams14
Typical Output Line Circuit
The above schematic shows a typical connection of one solid state relay controlled by output line 1 of the Signal Generator. A typical
load would be a plasma torch, spindle, a vacuum, a laser, etc. In this example, the solid state relay used is a Continental Industries
model S505-0SJ610-000. It takes a 3 to 32VDC input and has an output of 24-330VAC.
Signal Generator Model 401 A
Solid State Relay
Continental Industries
S505-0SJ610-000
+ 3
Load
1
2
AC Power
Fuse
3 .
3 K
4
OPT
5V
OPT-VCC DB25-22
DB25-23
DB25-24
DB25-25
VCC OPT-VCC
OPT-GND
PS2501-4
Signal Output
Connector
Signal
Output1

Torchmate Section 3Sample Wiring Diagrams 15
Since the Output lines are run off the optical couplers (PS2501-4) there must be an optical power source. In this example we have
bridged the optical power source with the internal power source of the Signal Generator by connecting lines 22 to 23 and 24 to 25 of
the DB25 Motor Signal connector.
Alternatively, we could have connected an external 5V power supply to pins 23 and 25 of the DB25 or the OPT GND and OPT +5V
pins of the output connector. Note that if an external power supply is used, the Load might get powered on if the Signal Generator is
turned off while the external 5V power supply is still on.
Also note that RP5 is a socketed 470 ohm pull-up resistor. This resistor value can be changed or removed depending on current
requirements for the input signal of the device you are switching. The resistor is an 8 pin 7 resistor package.

Torchmate Section 3Sample Wiring Diagrams16
Typical Input Line Circuit
The above schematic shows a typical connection of 5 normally closed switches. These
switches are connected between input lines 1-5 and ground. Lines 6-8 connected directly to
ground with jumper wires. All external connections shown are made through the Input
connector on the back of the Signal Generator.
Input lines 5, 6, 7 & 8 are internally connected to pins 5, 6, 7, & 8 respectively of the
DB25 Motor Signal connector.
Note that this is the same connections made by the Torchmate limit switch kit.
Signal Generator Model 401 A
DB25 Pin5
DB25 Pin6
DB25 Pin7
DB25 Pin8