Centroid RTK3 User manual

RTK3 Logic Controller User Manual
Revised 6-24-08
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Overview
The RTK3 is intended to simplify and expedite control wiring. Centroid’s PLCIO2 was the starting
point for the RTK3, and modifications were aimed at increasing efficiency on standard system configurations.
To reduce the number of connections in the control cabinet, input and most output voltages are standardized.
Logic and input power supplies are built in to the RTK3 to further simplify installation. Positive locking
connectors on pre-assembled cables eliminate the need to individually connect each wire to the RTK3.
Much remains common between the PLCIO2 and RTK3. The motion control card (CPU10 or
compatible) connected to the RTK3 must be equipped with an IO2PIC chip (see TB133 for upgrade procedure).
PLCCOMP or XPLCCOMP or both PLC compilers can be used with the RTK3, just like the PLCIO2. The
RTK3 also retains the Fast I/O feature, which is now dedicated to a sourcing sensor input and relay output.
There are three layers in the RTK3 to minimize footprint and maximize cabinet efficiency. Only rarely
used connectors are located on the backside of the unit to allow mounting against the cabinet wall if necessary.
The bottom board has six mounting holes for direct attachment to standoffs. See the “RTK3 Mounting
Dimensions” section for mounting standoff configuration. The bottom, or logic, board is home to the logic
controller’s processor, input isolators, analog output section, output drivers, and power supply section. This is
where the fiber optic and almost all input connections are made. The middle board has 10 relays, one logic
input, and two power inputs. Various voltage and load levels are controlled by relays on the middle board. The
top board is equipped with 110VAC outputs and the 110VAC power input connector.
RTK3 System Constraints
The lube pump output must be either 220VAC or 110VAC single phase. In addition, the E-stop power
loop must be 24VAC, solenoids and lights must be 110VAC, and sensors must be compatible with 24VDC
inputs when using an RTK3.

Wiring Concept Visual Comparison
Flood Pump Contactor
Inverter
PC
Intermediate Terminal Strip
Previous ATC Wiring Sample
Power Supply
Servo Drive
Estop Contactor
PLCIO2
Intermediate Terminal Strip
Transformer
Carousel Motor Contactor
Servo Drive
Transformer
PC
RTK3 Wiring Sample
Estop Contactor
Inverter RTK3
Note the simplified layout and wiring enabled by the RTK3. Fewer individual wires (thin lines) are
used and intermediate terminal block connections are reduced. Cables (thick lines) with quick connect ends
replace many individual wires. Integrated components and specialized connection points on the RTK3 reduce
the quantity of external hardware required. These advantages allow for quicker, more organized, more compact
and more reliable panel wiring.
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Power Connection
Three power connections are necessary on a full RTK3 installation. Five position plugs are used for the
220VAC and 24VAC power inputs. Three wires are positioned uniquely in the housing to prevent operation
with incorrect voltage connections. Screw terminals on the top board are used for 100VAC connection.
The 220VAC input supplies the 220VAC lube and spindle cooling fan outputs. The 110VAC input
powers the on board power supply as well as 110VAC outputs. The E-stop output and configurable outputs
may use the 24VAC input.
Input Wiring
All inputs on the RTK3 are optically isolated and 24VDC powered. Some inputs are sourcing and
others are sinking, see the “Input Map” section for details. The two basic input configurations are shown
below.
Internal Circuitry
24 GROUND
Sourcing Input
INPUT GROUND
INPUT
+24 VDC
INPUT
Internal Circuitry
24 GROUND
Sinking Input
+24 VDC
INPUT POWER
Either type of input may be used with a switch. Sourcing inputs may be used with sinking sensors that are
capable of sinking 15mA at 24VDC. Sinking inputs may be used with sourcing sensors that provide 15mA at
24VDC. Compare sensor and RTK3 input specifications using the “RTK3 Specifications” table to ensure
compatibility. Two wire sensors should not be used with the RTK3, since they normally do not meet the “Input
On Voltage” and “Input Off Voltage” specifications. Care must be taken to wire each input correctly, as the
cable for each input has signals that are not used in all cases. These include 24VDC and Input Ground for
powering sensors and a shield connection that should normally be connected only to the RTK3. The 24VDC
supply fuse is located on the bottom (logic) board. The “DIGITIZE PROBE” connector has an additional fuse
on its 24VDC supply pin, which can also be found on the logic board. These fuses are in series such that the
digitizer fuse could fail without affecting other inputs. However, a short in any other 24VDC circuit will blow
the main 24VDC fuse, causing a loss of all input voltages.
Connectors are available on the RTK3 to plug in limit and fault inputs from a Centroid DC brushed
servo drive. The “DRV FAULT” and “LIMITS TO DRIVE” headers are intended only for allowing straight
through cable connections to a drive. Limit switch wiring should be done from the “X- / X+ / Y- / Y+ LIMITS”
and “W+ / W- / 5+ / 5- LIMITS” headers. When using a Centroid DC brushed servo drive with an RTK3, the
“G” and “5” power DIP switches on the drive should be turned on.
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Output Wiring
Several output types are present on the RTK3 to reduce wiring time when interfacing with specific
components. These include 110VAC, 220VAC, and 3 phase outputs as well as a 24VAC and an analog output.
Open collector and relay contact outputs are also available for more general application. See the “Output Map”
section for more information.
Each power relay output is protected by a fuse. The “DOOR FAN” and “CONSOLE” unswitched
110VAC outputs are also fuse protected. Fuses are 5x20mm and should be rated equal to or less than the
ratings printed on the RTK3 for safety. Signal relays, such as those on the inverter outputs, are not fuse
protected.
110 VAC H
Internal Circuitry
Output
110VAC Output
Output
220 VAC L1
220VAC Output
Internal Circuitry
Output
Relay Output
Internal Circuitry
Output Common
Internal Circuitry
Open Collector Output
5 GROUND
Output
+5 VDC
FLOOD OUTPUT
Internal Circuitry
JB5
1 2
OUT 3
24 AC1
FLOOD COMMON
Flood Pump Output
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OUT 5
OUT 31
JB6
1 2
CAROUSEL DIRECTION 2
CAROUSEL COMMON
Internal Circuitry
24 AC1
CAROUSEL DIRECTION 1
CarouselOutputs
Configurable Outputs
Outputs 11 and 37 may be configured as 24VAC or relay contact outputs. These outputs are routed to
the “AUX 2 / CHILLER” connector. The configurable output jumper settings must be verified before
connecting these outputs to prevent damage to the RTK3 or associated hardware.
Configurable Relay Outputs
24 AC2
J2 or J4
1 2
Internal Circuitry
OUTPUT
J1 or J3
1 2
OUTPUT COMMON
24 AC1
24VAC Output Setting Relay Contact Output Setting
J2 or J4
J1 or J3
Pin 1
J1 or J3
J2 or J4
Pin 1
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Spindle Outputs
The RTK3 is equipped with an analog output and specialized relay outputs to simplify spindle drive
wiring. The analog output has a 12-bit resolution and can be configured for 0 to +5VDC or 0 to +10VDC
output. The analog ground should not be connected to other grounds on the RTK3. All input and output
functions required for a standard inverter connection are located on the 15 pin “INVERTER” connector.
ANALOG GROUND
-12 VDC
SPINDLE ANALOG OUTPUT
Analog Output
-
+
+12 VDC
ANALOG
GROUND
Internal Circuitry
Spindle Drive Outputs
SPINDLE DRIVE RESET COMMON
SPINDLE DIRECTION COMMON
Internal Circuitry
SPINDLE OUTPUT COMMON
J4
1 2
J5
1 2
OUT 14
OUT 15
SPINDLE ENABLE
SPINDLE REVERSE
OUT 13
SPINDLE DRIVE RESET
OUT 10
SPINDLE FORWARD
SPINDLE ORIENT
Jumper Setting for Direction Run Through Enable Jumper Setting for Direction Pulled to Common
J4 J5
Pin 1
J4
Pin 1
J5
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Analog Output Adjustment
Output voltage range can be set to 0 to +5VDC or 0 to +10VDC by setting jumpers J1, J2, and J3
according to the diagrams below. Trimming the output can be accomplished with VR1 and VR2
potentiometers. See the “RTK3L (Bottom) Board Connections” diagram for the location of adjustment
hardware. The analog levels are adjusted at the factory for the 0 to +10VDC range, so only slight adjustments
should be needed for each installation. Only adjust the “OFFSET” potentiometer (pot) (VR2) at the minimum
possible spindle speed. This adjustment is intended only to null the voltage level when 0 RPM is commanded.
The “GAIN” pot (VR1) should be used at maximum speed to match actual RPM with commanded RPM.
Adjustments to the analog output should be very minor and cannot be used to compensate for incorrect inverter
or control settings.
0 to 10 VDC Jumper Settings 0 to 5 VDC Jumper Settings
J1
Pin 1
J3 J2 J2J3
Pin 1
J1
Emergency Stop Connector
The E-stop connector has an input and output, unlike most RTK3 connectors. The input notifies the
control of an external E-stop press. The output allows an E-stop to be triggered by the PLC program. Because
the E-stop connector sources 24VAC, a 24VAC contactor coil must be used. This reduces the number of
connections at the cost of some versatility.
Internal Circuitry
24VAC E-stop Output
24 AC1
Output
OUT 1
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Fast I/O Operation
The Fast I/O is a hard-coded function that is enabled when output 40 is turned on in the PLC program.
The Fast I/O immediately turns off output 31 when a falling edge is detected on input 26. This is done
immediately before sending any data back to the control. The function is self-resetting - after output 31 is
turned off, output 40 must be turned on again in order to reactivate the Fast I/O. Using the Fast I/O prevents the
carousel from moving too far due to communication delays. When output 40 is off, output 31 and input 26
work normally. In the RTK3 implementation of the Fast I/O, input 26 is dedicated to a sourcing tool counter
sensor and output 31 controls the carousel enable relay. Output 40 is not a physical output, since using this
output for purposes other than Fast I/O enable could cause confusion.
Timing Diagram - Fast I/O Enabled Timing Diagram - Normal PLC Operation
OUT40
6mS
OUT31
INP26
30mS
OUT31
OUT40
INP26
Status Indicator LEDs
Six green indicator LEDs (lights) located on the bottom board display RTK3 status. All six LEDs will
be lit under normal operating conditions. Five of the LEDs indicate the presence of required operating voltages.
The 110VAC input feeds the power supply to generate these voltages. The “PLC OK” LED lights when the
RTK3 and motion control card (CPU10) have a working communication link. This LED will not be lit as soon
as power is applied. After the control software (CNC10) has initialized the motion control card, communication
can be established with the RTK3, which lights the “PLC OK” LED.
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Input Map
Input Specification Connection Location
Number Function Type Board Connector Pin
1 X- Limit Sourcing Bottom X- / X+ / Y- / Y+ LIMITS 1
2 X+ Limit Sourcing Bottom X- / X+ / Y- / Y+ LIMITS 3
3 Y- Limit Sourcing Bottom X- / X+ / Y- / Y+ LIMITS 5
4 Y+ Limit Sourcing Bottom X- / X+ / Y- / Y+ LIMITS 7
5 Z- Limit Sourcing Bottom Z+ / Z- LIMITS 1
6 Z+ Limit Sourcing Bottom Z+ / Z- LIMITS 3
7 W- Limit Sourcing Bottom W+ / W- / 5+ / 5- LIMITS 1
8 W+ Limit Sourcing Bottom W+ / W- / 5+ / 5- LIMITS 3
9 5th- Limit Sourcing Bottom W+ / W- / 5+ / 5- LIMITS 5
10 5th+ Limit Sourcing Bottom W+ / W- / 5+ / 5- LIMITS 7
11 Emergency Stop Sourcing Bottom ESTOP 1
12 Servo Drive Fault Sourcing Bottom DRV FAULT 2
13 TT1 Sourcing Bottom TT1 / AUX 1
14 Probe Sourcing Bottom DIGITIZE PROBE 1
15 Probe Detect Sourcing Bottom DIGITIZE PROBE 3
16 Error Check Internal
N
/A
N
/A N/A
17 Door Interlock Sourcing Bottom DOOR SWITCH 1
18 Low Lube Sourcing Middle LOWLUBE 1
19 Spindle Zero Speed Sourcing Bottom INVERTER 10
20 Spindle At Speed Sourcing Bottom INVERTER 13
21 Spindle Orient Complete Sourcing Bottom INVERTER 11
22 Tool Clamped Sourcing Bottom TOOL CLAMP/UNCLAMP 3
23 Tool Unclamped Sourcing Bottom TOOL CLAMP/UNCLAMP 1
24 Tool Release Switch Sourcing Bottom TOOL REL SW 1
25 Spindle Drive Fault Sourcing Bottom INVERTER 12
26 Tool Counter * Sinking Bottom CAROUSEL INPUTS 4
27 Carousel Out / TP Up Sinking Bottom CAROUSEL INPUTS 2
28 Carousel In / TP Dwn Sinking Bottom CAROUSEL INPUTS 1
29 Auxiliary 1 Sinking Bottom CAROUSEL INPUTS 3
30 Rotary Home Sourcing Bottom ROTARY INPUTS 1
31 Rotary Clamped Sourcing Bottom ROTARY INPUTS 3
32 Air Pressure Low Sourcing Bottom AIR LOW 1
33 NOT USED N/A
N
/A
N
/A N/A
34 NOT USED N/A
N
/A
N
/A N/A
35 NOT USED N/A
N
/A
N
/A N/A
36 NOT USED N/A
N
/A
N
/A N/A
37 NOT USED N/A
N
/A
N
/A N/A
38 NOT USED N/A
N
/A
N
/A N/A
39 NOT USED N/A
N
/A
N
/A N/A
40 NOT USED N/A
N
/A
N
/A N/A
41 NOT USED N/A
N
/A
N
/A N/A
42 NOT USED N/A
N
/A
N
/A N/A
43 NOT USED N/A
N
/A
N
/A N/A
44 NOT USED N/A
N
/A
N
/A N/A
45 NOT USED N/A
N
/A
N
/A N/A
46 NOT USED N/A
N
/A
N
/A N/A
47 NOT USED N/A
N
/A
N
/A N/A
48 NOT USED N/A
N
/A
N
/A N/A
49 NOT USED N/A
N
/A
N
/A N/A
50 NOT USED N/A
N
/A
N
/A N/A
51 NOT USED N/A
N
/A
N
/A N/A
52 NOT USED N/A
N
/A
N
/A N/A
53 NOT USED N/A
N
/A
N
/A N/A
54 NOT USED N/A
N
/A
N
/A N/A
55 NOT USED N/A
N
/A
N
/A N/A
56 NOT USED N/A
N
/A
N
/A N/A
57 NOT USED N/A
N
/A
N
/A N/A
58 NOT USED N/A
N
/A
N
/A N/A
59 Range 3 / Arm Clamp Sinking Bottom AUX SPINDLE INPUTS 1
60 Range 2 / Arm Stop Sinking Bottom AUX SPINDLE INPUTS 2
61 Range 1 / Arm Home Sinking Bottom AUX SPINDLE INPUTS 3
62 Spindle Chiller OK Sinking Bottom AUX SPINDLE INPUTS 4
* Fast I/O Related