CS-Lab CSMIO/IP-A User manual

Hardware version: v2
Firmware version: v2.030
Rev: 1.1
© copyright 2015 – CS-Lab s.c.

INDEX
1. General......................................................................................................................................... 6
1.1 Signs used in this guide.................................................................................................................. 6
1.2 Content .......................................................................................................................................... 7
1.3 Standards compliance.................................................................................................................... 8
1.4 Specification .................................................................................................................................. 8
2. Safety........................................................................................................................................... 9
2.1 Example of direct E-Stop signal connection .................................................................................. 10
2.2 Example of E-Stop Signal connection using PILZ module.............................................................. 11
3. Recommendations for mechanical installation ................................................................................ 12
3.1 Examples of components arrangement in a control cabinet. ......................................................... 12
3.1.1 Block scheme pictorial view .............................................................................................. 12
3.1.2 Control cabinet made by CS-Lab Company......................................................................... 13
4. Connectors, controls and electrical installation of the device............................................................ 14
4.1 Connectors arrangement on the device......................................................................................... 14
4.2 Analog inputs/outputs connector.................................................................................................. 15
4.2.1 Signals on a Terminal Block connector .............................................................................. 16
4.2.2 Example – connection and configuration of FRO and SRO potentiometers........................... 17
4.3 Encoder inputs connector (0 / 1 / 2).............................................................................................. 18
4.3.1 Signals on a Terminal Block connector .............................................................................. 19
4.3.2 Example - connection of an encoder to Ch0 channel........................................................... 19
4.4 Encoder inputs connector (3 / 4 / 5).............................................................................................. 21
4.4.1 Signals on a terminal block connector ............................................................................... 21
4.5 Digital inputs connector (0-11) ..................................................................................................... 22
4.5.1 Input circuits construction ................................................................................................ 23
4.5.2 Signals on a terminal block connector ............................................................................... 23
4.5.3 Examples - input signals connection.................................................................................. 24
4.6 Digital inputs connector (12-23) ................................................................................................... 26
4.6.1 Signals on a terminal block connector ............................................................................... 26
4.7 Digital outputs connector (0-15) ................................................................................................... 27
4.7.1 Output circuits construction.............................................................................................. 28
4.7.2 Signals on a terminal block connector ............................................................................... 28
4.7.3 Example – spindle activation signal................................................................................... 29
4.8 Expansion modules connector...................................................................................................... 30
4.9 Power connector .......................................................................................................................... 31
4.10 Communication connector – Ethernet .......................................................................................... 31
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4.11 Recommended cables................................................................................................................... 32
4.12 LED lights meaning....................................................................................................................... 33
4.12.1 Types and location of the LEDs.......................................................................................... 33
4.12.2 LEDs state description - STATx.......................................................................................... 34
4.13 Example - a scheme view of a 3-axis plotter (XYZ) ........................................................................ 35
4.13.1 Power supply.................................................................................................................... 35
4.13.2 Servo drives connection.................................................................................................... 36
4.13.3 Limit switches and E-STOP signal...................................................................................... 37
4.13.4 Inverter connection using analog output. ........................................................................... 38
4.13.5 Automatic control of drives power supply (HV)................................................................... 39
5. Recommendations and drives selection (motors drives)................................................................... 40
6. Precise homing with encoder INDEX signal ..................................................................................... 41
6.1 Homing on "index" enable ............................................................................................................. 41
7. LAN connection and configuration ................................................................................................. 42
7.1 Direct connection to the PC .......................................................................................................... 42
7.1.1 Windows®XP configuration ............................................................................................... 42
7.1.2 Windows®7 configuration................................................................................................. 43
7.2Local network with router and DHCP............................................................................................. 46
8. Mach3 program – general information ........................................................................................... 47
8.1 Recommended PC configuration................................................................................................... 49
9. Software installation.................................................................................................................... 50
9.1 Mach3 installation........................................................................................................................ 50
9.2 Microsoft®.Net installation (older operating systems).................................................................. 51
9.3 Installation of CSMIO/IP firmware................................................................................................. 51
9.4 Administrator rights in Windows® Vista and Windows® 7 ............................................................ 53
10.Mach3 program configuration ....................................................................................................... 54
10.1 Configuration profile creation ....................................................................................................... 54
10.2 The first run.................................................................................................................................. 55
10.3 Configuration of axes used in a machine....................................................................................... 57
10.4 Configuration of digital input signals ............................................................................................ 58
10.5 Configuration of digital output signals.......................................................................................... 60
10.6 Configuration of spindle and cooling............................................................................................. 62
10.6.1 Analog output configuration.............................................................................................. 62
10.6.2 Problematic PWM Control function.................................................................................... 63
10.7 Configuration of resolution, speed and acceleration...................................................................... 64
10.8 Configuration of directions, homing and software limits................................................................ 65
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10.9 Configuration functions in a plug-in window ................................................................................. 67
10.9.1 Axes special functions...................................................................................................... 67
10.9.2 Spindle configuration........................................................................................................ 70
10.9.3 Override sources – feed speed and spindle revs corrections source selection...................... 71
10.9.4 Plasma – additional functions for plasma cutters .............................................................. 72
10.9.5 Misc IO – Special functions related to I/O .......................................................................... 72
10.9.6 Other – other plugin functions........................................................................................... 73
10.10Selection of inch/mm units........................................................................................................... 75
10.11Some parameters in the General Config window ........................................................................... 75
11.PID controller (regulator).............................................................................................................. 77
11.1 What is PID controller................................................................................................................... 77
11.2 PID controller terms (parameters) operation................................................................................. 78
11.2.1 The proportional term – P................................................................................................. 78
11.2.2 The integral term – I ......................................................................................................... 78
11.2.3 The Derivative term – D .................................................................................................... 79
11.2.4 The „sixth” sense – the mysterious KVFF parameter ............................................................ 79
11.3 The actual controller in CSMIO/IP-A.............................................................................................. 80
11.4 The order of controllers tuning...................................................................................................... 80
11.5 „PID Regulator Tuning” window..................................................................................................... 81
11.6 Manual PID regulator tuning procedure in CSMIO/IP-A.................................................................. 83
11.7 PID tuning – practical tips ............................................................................................................ 85
11.7.1 Slave axis......................................................................................................................... 85
11.7.2 An axis with toothed racks (straight toothed)..................................................................... 85
11.7.3 Laud noises at standstill ................................................................................................... 86
11.7.4 Cannot start tuning because an axis does not move. .......................................................... 86
11.7.5 An axis after activation jerks or starts to move with max. speed.......................................... 86
11.7.6 Cannot tune an axis .......................................................................................................... 86
11.8 Autotuning – Automatic PID tuning .............................................................................................. 87
12.First tests ................................................................................................................................... 89
12.1 Checking the input signals............................................................................................................ 89
12.2 Verification of axes scaling and motion directions........................................................................ 90
12.3 HOMING and software limit switches test..................................................................................... 91
12.3.1 First homing..................................................................................................................... 91
12.3.2 SoftLimit switches............................................................................................................ 91
12.4 Test of spindle and cooling........................................................................................................... 92
13.Sample treatment step by step...................................................................................................... 93
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13.1 Project and G-Code files preparing................................................................................................ 93
13.2 Preparing machine and Mach3 program........................................................................................ 97
13.3 We begin the treatment ................................................................................................................ 99
14.A few practical notes about Mach3 program and CSMIO/IP-A ..........................................................101
15.VisualBasic® macros ...................................................................................................................104
15.1 Automatic tool-length measurement........................................................................................... 104
15.1.1 Configuration ................................................................................................................. 105
15.2 Automatic tool change macro..................................................................................................... 106
Addition A – Slave axis configuration example....................................................................................107
Defining axes used in Mach3 program ................................................................................................. 107
Axis scaling and configuration............................................................................................................. 107
Activation and choice of slave axis....................................................................................................... 107
LIMIT and HOMING switches................................................................................................................ 108
Axis direction settings ......................................................................................................................... 108
Manual feed test.................................................................................................................................. 108
Automatic reading of HOME switches position difference .................................................................... 108
Geometry correction mode activation .................................................................................................. 109
Addition B – –CSMIO/IP-A firmware update .......................................................................................110
How to check your current firmware version ........................................................................................ 110
Update application (uploader).............................................................................................................. 110
Plugin file update................................................................................................................................. 111
Update verification .............................................................................................................................. 111
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1. General
The CSMIO/IP-A product was designed for professional customers, who want to equip their machine tool
with an efficient, stable and flexible CNC control system for a reasonable price.
The main designing assumption was working stability – hence the PC connection via Ethernet (its physical
layer is galvanically isolated and protocols we use ensure reliable and fast transmission even in tough
industrial environment). Practically any others interfaces do not provide the continuity and reliability of
transmission on such a high level as the ETHERNET. That is why it is currently the worldwide standard for
high-speed digital communication.
Another important assumption was simplicity of installation. CSMIO/IP-A does not require any external
electronics for proper operation. Inputs/outputs signals are inside optically isolated, filtered, protected
against short circuit, overheating etc. Of course, all I/O signals are adjusted to industry standard 24V. The
device is enclosed in a compact cover, mounted on a DIN-rail, what makes that mechanical and electronic
installation in a control cabinet takes less time and is even simpler.
CSMIO/IP-A product works with Mach3 program because of its low price, popularity and enormous ability
to adapt to specific requirements. To meet customers' needs, who prefer +/- 10V servo drive control
standard, the CSMIO/IP-A was equipped in such an interface, and very fast encoder inputs allow for taking
full advantage of encoders with large number of pulses per rotation, and the same let you to achieve such
a precision and speed, which previously were unavailable in this price sector.
1.1 Signs used in this guide
________________________________________________________________________________________________________
Potential danger, possible injury risk
________________________________________________________________________________________________________
Useful information, tips
________________________________________________________________________________________________________
Warning, failure to comply with these warnings may lead to inappropriate functioning or damage of
the device
________________________________________________________________________________________________________
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1.2 Content
The CSMIO/IP-A device is placed in a cartoon box with DB->Terminal Block adapters for easier wires con-
nection in a control cabinet. More content details below:
•CSMIO/IP-A - CNC controller
•3x DB25Terminal block (2 pcs.)
•Ethernet connection wire
•DB25 connection tape (6 pcs.)
•„Phoenix” 3pin power plug
•CD with electronic version of the user guide and software
(always check if there is a newer version on http://www.cs-lab.eu )
In case of lack of any elements listed above, please contact your distributor.
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1.3 Standards compliance
The CSMIO/IP-A controllers were designed and made in accordance with the national and international
standards for industrial control systems based on electronic components:
•Detailed requirements for programmable controllers: working characteristics, shock resistance,
safety etc. EN61131-2 (IEC1131-2), CSA 22.2, UL508
•Compliance with European Guidelines (low voltage, level of electromagnetic interference
Electromagnetic Compatibility), the CE marking.
•Electrical and non-combustible properties of insulation materials: UL 746C, UL 94, etc.
•The Product made in lead-free technology, RoHS compliant.
1.4 Specification
Parameter
Value
Digital inputs number
24
Digital outputs number
16
Analog inputs number
4
Analog 0-10V outputs number
2
Analog +/-10V outputs number
6
Encoder inputs number
6
Supply voltage
24VDC +/-10%
Power consumption
5W
Maximum voltage on the in/out lines
30VDC
Maximum load of an output line
250mA
A voltage range of analog inputs
0-10VDC
Maximal load of analog outputs
50mA
Axis drives control type
Analog +/-10V
Maximum frequency of an encoder signal
6MHz
Encoder type
Incremental TTL
Encoder signal kind
Differential
PC connection
Ethernet 10/100Mb
Ambient temperature range
0oC do +60oC
Relative humidity
10% to 95%
(without condensation)
„KernelSpeed” a configuration parameter in Mach3 has no influence on CSMIO/IP working speed.
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2. Safety
CSMIO / IP-A device is powered by 24V safe voltage. I/O control lines are optically isolated also PC con-
nection is galvanically isolated. The device does not constitute direct threat to health and life of a user.
Designing a complete control system (control cabinet), you should draw attention to several issues, so
that the entire system does not pose any hazard during use.
Always use NC contacts (Normal Closed) for limit switches and safety switch. Thanks to it - a wiring mis-
take or i.e. plug-ins disconnection will stop the machine.
Pay special attention to an emergency stop circuit. Control system must be designed in such a way that
when you press an emergency stop mushroom, controlled machine stops immediately in all axes. You
should also take into account the possibility of failure of particular system components such as main
controller, or axis drives.
For that purpose you can use (not required) a standard safety relay (i.e. from PILZ Company). The safety
switch mushroom, FAULT signals of drives and inverter and eventually other alarm signals – you should
connect to input circuits. Output or outputs - depending on a used module - should be connected to
CSMIO/IP-A controller, and defined as emergency stop. Outputs of security module should be also
connected to axis drives, inverters, etc. This way we get double protection – if, by inappropriate
configuration or CSMIO/IP-A controller failure - the emergency would not work, then information goes to
axis drives, which can properly respond to it. It works both sides: if drives would not react, you always
have the controller.
The CSMIO/IP-A controller in active state on the input line - defined as an E-Stop stops the motion on all
output channels within 1ms.
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2.1 Example of direct E-Stop signal connection
In example above we used direct emergency signals connection. Such a connection is very easy and at the
same time it ensures satisfying safety level. Of course the easiest way is to connect the E-Stop only to
CSMIO/IP-A but then we lose double protection and it’s no longer so safe solution.
As a switch (mushroom) of emergency stop always use special switchers, specially designed for that. They
have different construction and you can be actually 100% sure that the circuit will be disconnected after
pressing the mushroom. Using common NC contacts is dangerous. It’s worth to use contacts from repu-
table companies. They are a little bit more expensive but their quality is much, much better.
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