Isel IT116 flash User manual

isel Germany AG, D-
36124 Eichenzell,
Opera
Eichenzell, Bürgermeister
-Ebert-Str. 40 (06659)981-0
IT116 flash
IT116 mini
Operating Instr ction
[phone]

All information, technical data and dimensions contained in this booklet correspond to
the technical state at the moment of p blication. However, possible misprints or
mistakes cannot be r led o t. We will appreciate all s ggestions for improvement and
error notes.
We wo ld like to point o t that all sed software and hardware names of the respective
companies generally are s bject to protection by brand, trademark and patent law.
All rights reserved. It is prohibited to process, d plicate or reprod ce this booklet
partially or on the whole in any form (print, copy, or other proced re) witho t written
permission of isel Germany AG
isel Germany AGisel Germany AG
isel Germany AG.
This booklet has been translated from the original German version into English
lang age. It does not lay claim to completeness nor flawlessness. In case of do bt the
German original has validity.
isel Germany AG
isel Germany AG isel Germany AG
isel Germany AG
controllers are conc rrent with CE norms and marked
accordingly. Commissioning of all other parts or components, for which
CE safety reg lations apply, is prohibited ntil all respective req ests
are met.
isel Germany AG
isel Germany AG isel Germany AG
isel Germany AG
as the man fact rer cannot take over g arantee if yo
change the controller in any way.
The EMC test is valid only for the controller’s original config ration ex
works, i.e. the delivery state.
Man fact rer: isel Germany AG
Bürgermeister-Ebert-Straße 40
D-36124 Eichenzell
Tel.: [phone]
Fax: [phone]
Email: a [email protected]
http://www.isel.com
Stat s: 07/2014 RL
Technical specifications s bject to change.
Up to date Operating instr ctions and man als for download yo
can find here:
www.isel-data.de/man als

Table of contents
1 Introduction ....................................................................................................... 4
2 Scope of delivery .............................................................................................. 6
3 Technical data ...................................................................................................
4 Control and notification elements ................................................................... 8
4.1 Front side IT116 mini / IT116 flash ...................................................................... 8
4.2 Back side IT116 mini / IT116 flash ..................................................................... 10
4.3 DIP - switch settings .......................................................................................... 15
4.3.1 DIP-switch settings on IT116 flash .............................................................................. 16
4.3.2 DIP-switch settings on IT116 mini ............................................................................... 17
5 Electrical connection and initial operation ................................................... 19
6 PALPC: User programming for CNC mode and download ......................... 20
6.1 Install programming software PALPC.exe ......................................................... 20
6.2 User programming for CNC mode and download .............................................. 22
Declaration of Conformity .............................................................................. 24
8 Bibliography .................................................................................................... 24
9 Index ................................................................................................................ 25
Table of figures
fig re 1– motor mod le connector 2- phase stepper motor ......................................... 11
fig re 2 – connection for external sec rity circ it ......................................................... 12
fig re 5 – imp lse control connection ......................................................................... 14
fig re 6 – digital inp ts wiring ...................................................................................... 14
fig re 7 – digital o tp ts wiring .................................................................................... 15

IT116 flash / IT116 mini operating instr ction
page - 4
1 Introduction
The controllers IT116 flash / IT116 mini are powerf l 1-axis-controllers for n merically
controlled motion of a linear or rotary axis with a 2-phase-stepper motor. The
controller has each fo r binary inp ts / o tp ts. For comm nication between a PC /
Notebook ( nder Windows operation system) and the controller a serial interface
(RS232) is sed.
The microprocessor (DSP) based controller incl des an internal flash memory with a
size of 128 KBytes for storing the firmware and the application program. The
controller is prepared for loading application programs from USB memory stick
(future option).
The controllers IT116 flash / IT116 mini have the feat re of micro stepping:
• IT116 flash: 128 micro steps per f ll step
• IT116 mini: 8 micro steps per f ll step
This feat re allows a very smooth motion of the connected 2-phase-stepper motor.
The a tomatic c rrent draw down red ces power dissipation as in the amplifier as in
the stepper motor.
The peak c rrent is 3,3A (IT116 mini) resp. 4,2A (IT116 flash), it can be red ced by
DIP switch to conform parameters of different stepper motors.
Using the imp lse inp ts for external Start, Stop and Reset those f nctions can be
remote controlled by an operator panel or master controller like a PLC.
The integrated sec rity circ it with safety category 3 has also a remote interface for
integration in a higher-level sec rity circ it.
Safety symbols
Attention
This symbol signalizes that there is danger for persons life and
health.
Danger
This symbol signalizes that there is danger for material, machine and
environment.
Information
This symbol signalizes important information.

IT116 flash / IT116 mini operating instr ction
page - 5
Safety instructions
 The 1-axis-controllers IT116 flash / IT116 mini are designed to
c rrent technical and recognized r les.
 The device may only be sed if it is in correct condition. Any fa lts
have to be eliminated immediately. Neither children nor non-
a thorized persons are allowed to p t the device into operation.
 The device may only be sed for the intended se: control of a linear
or rotational axis with br shed (MC1-10), br shless (MC1-20) DC
servo motors or 3-phase stepper motors (MC1-30) p to 500 W and
integrated incremental meas rement system (encoder) in CNC or
DNC mode.
 All work with the 1-axis controller IT116 flash / IT116 mini, especially
initial operation, installation as well as external wiring m st be
exec ted by a thorized personal regarding electrical ind stry r les
and accident prevention reg lations.
 Assembly and se of operating material has to be according to
machine directive 2006/42/EC resp. Low voltage directive
2006/95/EC. In case of in proper se even the observation the
respective r les and standards does not protect against physical
damages and damage to property.
 Ambient temperat re: +5°C to +40°C
 Storage temperat re: –25°C to +70°C
 Pay attention that there is eno gh free zone on the lo vers for air
circ lation. Ignoring this fact ca ses overheat and potential defect of
the controller.
 Do not expose the device to high h midity or high vibrations.
 Please take care of the instr ction man al. Be s re that all sers
know the instr ctions.
 Ignoring the instr ction man al can lead to damage, heavy physical
damage or to death.

IT116 flash / IT116 mini operating instr ction
page - 6
2 Scope of delivery
The controller will be delivered with the following components:
IT116 flash (Part.-No. 381016 (230VAC), 381016 0115 (115VAC))
• Stepper motor drive mod le in 22 TE-cartridge case, incl. power s pply nit
115V/230VAC
• Opposite connector controller side (DIN 41612 F24/H7 socket connector,
solder pin)
• Opposite connector power s pply nit side (DIN 41612 H15 socket connector,
solder pin)
• Serial interface cable for IBM compatible PCs (9 pin. S b D-female – RJ45-
male)
• Operating instr ction
IT116 mini (Part.-No. 381017)
• Stepper motor drive mod le in 22 TE-cartridge case, incl. power s pply nit
115V/230VAC
• Opposite connector controller side (DIN 41612 F24/H7 socket connector,
solder pin)
• Opposite connector power s pply nit side (DIN 41612 H15 socket connector,
solder pin)
• Serial interface cable for IBM compatible PCs (9 pin. S b D-female – RJ45-
male)
• Operating instr ction

page - 7
3 Technical data
IT116 flash IT116 mini
dimensions (B x H x T): 105 x 111 x 320 105 x 111 x 200
weight: 2380 g 1125 g
safety class: IP20 IP20
power supply: 115/230VAC 50/60 Hz (switchable) 90 - 264VAC 50/60Hz
power consumption: 250 W 150 W
peak current: 4,2 A 3,3 A
rated current: 3,5 A 2,3 A
am ient temperature: 0°C - +50°C 5°C - +40°C
storage temperature: -20°C - +65°C -25°C - +70°C
humidity: maxim m 90% not condensing maxim m 95% not condensing
CPU: 32Bit CPU kernel
program memory: 128KByte flash
communication: RS232 (19200 ba d, 8 data bit, 1 stop bit, no parity)
digital inputs: 4 via optoco pler (inp t c rrent ca. 8mA)
digital outputs: 4 relays, close contact 24VDC/1 A max
maximum input frequency: 40 kHz (f ll step) 15 kHz (f ll step)
safety category: 2
stop category: 0
fuse: 2 A/250V time lag 1 A/250V time lag

IT116 flash / IT116 mini operating instr ction
page - 8
4 Control and notification elements
4.1 Front side IT116 mini / IT116 flash
1 - Power-button
Use this b tton to switch on motor power s pply voltage for the motor power
amplifiers.
Conditions for switch on:
- Main power switch on the controller back side is switched on
- Emergency stop b tton is p lled o t
Be sure that the contacts for external emergency stop switch
on the remote connector are ridged!
If power s pply voltage is s ccessf lly switched on the power b tton is lighted green.
2 – Emergency stop button
T rns off the power s pply for the motor power amplifiers and the working spindle in
case of any danger. This means dangers for the ser’s health or machine safety.
If you push the emergency stop switch the motor power supply will
be switched off immediately (stop category 0, EN 60204-1) and any
axes motion will be stopped. The main power supply voltage of
115/230VAC lies still on the device, only the motor power supply
voltage for the amplifiers is switched off.

IT116 flash / IT116 mini operating instr ction
page - 9
3 - LED – power
This LED signalizes that the net power s pply voltage is switched on by the main
switch on the back side of the controller.
4 - LED – diagnosis (future extension)
In case of any fa lt a blink code will be shown.
5- LED – over temperature
This LED signalizes a over temperat re of the motor power amplifier.
LED only availa le on IT116 mini!
6- Reset button
Use this b tton to reset the micro processor and the motor power amplifier. All
activities will be interr pted and signal o tp ts are set to defa lt state. Possible
appeared step losses will be ignored!
- Start button
Press this b tton to exec te a stored ser program in the flash memory of the
controller.
8 - Stop button
Use this b tton to stop a r nning ser program / axis motion. Press the start b tton to
contin e the exec tion of the ser program / axis motion.
9 - USB slot (future extension)
This interface is sed to connect a USB flash drive download ser programs in the
flash memory of the controller.
10 - RS232 programming interface
Comm nication between IT116 and control PC is realized via a serial interface
(RS232). Use the delivered comm nication cable for connection. Pl g the S b-D (9-
pin) connector to a COM port on the PC and the RJ45 connector to the controller front
side socket.
A software protocol realizes the fa ltless transmission of the ASCII characters.
Therefore it’s necessary that both systems respect the comm nication protocol:
• The connected control PC sends a command which ends with a line end
character [CR, char(13).
• The processor nit q its the exec tion or storing of a command with the
q itting signal 0[char(48)] or ret rns an occ rred error with an ASCII character
neq al 0.
Data transfer parameters on IT116 are defined as follows:
• 19200 ba d, 8 data bits, 1 stop bit, no parity

IT116 flash / IT116 mini operating instr ction
page - 10
4.2 Back side IT116 mini / IT116 flash
IT116 flash IT116 mini

IT116 flash / IT116 mini operating instr ction
page - 11
AC input – main net input module
The net inp t mod le consists of net inp t socket, net filter, f se holder nd net main
switch. Connect the controller via delivered net cable to a free receptacle. After that
yo can switch on the controller with the net main switch.
Stepper-motor – connector
S b-D 9-pin connector for motor mod le (CNC axis).
Connect / disconnect the S b-D pl g only if controller is switched off.
dieses Ignoring this instr ction can lead to damage the motor cable or
stepper motor amplifier.
p
in
description
1 motor phase 2B
2 motor phase 2A
3 motor phase 1B
4 motor phase 1A
5 +24VDC
6 brake (+24VDC/1,8A o tp t with reference potential GND)
7 limit switch 2 (Inp t  +24VDC, if limit switch 2 is not act ated: NC
8 GND
9 limit switch 1 (Inp t  +24VDC, if limit switch 1 is not act ated: NC
fig re 1– motor mod le connector 2- phase stepper motor

IT116 flash / IT116 mini operating instruction
page - 12
Remote - interface to security circuit
This connector is used to integrate the controller into a higher ranked security circuit
system. Please note that the external power utton input is only usea le if the power
utton in the front side of the controller is switched off. That will e realized y setting
a jumper on the control oard. Therefore you have to unscrew to front cover of the
controller (look at figure 3, 4)
p
in
description
1 potential free contact (make contact)
2 potential free contact (make contact)
3 external emergency stop ( rake contact 1), 11
4 external emergency stop ( rake contact 1), 12
5 external emergency stop ( rake contact 2), 21
6 external emergency stop ( rake contact 2), 22
7 external power (make contact)
8 external power (make contact)
figure 2 – connection for external security circuit
The length of the connection cable for the external emergency
stop button must not more than 5m.

IT116 flash / IT116 mini operating instruction
page - 13
figure 3 – IT116 flash, jumper JP4 for power e tern / intern
figure 4 – IT116 mini, jumper JP4 for power e tern / intern

IT116 flash / IT116 mini operating instruction
page - 14
Impulse - interface impulse control
Use this connector to integrate the function keys start button, stop button and reset
from the controller front side as external signal inputs
p
in
description
1 start
2 +24VDC
3 stop
4 +24VDC
5 reset
6 +24VDC
figure 5 – impulse control connection
Input - digital inputs
The controller IT116 flash / IT116 mini has 4 digital user inputs Use these inputs to
connect external devices like sensors, switches or outputs from other devices All
inputs are opto-decoupled If +24VDC lies on the input a logical HIGH is signalized
Not connected (e g switch open) a logical LOW is signalized
The input current is about 8 mA
figure 6 – digital inputs wiring

IT116 flash / IT116 mini operating instruction
page - 15
Output - digital outputs
The controller IT116 flash / IT116 mini has 4 digital user outputs. Use these outputs
to connect external devices like rela s, or inputs from other devices. The maximum
load of each rela output is 24 VDC/1 A.
figure 7 – digital outputs wiring
4.3 DIP - switch settings
The DIP-switches are used to configure the motor amplifier. Depending on controller
t pe the DIP switch is based on the top side (IT116 flash) or on the back side (IT116
mini) of the controller.
Configuration of the controller should be done before first startup so
that a connected motor will not be damaged because of an incorrect
power setting.
IT116
flash
IT
116
m
ini
DIP switch is based on the
top side of the controller.
DIP switch is based on the
back side of the controller.
1:
current setting 1
2: current setting 2
3: current setting 3
4: current reduction
5: step resolution 1
6: step resolution 2
7: step resolution 3
: step resolution 4
1:
switch motor brake „manuall “
2: current reduction
3: step resolution 1
4: step resolution 2
5: current setting 1
6: current setting 2

IT116 flash / IT116 mini operating instruction
page - 16
4.3.1 DIP-switch settings on IT116 flash
current setting (DIP-switch 1, 2, 3)
Use the DIP switches 1, 2 and 3 to set the current of the motor The following table
shows the motor current (RMS) setting for the different switch positions:
The factory set of the motor current is 2,03 A (RMS)on all motor
power amplifiers.
current reduction (DIP-switch 4)
Use the DIP switch 4 to set the automatic current reduction If the DIP switch is set to
ON the automatic current reduction is deactivated DIP switch in state OFF means
that the current is set to 60% of the motor current if the motor standstill
DIP 4 current reduction in
ON 0% reduction (deactivated)
OFF 60% reduction
If the hol ing torque is sufficient, the activate automatic current
re uction is recommen e .

IT116 flash / IT116 mini operating instruction
page - 17
step resolution (DIP-switch 5, 6, 7, 8)
Use the DIP switches 5, 6, 7 and 8 to set the step resolution Setting the factor to a
higher value causes a smooth motion of the motor but the maximum reachable
velocity will taking down Also the motor torque will be reduced to 75% in microstep
mode The following table shows the DIP switch settings for the different step
resolutions:
micro steps
steps
/
rev.
(1,8 °
motor
)
SW5
SW6
SW7
SW8
2 400 OFF ON ON ON
4 800 ON OFF ON ON
8 1600 OFF OFF ON ON
16 3200 ON ON OFF ON
32 6400 OFF ON OFF ON
64 12800 ON OFF OFF ON
128 25600 OFF OFF OFF ON
5 1000 ON ON ON OFF
10 2000 OFF ON ON OFF
20 4000 ON OFF ON OFF
25 5000 OFF OFF ON OFF
40 8000 ON ON OFF OFF
50 10000 OFF ON OFF OFF
100 20000 ON OFF OFF OFF
125 25000 OFF OFF OFF OFF
The Factory set of the step resolution is 800 steps/rev for all motor
power amplifiers.
4.3.2 DIP-switch settings on IT116 mini
switch motor brake „manually“ (DIP-switch 1)
Use this function to switch the motor brake manually It can be necessary if you wish
to move the motor with a hand wheel if main power supply voltage is switched off In
nromal mode the DIP switch should be set to OFF
DIP
1
brake
ON output brake is always switched on
OFF output brake will be switched automatically

IT116 flash / IT116 mini operating instruction
page - 18
current reduction (DIP-switch 2)
Use the DIP switch 2 to set the automatic current reduction If the DIP switch is set to
ON the automatic current reduction is deactivated DIP switch in state OFF means
that the current is set to 50% of the motor current if the motor standstill
DIP 4 current reduction in
ON 0% reduction (deactivated)
OFF 50% reduction
If the hol ing torque is sufficient, the activate automatic
current re uction (DIP2 = OFF) is recommen e .
step resolution (DIP-switch 3,4)
Use the DIP switches 3 and 4 to set the step resolution Setting the factor to a higher
value causes a smooth motion of the motor but the maximum reachable velocity will
taking down Also the motor torque will be reduced to 75% in microstep mode The
following table shows the DIP switch settings for the different step resolutions:
micro steps steps/rev
(for 1,8° motor)
max velocity in kHz DIP 3 DIP 4
1 200 15 KHz ON ON
2 400 7,5 KHz OFF ON
4 800 3,75 KHz ON OFF
8 1600 1,875 KHz OFF OFF
current setting (DIP-switch 5,6)
Use the DIP switches 5 and 6 to set the current for the motor It is possible to set the
current in four steps:
current in A DIP 5 DIP 6
3,33 A ON ON
2,50 A OFF ON
1,67 A ON OFF
0,67 A OFF OFF

IT116 flash / IT116 mini operating instruction
page - 19
5 Electrical connection and initial operation
Preparation
Before first startup of the controller please check the scope of delivery The following
parts should be included:
- Net power supply cable
- Null modem cable Sub-D 9-pin RJ45
- Package with connectors
- Operating instruction
If all this parts are included you can begin initial operation
Provide all electrical connections
Connectors
- Connect Net power supply cable
- Connect axis (motor) with the controller IT116 (back side)
configuration
- Set DIP-switches (see chapter 4 3)
Initial operation
- Switch on controller with main power switch on the back side
- Check if power LED lights
- Check if emergency switch is pulled out
- Push power button on the front of the controller
- If a user program is saved on the controllers flash memory you can press the
start button to execute the program
- If no user program is saved in the flash memory you have to download your
program from PC to controller (future extension – loading a user program from
an USB flash device)
- Now it should be able to start execution of the program by pressing the start
button
- If you have not written a user program you should be write your first user
program with help of the software PALPC 2 1

IT116 flash / IT116 mini operating instruction
page - 20
6 PALPC: User programming for CNC mode and download
Creating user programs for 1-axis-controller IT116 flash /IT116 mini is realized with
the software PALPC exe The implementation method is simple and described in /3/
Analyze technological problem definition:
• Layout program algorithm (solve problem definition)
• Implementation of the control algorithm into a PALPC source program * ppc; edit
code with text editor
• Compile PALPC source file with PALPC compiler; on faultless translation an
output file * out is created by the compiler
• Download output file * out into the flash memory of 1-axis-controller MC1
• Start program and check control behavior regarding technological problem
definition
6 1 Install programming software PALPC exe
To install PALPC software do the following:
1 Insert PALPC 2 1 (Part -No : Z11-331810) installation CD in your PCs / Notebooks
CD/DVD drive The following window will be shown