MachMotion IO6 V4.0 User manual

MachMotion
IO6 V4.0 Breakout Board Manual
(with Parallel Port)
Version 4.0
Released 08/0 / 0
MachMotion
45 8 County Road 7240
Newburg, MO 65550
www.machmotion.com

2
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**************WARNING**************
Improper installation of this motion control interface can cause DEATH,
INJURY or serious PROPERTY DAMAGE. Do not attempt to install this
board unless you are a properly qualified electrical engineer and system
integrator. Not every detail of the installation is included here. A
familiarity with electronic circuits, power circuits, and the MACH3 control
is a pre-requisite to knowing how to install or use this equipment.
**************WARNING*************

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Table of Contents
MachMotion IO6 Layout .................................................................... 3
IO6 General Description ................................................................... 4
Features .............................................................................................. 4
Input & Output List ............................................................................... 4
Use of this manual ................................................................................ 4
IO6 System Requirements ................................................................ 4
• 2 C arallel ports ........................................................................... 4
• ower Requirements ........................................................................ 4
Description of the interface assemblies ............................................ 5
2. Digital (pulse and direction) interface for 6 axis motion control ........... 6
a. Differential step and direction interface ............................................................. 6
3. Spindle Control Overview ............................................................... 7
4. IO6 CW and CCW relay outputs ...................................................... 8
5. I06 analog spindle voltage output ................................................... 8
6. Configuring the 0-10V analog output ............................................... 8
7. I06 Inputs for measuring spindle R M ............................................. 9
9. Opto-Isolated digital inputs terminals ............................................ 10
1. +24 V Limit Switch Input ......................................................................................................... 13
2. PNP Proximity Sensor .............................................................................................................. 13
Opto sensor input ........................................................................................................................... 13
3. NPN Proxy Switch +5V only. .................................................................................................... 14
Opto sensor input ........................................................................................................................... 14
4. +5V input si nal or drive error input ....................................................................................... 14
5. +24V si nal input ..................................................................................................................... 15
6. Digitizing robe Input ................................................................................... 15
11. Digitizing probe input terminal ...................................................... 16
12. Estop terminals .......................................................................... 16
13. Error Input ................................................................................. 16

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14. Very high speed opto-isolated inputs ............................................. 16
15. Relay outputs ............................................................................. 17
Relay Output Configuration (See page 3) ....................................... 8
Mod-Jack Pin-outs .......................................................................... 20

3
****************************************************************************
Warning
Do not use 115VAC on any part of the breakout board including the relay
outputs. It could cause serious damage to your board.
****************************************************************************
MachMotion IO6 Layout

4
IO6 General Description
MachMotion’s IO6 breakout board provides a flexible, plug-in-play interface for CNC controls
using C based parallel port control software. The breakout board interfaces to the servo
drives and spindle relay outputs with RJ45 mod jacks and hoenix screw terminals for
flexibility.
Features
•Single unregulated 24 VDC supply power.
•Digital differential and single ended TTL ( ulse and Direction) interfaces for motion control
for up to six axes.
•2 Amp bare relay contact outputs.
•Opto-isolated inputs.
•Complete spindle speed control circuitry and spindle feedback.
•Charge pump safety circuit integrated to control all outputs.
•On board switching +5V regulated power supply.
•Drive enable can be configured at 5V, 24V, GND, or a user supplied voltage.
•Total of 34 I/O.
Input & Output List
•12 - Outputs generally used for step and direction for 6 axes. If less than six axes are to
be controlled, some of these 12 outputs can be used for general purpose outputs.
•10 - Inputs (1 input is typically used for spindle encoder input). These inputs can be
configured for 5V inputs, 12-24V inputs, N or N N sensors.
•8 - 2 Amp 5-24V relay outputs.
•2 - Spindle relay outputs.
•1 - Analog output 0-10V.
•3 - Charge pump outputs.
•E-Stop circuit
•Digitizing probe interface with 12V power supply.
Use of this manual
This manual explains the functions of the IO6 in a logical progression. To understand how to
safely connect and use the IO6, it is important that the system integrator read and understand
the manual in its entirety before attempting to set up and use this I/O board.
IO6 System equirements
•2 PC Parallel ports
•Power equirements
+24 VDC filtered, regulated or unregulated
power is all that is required. The IO6 board
generates +5 volts and +12 volt supplies for
user. (See Figure 1)
Figure
+
24vdc
GND

5
Description of the interface assemblies
1. Charge pump circuit and enable signals
When there is no E-stop condition and the Mach3 software based control is running
properly, Mach3 outputs a steady pulse stream to the IO6 breakout board. The IO6
receives this pulse stream and sends an enable signal to every axis mod jack
connector, on mod jack pin #4. It also enables all outputs of the IO6. If this pulse
stream is interrupted, the IO6 will correspondingly disable all outputs from the IO6.
This safety circuit prevents spurious outputs from the C from producing unexpected
results.
The charge pump circuit energizes a relay that provides a pair of bare relay contacts,
and +5V & +24V enable signal for system integrators to use to implement other safety
measures. We also provide direct access to the charge pump signal. This phoenix
terminal is located on the Auxiliary Terminal Block. (See Figure 2)
The charge pump input can be over-ridden by switching dip switch #4 to the “closed”
position (See Figure 3). This removes the safety provision of the system thus a machine
must not be operated with the charge pump disabled. This provision is only made
available for the use of the systems integrator’s use in setup or troubleshooting.
**************WARNING**************
Use of the IO6 in a machine application with the Charge pump
disabled is forbidden. Computer based controls running the
Windows operating system may encounter unexpected
interruptions due to outside influences and computer failures. The
Charge pump circuit is a safeguard against these occurrences.
Disabling it can allow for DEATH, INJURY or serious PROPERTY
DAMAGE.
**************WARNING**************
Figure 3
Closed
Opened
5
4
3
2
1
Figure 2
Charge pump output bare
relay contacts (CP/CP)
Auxiliary Terminal
Charge pump pulse stream. Port# 2 pin 17
Charge pump enabled output (+5v) / (+24v)

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2. Digital (pulse and direction) interface for 6 axis motion control
The IO6 breakout board provides differential and single ended step and direction both
of which may be employed at the same time.
a. Differential step and direction interface
The first 6 jacks of the 8 jack module provide differential step and direction
outputs for servo drives. The differential interface provides common mode noise
rejection. This interface requires the use servo drives that expect a differential
input or differential adapters connected near the servo drives. Modular Jack
for Axis 1 is located on the bottom row of jacks, closest to arallel ort 1. (See
Figure 5)
The pin-out for each of these six mod jacks is:
in 1. Optional Input pin for limit switch input signals. This pin connects to
parallel port 1 input pins 11, 12, 13, and 15 for axis 1-4 respectively and
parallel port 2 input pins 10 and 11 for axis 5 and 6 respectively.
(Consult the Opto_Input Connection Guide 11)
in 2. Drive error signal (Hard wired to opto-coupled circuit connected to input
pin 10 of the C port).
in 3. Direction
in 4. Drive Enable. The drive enable voltage is determined by the voltage
that is provided by the user at the EXT (External Enable Voltage Supply)
terminal. (See Figure 4) The enable signal will be active whenever the
Charge ump circuit is enabled.
in 5. GND
in 6. Direction/
in 7. Step
in 8. Step/
External Power for
drive enable (EX
-
EN)
Figure 4
Figure 5
External Power for
drive enable (EX
-
EN)
Axis 1 (X)

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b. Single ended (non-differential) step and direction interface
The rimary Terminal Block has six phoenix screw terminal connectors for single
ended (5V TTL) step and direction control signal access for connection to servo
drives.
The labeling below the six green phoenix terminal block indicates the
corresponding C parallel port pin that is interfaced by the terminal. For
example, terminals labeled D-2, D-4, D-6, D-8, D-14, and D-1 are to be
configured as direction outputs in the Mach3 configuration table, for axis 1-6
respectively. Terminals 3, 5, 7, 9, 16, and 17 are to be configured as step
outputs for axis 1-6 respectively. The Ground terminals for these signals are
also marked on the circuit board.
3. Spindle Control Overview
The IO6 controls the spindle in this way: The machine operator manually sets the
spindle speed on the Mach3 control panel display or it is set via the G-code file. Then
**************WARNING**************
All Servo drive fault signals should be connected together so that a
failure in one drive shuts down every servo drive at the same time.
Failure to configure the servo drives in this manner can cause DEATH,
INJURY or serious PROPERTY DAMAGE. Do not install drives that do
not share the same fault line.
**************WARNING**************
Direction Row
2, 4, 6, 8, 14
Step Row
3, 5, 7, 9, 16, 17
Ground
PC Parallel Port
#1 Pin
-
outs
2 4 6 8 14 1
3 5 7 9 16 17
GND GND GND GND GND GND
Step Row
Direction Row
Figure 6

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either the appropriate M-code or the operator turns on the spindle with the “button” on
the control screen. The hardware control sequence is as follows: The Mach3 control
turns on either a CW or CCW relay. Then the IO6 sends an appropriate 0-10 volt
analog signal out to the Variable Frequency Drive (VFD) which controls the spindle
motor speed. Finally, the Mach3 control measures and monitors the Spindle R M by
measuring the pulse rate of a pulse stream that it receives through the IO6 from a
sensor or encoder mounted on the spindle, and displays the R M on the Mach3 control
panel display.
Interfacing the Spindle is accomplished either through the two mod jack connectors 7
and 8 or through hoenix screw terminal connections to the IO6. For convenience, the
mod jack connections are preferred, and will be discussed first in this section. All of
the signals mentioned and used in the mod jack connections correspond to the
connections that can be made using the screw terminal connections.
4. IO6 CW and CCW relay outputs
Mod Jack #8 of the 8 mod jack module is dedicated to spindle output signals. See
page 6 Figure 5. All of the connections to the mod jack are also available on phoenix
screw terminals (See page 7 Figure 6), but mod jack connections are made available
for convenience. The relay contacts are rated at 1 amp 115 VAC, and 3 amps at 30
VDC. These relay contacts can be connected to turn on a power contactor for the
spindle motor or for VFD inputs to control direction of rotation. The pin-out of mod
jack # 8 are as follows:
in 1 0-10 VDC analog signal for VFD spindle speed control.
in 2 CW spindle dry relay contact.
in 3 CW spindle dry relay contact.
in 4 Enable - voltage provided at external enable voltage supply (EXN)
This will be the same as terminal SOV on the Auxiliary Terminal Block.
in 5 GND (for analog voltage on pin 1 and the enable voltage.
in 6 No Connection.
in 7 CCW spindle dry relay contact.
in 8 CCW spindle dry relay contact.
5. I06 analog spindle voltage output
The Mach3 control software program provides a variable frequency pulse output on a
step signal line which is scalable through the configuration menus in Mach3. This
signal is converted to a proportional analog 0-10 volt signal which is typically used to
control the speed of Variable Frequency Drives (AKA inverters). The hardware on the
IO6 board performs this conversion. The setup to implement this function is
configured in the Mach3 configuration tables. The setup procedure is provided below.
6. Configuring the 0-10V analog output
1. In Mach3 go to Config / orts& ins / Motor Outputs. Enable the spindle and set the
step pin to 1 and step port to 2. Set the DIR pin to 14 and ort2.
3. Go to Config / orts& ins / Spindle setup / motor control. Check the box for “Use
Spindle Motor Output” and check the box for Step /Dir Motor.

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4. Go to Config / orts& ins / Spindle Setup / Relay Output. Enter “1” for M3 output
# and “1” for M4 output #.
5. Go to Config / Motor Tuning / Spindle. On Steps per Unit enter 1000, change the
velocity to 1575. Set acceleration to 50 or choose the acceleration that you feel
comfortable with. The acceleration set here must be within the range of the VFD
acceleration setup if a VFD is used. Mach3 will then produce the appropriate
voltage for speeds less than the maximum.
7. I06 Inputs for measuring spindle PM
The IO6 provides interfaces for receiving a pulse stream from a sensor configured to a
rotating spindle, which is used to measure the R M of the spindle. The IO6 provides
for three different methods of receiving this pulse stream. The IO6 also includes a
pulse stretching circuit which sends a 9 us pulse to the CNC control for any length input
pulse received by an encoder or photo interrupter sensor configured on the spindle.
This pulse stretching circuit ensures that the MACH3 control will not miss any pulses.
An incremental encoder, providing the usual 5 volt A, A/ B, B/, I, and I/ differential
signals can be used to sense spindle R M. Using differential signals provides common
mode noise reduction for reliable pulse monitoring. Modular Jack #7 (located on the
lower layer of the 8 jack module) is provided for a convenient differential spindle
feedback connection to the IO6. Obviously, to utilize these noise immune inputs, a
differential encoder driver or differential encoder must be mounted on the spindle, and
connected to the cable with the CAT5 mod jack connection for mating to the IO6 board.
The system integrator may choose to select only the index pulse provided by an
encoder mounted on the spindle, or all of the encoder signals (A, B, and I) provided by
using the Dip Switch settings below. The use of the A and B encoder inputs may be
useful in applications where the exact rotational position of the spindle is needed.
Normally, MACH3 derives spindle speed from one incoming pulse such as the index
pulse.
Alternatively, a photo interrupter sensor, inductive sensor or other sensor can be
configured to produce one pulse per revolution of the spindle. The signal can be
converted near the sensor to differential through the use of a converter such as the
MachMotion’s R2210 converter and then interfaced to the IO6 through a shielded CAT5
cable and Mod Jack #7 mentioned in the previous paragraph. The inputs to this mod
jack are expected to be based on 5v differential signals, as are provided by a 26C31
Differential driver. The pin out of Mod Jack #7 is provided:
in 1 Encoder A
in 2 Encoder A/
in 3 Encoder B
in 4 +5V to power the encoder
in 5 GND
in 6 Encoder B/
in 7 Encoder I
in 8 Encoder I/
Both spindle R M monitoring signals and Spindle speed control output signals can be
connected to the IO6 board through the mod jacks as mentioned above. The speed
measuring signal can also be a single ended opto-isolated signal connected to the

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hoenix Auxiliary terminal connections described in arallel ort I/O Interface
connections below. The speed measuring input is used in Lathe threading operations.
The most reliable spindle speed sensing and position sensing is obtained by employing
a differential incremental encoder mounted to the spindle. Alternatively, a 5V N N
optical sensor can be mounted on the spindle which would provide one pulse per
spindle revolution. The single ended signal from the sensor would be connected to the
NDX terminal on the Auxiliary Terminal Block. Both the encoder index pulse and the
single ended input are routed through the IO6 on-board C U for signal conditioning and
then routed to the Mach3 CNC control program running on the C.
Three DI switches are provided to allow selection of either the differential signals or
the 5V single ended inputs to be used for R M measuring. To enable differential input
from a spindle encoder through the mod jacks, close the following Dip switches:
Dip Switch 1 (closed) connects spindle encoder signal A to C parallel port 2 input pin
12 (Used for spindle rotational position indication only)
Dip Switch 2 (closed) connects spindle encoder signal B to C parallel port 2 input pin
15 (Used for spindle rotational position indication only)
Dip Switch 3 (closed) connects spindle encoder index pulse to the IO6 C U. (This
encoder input can be used for spindle speed measuring and lathe threading.
To allow R M measuring with a single ended signal input at the NDX terminal on the
Auxiliary Terminal Block, leave the three dip switches mentioned above in the open
position.
Dip Switch 3 (closed) connects the differential spindle encoder
signal I (index) to the IO6 C U. Setting this switch to “open”
allows either the single ended signal connected to the phoenix
screw terminal labeled NDX, (See page 16 Figure #12) All of
these inputs are routed through the opto-isolated digital input
circuits and to their respective C parallel port pins (see next
paragraph).
A third Spindle Speed measuring option is also available: A 5V
index signal may be connected to opto-isolated input port B, pin
13. This input is not routed through the IO6 C U for signal
conditioning. Use the Mach3 ports and pins Spindle input
configuration pull down menu to tell Mach3 control to receive
this input for spindle speed.
8. Mixed assortment of digital I/O interfaces
The IO6 provides ten high speed general purpose digital opto-isolated inputs. The IO6
also has 8 relays with 2 amp output contact pairs.
9. Opto-Isolated digital inputs terminals
For noise immunity, ten terminals are available for opto-isolated inputs to the Mach3
control. The first seven of these opto-isolated inputs (parallel port 1, pins 10,11,12,13,
and 15, as well as parallel port 2, pins 10 and 11) are connected to the phoenix rimary
Terminal block and also to pin 1 of each of the six axis mod jacks respectively. These
are provided to allow an optional input from a servo drive if needed. Each input has an
Closed
Opened
5
3
2
1
4
Figure 7

11
Figure 9
LED indicator below the corresponding input below the rimary terminal block. See
page 17 figure 13 and 14.
These seven inputs can be connected to a number of different types of devices and
configured as described in the next section (10) entitled, O TO-Input Connection
Guide.
10. Opto-input connection guide
This guide will assist the systems integrator in the installation of the seven general
purpose opto-isolated inputs. The options for the inputs are given as examples in this
guide.
The various options are selected by installing a Jumper on one of two pairs of pins for
each of the seven inputs. The Jumper will connect between a center pin and either a
pin in the row labeled GND or to a pin in the row labeled +5V. The Jumpers correspond
to the appropriate input port/pins and are labeled A10, A11, A12, A13, A15, B10, and
B11 on the printed circuit board.
Primary
Terminal
Block
+24v
GND
+5v
Port 1
—
11
Port 1
—
13
Port 1
—
12
Port 1
—
10 (Error)
Port 2
—
10
Port 2
—
11
Port 2
—
12
Port 1
—
15
Port 2
—
13
Port 2
—
15
Port 1-11L Port 1-13L Port 1-12L Port 1-10L Port 2-10L Port 2-11L Port 1-15L

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The example drawings have terminals with representative labels. The top row of
terminals above the opto-isolated input terminals on the rimary Terminal Block has
three terminals labeled GND and three terminals labeled +24 Volts. These labels
correspond to the example drawings and are provided as voltage sources for the
opto-isolated inputs.
The example drawings in the Opto-Input Connection Guide show the middle row of
terminals in the rimary Terminal Block labeled as X-XX. These connections in the
guide correspond to terminals labeled 1-11, 1-12 etc.
The example drawings show the lower level of terminals labeled X-XXL. These
terminals are located at the circuit board level and are labeled 1-10L, 1-11L, 2-10L on
the rimary Terminal Block.
For example, in the first diagram for wiring up a 24V limit switch, one side of the switch
is connected to 24V on the rimary Terminal Block and the other side of the switch is
connected to an input X-XX. As stated above this could be 1-11, 1-12, 1-13, 1-15,
2-10, and 2-11. Remember that Mach3 must be configured accordingly. Note that the
input X-XXL is not used in this example. Also the jumper for the input must be
connected to GND, not to 5V.

13
1. +24 V Limit Switch Input
2. PNP Proximity Sensor
( roxy switch) N 24V is preferred, such as Jameco Electronics TS12-02 -1
Opto sensor input
(Omron EE-SX872 N Sensor, sensing 24 volts) ( N preferred)
+V Brown
0v Blue
Load Black
+24V GND
X-XXL
+5
V
330ohm
3.9K
GND
Jumper
4.7nf
XX-X
Sensor
IO6 Board
+24V
GND
X-XXL
+5
V
330ohm
3.9K
GND
Jumper
4.7nf
XX-X
N
O
or NC Limit Switch
IO6 Board

14
3. NPN Proxy Switch +5V only.
Jameco part number 167020
Opto sensor input
(Omron EE-SX872 N N Sensor) 5V sensing only.
4. +5V input signal or drive error input
+24V GND
X-XXL
+5
V
330ohm
3.9K
GND
No Jumper
4.7nf
XX-X
IO6 Board
GND
+5V Signal Input
User Input
No Jumper
+V Brown
0v Blue
Load Black
Sensor
+5V
GND
X-XXL
+5
V
330ohm
3.9K
GND
Jumper
4.7nf
XX-X
IO6 Board

15
5. +24V signal input
6. Digitizing Probe Input
+5 volt is connected to GND by probe
+24V GND
X-XXL
+5
V
330ohm
3.9K
GND
Jumper
4.7nf
XX-X
IO6 Board
Probe Signal
+5V
GND
+12V
On Board
On Board 5V
+24V GND
X-XXL
+5
V
330ohm
3.9K
GND
Jumper
4.7nf
XX-X
IO6 Board
GND
+24V Signal Input
User Input

16
11. Digitizing probe input terminal
The four terminal hoenix Jack located in front of the rimary Terminal Block is for
interfacing to a digitizing probe such as those manufactured by TORMAC.
It provides 5V, 12V, a common ground and an input signal line for a probe switch
contact.
The probe signal input terminal is not connected to any inputs. It is provided for the
convenience of the installer. The probe input can be connected to a selected opto
isolated input terminal with an external wire and configured as a 5 volt signal input as
described in the O TO-input connection guide or as a high speed input on terminals
2-12, 2-13 or 2-15. Take care to insure that the probe input signal never rises above
+5 volts DC.
12. Estop terminals
The two terminals next to the Digitizing robe input terminals, located in front of the
rimary Terminal Block are provided so that a hardware Estop connection can be made
to the Mach3 control. These pins, E1 and E2, must be connected together for the
control to run.
13. Error Input
The terminal labeled 10/ER is dedicated in the IO6 system for error input use, and is
connected to C parallel port 1 input pin # 10 through an opto-isolator. This input is
also bussed to all of the differential drive axis modular jacks, pin 2, to pick up any servo
drive errors. A drive error can be configured for several different voltage signals as
detailed in the O TO-Input connection guide (section 10[6] of this manual) See page
Error! Bookmark not defined..
14. Very high speed opto-isolated inputs
The remaining three opto-isolated input terminals ( C parallel port 2, input pins 12, 13
Figure 0

17
and 15) can be configured as general purpose inputs through the phoenix terminals so
labeled. For example, inputs 12, 13 and 15 can be used for spindle control as
described under the section of this manual entitled Spindle control. See the
description of these features and the pertinent DI switch settings in the paragraph
entitled Spindle control above. See page 7 Figure #13. These three inputs are limited
to 5v signal inputs and the three terminals below the input terminals of the rimary
Terminal Block provide the 5V source if needed.
15. elay outputs
For noise immunity, the IO6 provides a CB mounted bank of 8 relays used as outputs.
See page 15 Figure #11. The connections to the Relay bank CB are found on the
Auxiliary Terminal Block. The output connections are labeled in pairs: +R2 R2, +R3 R3
etc.
The output pairs are dry contacts capable of handling 2 amps each. To set up in Mach3
go to Config/ orts and ins/Setup and Axis Selection, ort 2 configuration table, then
deselect Pins 2-9 as inputs.