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

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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

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****************************************************************************
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

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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

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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