CS-Lab CSMO IP-M Manuale utente

4-axis CNC Ethernet controller

User guide

Applies to firmware version: v1.200

First edition

CS-Lab s.c. –CNC CSMIO/IP-M controller

Page 2

Index

1. General .................................................................................................................................... 4

1.1 Signs used in this guide ................................................................................................... 4

1.2 Contents .......................................................................................................................... 5

1.3 Standards compliance ..................................................................................................... 6

1.4 Specification .................................................................................................................... 6

2. Safety....................................................................................................................................... 7

2.1 Example of E-STOP signal connection ............................................................................. 8

3. Recommendation for mechanical installation ........................................................................ 9

4. Connectors, controls and electrical installation of the device.............................................. 10

4.1 Arrangement of the connectors on the device ............................................................. 10

4.2 STEP/DIR controlling signals and digital outputs connector ......................................... 11

4.3 Digital inputs connector ................................................................................................ 13

4.4 Analog I/O connector .................................................................................................... 14

4.5 Expansion modules connector ...................................................................................... 14

4.6 Power connector ........................................................................................................... 15

4.7 Communication connector – Ethernet.......................................................................... 15

4.8 Recommended cables ................................................................................................... 16

4.9 Installation examples..................................................................................................... 17

4.9.1 The simplest connection of inverter with the use of analog output......................... 17

4.9.2 Illustrative diagram of XYZ plotter............................................................................. 18

4.9.3 Automatic control of drives power supply (HV)........................................................ 20

4.10 LED lights meaning ........................................................................................................ 21

5. Recommendations and drive selection (motor drives)......................................................... 22

6. Precise homing with use of the servo drive and the encoder INDEX signal.......................... 24

7. LAN connection and configuration........................................................................................ 26

7.1 PC direct connection ..................................................................................................... 26

7.2 Local network with router and DHCP............................................................................ 28

8. Mach3 program – general information................................................................................. 29

8.1 Recommended PC configuration................................................................................... 31

9. Software installation ............................................................................................................. 32

9.1 Mach3 installation......................................................................................................... 32

9.2 Microsoft® .Net installation (older operating systems) ................................................ 33

9.3 Installation of the plug-in for Mach3............................................................................. 33

9.4 Administrator rights in Windows® Vista and Windows® 7. .......................................... 34

10. Mach3 program configuration .......................................................................................... 35

10.1 Configuration profile ..................................................................................................... 35

10.2 The first run ................................................................................................................... 36

10.3 Configuration of axes used in the machine................................................................... 37

10.4 Configuration of the digital input signals ...................................................................... 38

10.5 Configuration of digital output signals .......................................................................... 40

10.6 Configuration of spindle and cooling controlling .......................................................... 42

10.7 Configuration of the resolution, speed and acceleration of the axes........................... 44

10.8 Configuration of motion directions, homing and software limits................................. 45

10.9 Additional configuration functions in the plug-in window............................................ 46

CS-Lab s.c. –CNC CSMIO/IP-M controller

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10.9.1 Servo drive fault signals......................................................................................... 46

10.9.2 Override sources tab, feed rate correction speed and spindle revs ..................... 47

10.9.3 Spindle tab, selection of analog output that controls the spindle revs ................ 47

10.9.4 Special functions tab, HVEnable and ServoReset.................................................. 48

10.10 Selection of inch/mm units ....................................................................................... 49

10.11 Parameters in the General Config window. .............................................................. 49

11. First tests ........................................................................................................................... 51

11.1 Checking the input signals............................................................................................. 51

11.2 Verification of axes scaling and motion directions ....................................................... 52

11.3 HOMING and software limit switches test.................................................................... 53

11.3.1 First homing........................................................................................................... 53

11.3.2 SoftLimit switches.................................................................................................. 53

11.4 Test of spindle and cooling............................................................................................ 54

12. Sample processing step by step ........................................................................................ 55

12.1 Preparation of project and G-Code files........................................................................ 55

12.2 Preparation of the machine and the Mach program .................................................... 59

12.3 We begin the work ........................................................................................................ 61

13. A few practical notes about Mach3 program and CSMIO/ IP-M....................................... 63

14. VisualBasic® macros ........................................................................................................... 65

14.1 Automatic tool-length measurement............................................................................ 65

14.1.1 Configuration......................................................................................................... 65

14.2 Automatic tool change macro ....................................................................................... 67

15. Addition A – CSMIO/IP-M software updates..................................................................... 68

15.1 How to check your software version............................................................................. 68

15.2 Updating application (uploader) ................................................................................... 68

15.3 Plugins file update ......................................................................................................... 69

15.4 Checking the update...................................................................................................... 69

CS-Lab s.c. –CNC CSMIO/IP-M controller

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1. General

CSMIO/IP-M product was designed for customers, who are looking for a compromise between

advanced CSMIO/IP-S controller and a simple LPT based device. The biggest advantage if the

CSMIO/IP-M controller is its 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-M does not require any

external electronics for proper operation. Inputs/outputs signals are inside optically isolated, filtered,

protected against short circuit, overheating etc. All signals are adjusted to

industry standard 24V. The

device is enclosed in a compact

CSMIO/IP-M product works with Mach3 program because of its low price, popularity and

enormous

cover, mounted on a DIN-rail, what makes that the mechanical and

electronic installation in the control cabinet takes less time and is even simpler.

ability to adapt to specific requirements. As a drives control interface the choice was a

popular step/direction (step / dir) standard. It allows controlling both the stepper motor drives and

the most modern servo drives. Max. frequency of stop signal is 125 kHz

so it is sufficient value for

many uses. What is important the controller is responsible for pulses generation, the same it ensures

that the signal is stable in the frequency domain and its fulfillment is 50%. This enables a greater

culture of machine work than it is while using LPT based controller.

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.

__________________________________________________________________________________

CS-Lab s.c. –CNC CSMIO/IP-M controller

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1.2 Contents

CSMIO/IP-M device is placed in the cartoon box with the DB->Terminal Block adapters1

•CNC CSMIO/IP-M Controller

for easier

wires connection in the control cabinet. More content details below:

•1xDB25 -> Terminal Block adapter

•1xDB25 + 1xDB9 -> Terminal Block adapter

•Ethernet connection wire

•2xDB25 connection tape

•1xDB9 connection tape

•1x„Phoenix” 3 pin power plug

•CD with electronic version of the user guide and

software

In case of lack of any elements listed above, please contact your distributor.

1CSMIO/IP-M can be bought without the DB->Terminal Block adapter.

CS-Lab s.c. –CNC CSMIO/IP-M controller

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1.3 Standards compliance

CSMIO/IP-M controllers were designed and made in accordance with the national and international

standards

•Detailed requirements for programmable controllers: working

for industrial control systems based on electronic components:

characteristics, shock

resistance, safety

•

etc. EN61131-2 (IEC1131-2), CSA 22.2, UL508

Compliance with European Guidelines (low voltage, the level of electromagnetic interference

Electromagnetic Compability),

•

the CE marking.

Electrical and non-combustible properties of insulation materials

•The Product

: UL 746C, UL 94, etc.

made in lead-free technology

, RoHS compliant.

1.4 Specification

Parameter

Value

Number of digital inputs 12

Number of digital outputs 4

Number of analog inputs

Number of analog outputs

Supply voltage

Power consumption

24VDC +/-10%

Maximum voltage on the in/out lines

Maximum load of output line

30VDC

The voltage range of analog inputs

250mA

Maximal load of analog output 0-10VDC

Axis Drives control type 5mA

Maximum frequency of the STEP signal (STEP/DIR)

Fill factor of the STEP signal 125kHz

PC connection 50%

Ambient temperature range Ethernet 10/100Mb

Relative humidity 0

C to +60

Number of digital inputs 10% to 95%

(without condensation)

The STEP outputs signals frequency are in no way limited by the „Kernel speed” settings in Mach3

program. While using the CSMIO/IP-M controller this Mach’s configuration parameter is unused and

can be set on any value

CS-Lab s.c. –CNC CSMIO/IP-M controller

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2. Safety

The CSMIO / IP-M device is powered by 24V safe voltage. I / O control lines are optically isolated, also

the PC connection is galvanically isolated. The device does not constitute a direct threat to the health

and life of the 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 the NC contacts for limit switches and safety switch. Thanks to it - a wiring fault or i.e.

plug-ins disconnection will stop the machine

Pay special attention to the emergency stop circuit. The control system must be designed in such a

way that when you press the 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 the main controller, or axis drives

Best way is, to use for that purpose a standard safety relay (i.e. from PILZ Company). The safety

switch mushroom, FAULT signals of the drives and inverter and eventually other alarm signals – you

should connect to the input circuits. The output or outputs should be connected to the CSMIO/IP-M

controller, and defined as the emergency stop. Outputs of the security module should be also

connected to the axis drives, inverters, etc. This way we get double protection – if, by inappropriate

configuration or CSMIO/IP-M controller failure - the emergency would not work, the information

goes to the axis drives, which can properly respond to it. It works both sides: if the drives would not

react, you always have the controller

CSMIO-IP/M Controller in the active state on the input line - defined as E-Stop, blocks the STEP

signals within 0.000! s. It happens autonomously, without Mach3 program and thus the machine

stops very fast. The same happens with reaction

to signals from limit switches.

CS-Lab s.c. –CNC CSMIO/IP-M controller

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2.1 Example of E-STOP signal connection

The simple example above shows the E-Stop signal connection to the CSMIO/IP-M controller and to

the axis drives, using Pilz company safety relay (PNOZ X7 24V symbol). S1 is a reset button (safety

relay switching on), S2 is an emergency stop

This module has one input, and due to it, all the alarm sources are connected to this input (A1). In

addition to the mentioned emergency stop (S2) there are NC contacts - NC1 and NC2, which may be,

i.e. opening sensors for the cover and the control cabinet. Moreover, there are drives’ FAULT signals

connected in series. Two outputs of the safety relay were used as an E-Stop signal for the CSMIO/IP-

M controller and axis drives

This combination assures the machine stops in case of failure on any axis (FAULT signals of the

drives), by pressing emergency stop mushroom and opening of the cabinet or cover. Separation of

the safety relay output channels gives double protection for the system and significantly increases

the reliability of the entire system.

PILZ

PNOZ X7 24 V

CS-Lab s.c. –CNC CSMIO/IP-M controller

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3. Recommendation for mechanical installation

CSMIO/IP-M controller and DB->Terminal block - connection modules were designed to be installed

on standard DIN-rail. It is the quickest and best way of installation.

The Controller uses a small amount of electricity and creates a negligible amount of heat.Aluminum

housing provides adequate cooling for the electronics inside, even if the ambient temperature

reaches 40OC.

As for the same controller, there are no special precautions for ventilation and the minimum

distances. However, usually, next to the controller in the control cabinet, there are also inverters,

power supplies, motor drives - these components emit a lot of heat, so you should always remember

about their proper location and proper ventilation of the cabinet

Here is an example - components arrangement in the control cabinet

Caution is advised during the mechanical and electrical installation. Poorly tightened cable may cause

many problems, it is also very difficult to find such a defect while launching/using the system.

CS-Lab s.c. –CNC CSMIO/IP-M controller

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4. Connectors, controls and electrical installation of the device

4.1 Arrangement of the connectors on the device

Detailed description of signals on individual connectors is placed in next sections.

DB->Terminal block modules have the same pin numbers as DB connectors in CSMIO/IP-M device.

In example: 15 pin of DB25 connector match with the 15 pin on the terminal block.

Signals that control the drives (STEP/DIR)

and digital outputs (relays either)

Analo inputs and outputs (0-10V)

Expansion modules connector

Power connector

Digital inputs Communication

connector (ETHERNET)

Indice

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