Summary of Contents for CSLab CSMO IP-M
- Page 1 4-axis CNC Ethernet controller User guide Applies to firmware version: v1.200 First edition © Copyright 2012 – CS-Lab s.c.
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Page 2: Table Of Contents
Index General ............................ 4 Signs used in this guide ....................4 Contents .......................... 5 Standards compliance ..................... 6 Specification ........................6 Safety ............................7 Example of E-STOP signal connection ................8 Recommendation for mechanical installation ................ 9 Connectors, controls and electrical installation of the device ..........10 Arrangement of the connectors on the device ............. - Page 3 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 ..................
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Page 4: General
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). -
Page 5: Contents
Contents CSMIO/IP-M device is placed in the cartoon box with the DB->Terminal Block adapters for easier wires connection in the control cabinet. More content details below: • CNC CSMIO/IP-M Controller • 1xDB25 -> Terminal Block adapter • 1xDB25 + 1xDB9 -> Terminal Block adapter •... -
Page 6: Standards Compliance
Standards compliance CSMIO/IP-M 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 •... -
Page 7: Safety
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 . -
Page 8: Example Of E-Stop Signal Connection
Example of E-STOP signal connection PILZ PNOZ X7 24 V 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 . -
Page 9: Recommendation For Mechanical Installation
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 40 As for the same controller, there are no special precautions for ventilation and the minimum... -
Page 10: Connectors, Controls And Electrical Installation Of The Device
4. Connectors, controls and electrical installation of the device Arrangement of the connectors on the device Signals that control the drives (STEP/DIR) and digital outputs (relays either) Analo inputs and outputs (0-10V) Expansion modules connector Power connector Communication Digital inputs connector (ETHERNET) Detailed description of signals on individual connectors is placed in next sections. -
Page 11: Step/Dir Controlling Signals And Digital Outputs Connector
STEP/DIR controlling signals and digital outputs connector PIN number Description DIR[0]+ STEP[0]+ DIR[1]+ STEP[1]+ DIR[2]+ The differential outputs, which are STEP[2]+ available on this connector, have low DIR[3]+ permissible load (50mA) and serves STEP[3]+ only to control the LEDs in the 24V power supply for 0..3 outputs optically isolated inputs of motor 0 output... - Page 12 During launching the machine it is worth to check if step signal is polarized properly. The easiest way is to make the reference, next to ride on zero point and do the mark e.g. on the axis of motor or on the cover.
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Page 13: Digital Inputs Connector
Digital inputs connector PIN number Description 0 (+) Input 1 (+) Input 2 (+) Input 3 (+) Input 4 (+) Input 5 (+) Input 6 (+) Input 7 (+) Input Pay special attention to not exceed 8 (+) Input the permissible voltage (30VDC) on 9 (+) Input the inputs lines. -
Page 14: Analog I/O Connector
Analog I/O connector PIN number Description 0 analog output 1 analog input 10V (max. 50mA) 1 analog output 0 analog input Pay special attention to not exceed the permissible voltage (10VDC) on the inputs lines. It may cause the device damage. 10V output has 50mA load and serves only to supply the potentiometers, if you want to connect the potentiometers, such as regulation of feed rate or spindle speed correction. -
Page 15: Power Connector
Power connector PIN number Description Power – 24V DC Ground View of the plug from the side of connecting wires Pay special attention to not exceed the permissible voltage (30VDC) on the inputs lines. It may cause damage of the device. If you use in the system such inductive loads as electromagnets, solenoids, electromagnetic clutches –... -
Page 16: Recommended Cables
Recommended cables Connections type Recommended cable Digital In/out Minimum cross-section 0,25mm Analog In/out Cross-section 0,25mm best - shielded or pair of signal-to- mass weirs twisted together along the entire length Drives controlling (STEP/DIR) Cross-section 0,25mm ; shielded–twisted. You can possibly use the FTP computer cable. -
Page 17: Installation Examples
Installation examples 4.9.1 The simplest connection of inverter with the use of analog output. This example above shows the simplest connection of the inverter to operate e.g. spindles in the engraving plotter. CSMIO/IP-M used outputs: CSMIO/IP-M signal Connector on CSMIO/IP-M PIN number in Inverter function CSMIO/IP-M connector... -
Page 18: Illustrative Diagram Of Xyz Plotter
4.9.2 Illustrative diagram of XYZ plotter C S - L a b s . c . – C N C C S M I O / I P - M c o n t r o l l e r Page 18... - Page 19 A scheme presented in this section is the simplest implementation of 3axis plotter (XYZ). Two power supplies were used: 24V to supply the CSMIO/IP-M controller and 80V for the stepper motors drives. Switches used: NC switches for axis homing (HOME) and limit switches (LIMIT). In practice, it is necessary to build more comprehensives systems, however the example above shows the main rule.
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Page 20: Automatic Control Of Drives Power Supply (Hv)
4.9.3 Automatic control of drives power supply (HV) CSMIO/IP-M controller allows for automatic control of drives power supply and some other devices. Switching on this function was described in 10th Chapter. The logic of the output working, define as so called „HV Enable” is very easy. The voltage is switched ON at the moment of requesting “Reset” by Mach program. -
Page 21: Led Lights Meaning
4.10 LED lights meaning On the front panel of CSMIO/IP-M device, there are groups of LED lights that simplify verifying the correctness of electric installation and diagnostic of the components such as HOME switches, LIMIT switches and safety switches (E-Stop) etc. LED light type Description Shows current digital outputs state... -
Page 22: Recommendations And Drive Selection (Motor Drives)
5. Recommendations and drive selection (motor drives) Selection of the appropriate motors to the machine is very individual . In this chapter, we briefly describe the difference between stepper and servomotors. Designers' practice shows there is a dilemma – what solution should be chosen. Not so long ago – because of high prices of servo drives, in the simpler machines usually the stepper motors were used. - Page 23 However, everything has its pros and cons. So what are the disadvantages of servo drives ? They are certainly more expensive - how much, it depends what kind of stepper and servo drives you compare. There are e.g. stepper motors controllers that cost 800 USD and there are some other that cost 40 USD (with the same power!).
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Page 24: Precise Homing With Use Of The Servo Drive And The Encoder Index Signal
6. Precise homing with use of the servo drive and the encoder INDEX signal Homing with use of so-called encoder INDEX signal is another argument for servo drives. This type of homing is very precise even if the HOME switch has large toleration of the set point. In practice, homing with the INDEX allows to eliminate inaccuracy of the HOME switch. - Page 25 •HOME switch off -inactive •HOME output of the drive - inactive 1.Homing start •HOME switch off - activ •HOME output of the drive - active 2. Ride on the HOME sensor •HOME switch off - inactiv •HOME output of the drive - activ 3.
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Page 26: Lan Connection And Configuration
7. LAN connection and configuration PC direct connection CSMIO/IP-M controller can be connected directly to the PC computer without any switches or routers. In this connection, you should remember to use the crossover cable. This cable is attached to the controller. Below – how to perform the wiring. Plug-in 1 Cable color Plug-in 2... - Page 27 • In this window – select the „Internet protocol (TCP/IP)” position and click left mouse button on the „Properties”. • In this window enter the IP address: 10.1.1.1 and a mask: 255.255.255.0. Click “OK”. • Close the window. • The network is now set to work with CSMIO/IP-M. CSMIO/IP-M controller after turn on automatically sets the IP address (it sends request to the DHCP sever).
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Page 28: Local Network With Router And Dhcp
Local network with router and DHCP If we plug in the CSMIO/IP-M controller to the computer network where is a router that allocates the IP addresses, the device automatically downloads the address and network mask settings. Usually there is no need to know what IP address was assigned to the device because the plug-in and the application that updates the controller software automatically searches the CSMIO/IP-M in the network. -
Page 29: Mach3 Program - General Information
8. Mach3 program – general information Mach3 software of the ArtSoft® Company has developed over many years and during these years, it gathered many users. For relatively low price (~170USD) we get complete solution for multi-axis CNC machining. Key benefits of the program are: •... - Page 30 The CS-Lab company is an authorized distributor of the Mach3 program in Poland. If you would like to buy the license, please contact us: biuro@cs-lab.eu. If you order the CSMIO/IP-M controller and you want to order the license right away, please note it in your order and specify person/company, the license should be issued.
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Page 31: Recommended Pc Configuration
Recommended PC configuration The Mach3 program has no unreasonable requirements about the PC computer, unless the tool paths you use take a few or even tens of megabytes – then we rather recommend faster computer. Even simulation of the runtime with so large paths will follow more efficiently on faster PC computer. Minimum configuration Recommended configuration Intel Pentium IV 1GHz... -
Page 32: Software Installation
9. Software installation Before we begin the work, we should install on the PC computer the Mach3 software and plug-in that ensures proper cooperation of the program and the CSMIO/IP-M controller. Mach3 installation The latest version of Mach3 program can be downloaded from the ArtSoft® website: http://www.machsupport.com/downloads.php After the file is downloaded, you should launch it and follow the instructions on the screen. -
Page 33: Microsoft® .Net Installation (Older Operating Systems)
After you click on one of the buttons, you will see the window where you can name your configuration profile, e.g. “MyMillingMachine_400x250_CSMIO_IP”. Avoid spaces and special signs (an underscore is allowed). Microsoft® .Net installation (older operating systems) If you use OS older than Windows® 7, it may be necessary to install Microsoft® .Net. This program is available on Microsoft®... -
Page 34: Administrator Rights In Windows® Vista And Windows® 7
Administrator rights in Windows® Vista and Windows® 7. It is recommended to launch the Mach3 program in OS Windows® Vista and 7 with an administrator rights. Open the „C:\Mach3” directory, find the Mach3.exe file and click right mouse button. In the menu select the “Properties”... -
Page 35: Mach3 Program Configuration
10. Mach3 program configuration After software installation, you should configure all to match the settings and the controlled machine with all its electrical system. Elements to configuration: • Scale-up of each axis (e.g., how many pulses on the millimeter/inch). • Speed and acceleration settings for each axis. -
Page 36: The First Run
right mouse button and select the “Properties”. On the “General” tab enter any name e.g. “MyMillingMachine”, go to the „Shortcut” tab and in the „Target element” enter: C:\Mach3\Mach3.exe /p MojaFrezarka_400x250_CSMIO_IP Be careful to type the special signs „/”and „\” in appropriate places. You can type any other name of course but it must be identical as the created profile name. -
Page 37: Configuration Of Axes Used In The Machine
If during launching the Mach3 program, the „CSMIO/IP-M connection” window will appear, and the „Connection status” light in the diagnostic window flashes red, it means that the CSMIO/IP-M was not found in the network. In that case, check some possible reasons: •... -
Page 38: Configuration Of The Digital Input Signals
10.4 Configuration of the digital input signals Configuration of the input signals is selected in „Config” menu, „Ports and Pins” position, by selecting the „Input Signals” tab. The list of the standard input signals will appear and you can assign these signals to the hardware inputs of the CSMIO/IP-M controller. - Page 39 stops automatically, when this signal becomes inactive. THC Up For the plasma cutters. Signal of automatic torch high control, the active state causes the Z-axis raising. THC Down For the plasma cutters. Signal of the automatic torch high control, the active state causes the Z-axis lowering. OEM Trig 1-15 Using these signals, you can e.g.
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Page 40: Configuration Of Digital Output Signals
There is a possibility to give the same input PIN as LIMIT or HOME. You should turn off the „Home Sw. Safety” option in the „General Config” window of the Mach3 program. With the turned off „Home Sw. Safety” option, during the LIMIT signals are not monitored. - Page 41 with full current. This signal becomes active, when any axis is not moving. Current limit lets to reduce energy consumption and motors heating up – the same lengthening its life. Unfortunately, many controllers of the stepper motors do not have correct input to connect this signal.
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Page 42: Configuration Of Spindle And Cooling Controlling
10.6 Configuration of spindle and cooling controlling First, you must configure the output signals. To do this select from the menu the „Config/Ports and Pins” position and go to the „Spindle setup” tab. In the „Relay control” group set the Mach output signals numbers (those are not the numbers of CSMIO/IP outputs, see previous section about output signals configuration). - Page 43 For correct control of the revs you have to specify what range of the revs our spindle has (taking into account the inverter settings and eventually the ratio). Select the „Config/Spindle Pulleys..” menu position. If we use one ratio then enter „Min” and „Max” revs. Approve it with „OK.”...
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Page 44: Configuration Of The Resolution, Speed And Acceleration Of The Axes
10.7 Configuration of the resolution, speed and acceleration of the axes Before starting the work, it is necessary to set correctly the resolution (called scaling) of the axis and to set their max. speed and accelerations -in the Mach3 program - „Config/Motor Tuning” menu. In the window, first select the axis you want to configure, next enter the parameters and click on „SAVE AXIS SETTINGS”. -
Page 45: Configuration Of Motion Directions, Homing And Software Limits
While connecting the STEP/DIR signals to the drive (both servo and stepper drives) pay attention which STEP edge is active. The active edge in the CSMIO/IP-M is the growing edge – namely change of the STEP+ signal from the logic “0” state (0V) to logic “1” (5V). While connecting the controller–... -
Page 46: Additional Configuration Functions In The Plug-In Window
If the software limits option is set („Soft Limit” on the Mach main screen), the CSMIO/IP-M controller does not let for any move if axes of the machine are not homed. The current status of the function is shown with the green light around the „Soft Limit”... -
Page 47: Override Sources Tab, Feed Rate Correction Speed And Spindle Revs
10.9.2 Override sources tab, feed rate correction speed and spindle revs The Mach3 program allows you to change the feed rate and rotational speed of the spindle during the work. Normally it is made by two sliders on the main screen. If the machine is equipped in additional desktop with the buttons etc., using the CSMIO/IP-M controller you can control the feed rate and spindle rotations by the... -
Page 48: Special Functions Tab, Hvenable And Servoreset
10.9.4 Special functions tab, HVEnable and ServoReset. In some systems, the high voltage on some components is turned off in case of E-STOP pressing or when error occurs such as e.g. LIMIT or FAULT from the servo drive. It is usually made by the contactor. -
Page 49: Selection Of Inch/Mm Units
10.10 Selection of inch/mm units Selection of the units by which the axes in „Motor Tuning” are scaled is set in the „Config/Select Native Units” menu position. Select the unit in the window and close „OK”. 10.11 Parameters in the General Config window. In the „Config/General Config”... - Page 50 also LIMIT signals are not taken into account. With this option selected safe homing is made, LIMITs are all the time taken into account. Look Ahead Mach3 makes dynamic trajectory analysis in advance, to adjust motion speed in every trajectory place. In the „Look Ahead” area, you can enter number of G-Code lines, which should be analyzed in advance.
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Page 51: First Tests
First tests 11.1 Checking the input signals Before starting the tests in motion, you should first check the main input signals, such as: • Homing sensors – HOME • Limit switches – LIMIT • Emergency stop – ESTOP After running Mach3, go to „Diagnostics” tab. In the „Input signals current state”... -
Page 52: Verification Of Axes Scaling And Motion Directions
11.2 Verification of axes scaling and motion directions First control of the motion should be made at low speed. After pressing Tab key on the keyboard – the manual feed rate panel should open. In the „Slow Jog Rate” enter e.g. 10%. It means that the motion will have 10% of the maximum speed, defined in the Motor Tuning. -
Page 53: Homing And Software Limit Switches Test
11.3 HOMING and software limit switches test 11.3.1 First homing When the axes are scaled correctly and the motion directions are correct – it is time to make first machine’s homing. During normal work, most comfortable is to use the button of all axes homing („Ref All Home”... -
Page 54: Test Of Spindle And Cooling
11.4 Test of spindle and cooling. At this stage, almost all major elements of the system were set and the tool machine is almost ready to work. One important issue left – spindle test. Mach should be in the active mode. The quickest way to test the spindle is MDI mode. -
Page 55: Sample Processing Step By Step
Sample processing step by step To look closer for the rules of using the machine equipped with the CSMIO/IP-M control system – here is an example of a simple work. An example includes the area planning and milling the logo in the 30.6x30.6x48mm size cube made of hard aluminum alloy. - Page 56 The newly created object coincides exactly on the position and size with the working area. Now you should add the mentioned additional enlargement, so that the milling cutter will go with its whole diameter out of the material – thus we get a better surface.
- Page 57 You should inform the program what kind of tool you use. Below the Tool List click the Add button. In the tool-base window, click the Add Tool, to add a new tool. Enter the parameters as the picture shows. Some parameters like description...
- Page 58 Next, generate the tool trajectory for the logo. Go back to 2D preview, and in the Toolpaths tab panel, next to the last generated path – uncheck the Show In 2D|3D. Previous trajectory disappears so it will not disrupt our view. Now select our logo and again click the Area Clearance icon.
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Page 59: Preparation Of The Machine And The Mach Program
12.2 Preparation of the machine and the Mach program When files are ready, you only need to place and base the material. First launch the Mach3 program and make the reference ride of all axes pressing „Ref All Home” button on the main screen. - Page 60 At this point, we can set the material base in the X-axis by clicking „Zero X” button on the Mach screen. Coordinate X on the screen will be reset. Switch the feed rate mode on continuous one, „Slow Jog Rate” speed – e.g. 2% because we are very close to the material and the same way we set the Y base on the lower edge of the cube.
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Page 61: We Begin The Work
12.3 We begin the work In Mach program, we select „File/Load G-Code” menu position or click the „Load G-Code” button on the main screen. Select a created earlier file: „planing.tap”. When the file is loaded, we can initially set the machine over the material and enter on the MDI screen. •... - Page 62 After this operation, we can start the work from the second file not forgetting about the measurement after tool change („Auto Tool Zero” button). When the file is loaded, and the tool is measured we can set the axes again over the material with the MDI like before.
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Page 63: A Few Practical Notes About Mach3 Program And Csmio/ Ip-M
13. A few practical notes about Mach3 program and CSMIO/ IP -M Here are a few tips that can help people unfamiliar with the Mach3 program. 1. Computer keyboard. a. Do not use a wireless keyboard, sometimes this keyboard record keystroke, but does not notice releasing it, which can be very dangerous while controlling the machine. - Page 64 a. If you do not use the tool changer but you have the automatic tool-length measurement sensor, after starting Mach program always enter “1” in the pole “Tool”. 8. STOP button on the Mach3 screen stops the machine instantly. With the stepper motors it may cause motor will fall out from the position, with the servodrives the motors controllers may report an overload error or overstaying error and you will need to re- base the machine.
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Page 65: Visualbasic ® Macros
VisualBasic macros ® On the website: www.cs-lab.eu you can download standard scripts for handling automatic measurement of tool-length and for automatic tool replacement. These are usually the most desirable functions and make the work easier. For advanced users we invite to learn more about macros, which provide great opportunities for self-expanding functionality of Mach3 program 14.1 Automatic tool-length measurement Automatic tool-length measurement is one of most implemented function, e.g. - Page 66 4. Secure the tool in the spindle holder (for the firsts test – the cheapest is the best On the manual feed mode move to the center of the sensors measuring surface. Note the XY coordinates On the stepper mode slowly lower the Z axis until the signal from the sensor appears and note the Z coordinate.
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Page 67: Automatic Tool Change Macro
] – [ Parameter Details If you e.g. reaching the table Z=-122.070mm, and sensor gave an active signal at SENS_Z Z coordinate of sensor response Z coordinate of table level Z=-110.656mm – the entered value should be 11.414. It is parameter describing what height the Z-axis can slide down fast (G0). If we have doubts how long tools will be measured it is safer to enter „0”. -
Page 68: Addition A - Csmio/Ip-M Software Updates
15. Addition A – CSMIO/IP-M software updates We invite you to visit our website: http://www.cs-lab.eu for the CSMIO/IP-M software updates in the „download” section. The controller updates includes corrections and often enrich the device with new features so it is worth to update the controller regular. 15.1 How to check your software version The controllers’... -
Page 69: Plugins File Update
CSMIO/IP-M controller is protected if the programming will fail. There is always the possibility of re- programming the uploader application . Before updating – close the Mach3 program. 15.3 Plugins file update Last update step is to copy the new plugin version to the file directory: „C:\Mach3\PlugIns”. In the update package, the plugins file is called „CSMIO_IP_plugin.dll”.
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