KUNDLER CONTROLLERS TURBO-STEP. Step Motor Controllers. for. Special Control Applications. with Individual User Surface. and for

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1 TURBO-STEP Step Motor Controllers for Special Control Applications with Individual User Surface and for Standard CNC Controls (ISO/DIN 66025) A very Economic Alternative Solution Using a Powerful 1- through 8- Axis Interpolating Step / Servo Motor Controller PC Board Or a Programmable Module July

2 KUNDLER CONTROLLERS We are a Specialized Creative Team Located close to the Black Forest Since 1989 our Goal is: Create the most Efficient PC-Motor-Controllers Take Advantage of our Development Power, Reliability, Quality 2

3 Index TURBO-STEP Motor Controllers on PC Boards or Modules 4 Stand-Alone Controller Modules for Permanent Programs 6 Board TURBO-STEP 45 D 6 Board TURBO-STEP 45 S 8 Board TURBO-STEP 45 PCI 9 Board and extension TURBO-STEP 45 PCI-SPS 10 Extension SPS-Adaptor 2 11 Module TURBO-STEP 45 USB 12 Module TURBO-STEP 45 USB-V 13 Stand Alone Module CNC 45 S 14 System Box for TURBO-STEP 45 S or for CNC 45 S 15 Connection Board for TURBO-STEP 45 PCI 16 Power Controller Type CNC Program PCT25 18 Transparent Graphic Editor CNCGraph 22 Pin Assignments 23 3

4 TURBO-STEP Step Motor Controllers on PC Boards or Modules Powerful Motor Controllers for 1 through 8 Axis' with built-in Intelligence Properties These controllers plug into personal computers with the short ISA slot or the PCI slot. The controllers may drive 1 through 8 axis. The standard controller for the actual generation of personal computers is the type TURBO-STEP 45 PCI, plugging into a PCI slot. This type drives up to 8 axis, and special product derivates for special purposes are available. The controllers contain an own microprocessor with quartz timers and are thus vastly independent of the performance of the personal computer. All firmware has been created in assembler language, thus performing high speed, precise pulse timing and frequency stability. Data transfers between the PC program and the controller are working with handshake via the PC interface bus. Application With the motor controllers TURBO-STEP and a standard personal computer, a perfect and powerful machine control can be created within very short time. Using one of the modern software development systems, even complex special applications are created within a calculable period of time. Since all parameter settings, motion and i/o commands are ready to use within the controller's firmware, the programmer may focus his full attention on optimizing the application design. More than 70 simple and sophisticated commands are available, starting with linear interpolation and ending up with Spline interpolation with programmable speed profile. The step motor controllers may also be used for servo motor amplifiers with incremental control inputs. Please request detailed information from us. In order to build control systems with a high number of input ports and output ports, we supply the controller TURBO-STEP 45 PCI-SPS, consisting of a modified controller TURBO-STEP 45 PCI, a SPS-adaptor board placed outside the computer and connected to the controller, and the software package PCT25. This system is especially useful for customized machinery, units in production lines, etc. Additional external control components may be saved, because this system will control external valves, pumps, magnetic elements and read light barriers, actuators, switches etc. and can establish logic combinations through software configuration commands. All inputs and outputs are isolated. Occasionally, in a multi-axis control an auxiliary analogue output may be required, perhaps in order to control the power of a pump or any other motor drive, which is not used for positioning. For such applications the model TURBO-STEP 45 PCI-1 is available. This type contains an operational amplifier which supplies a programmable dc output within the range of 0 through +10 volts. Function All controllers are initialized by loading the firmware from the PC and then starting the controller program. In other words: the firmware is not self-contained within an EPROM, thus allowing for a very simple software update. All updates are developed with regard to permanent market observation and with respect to the wishes of our customers. All upgrades are compatible to the lower grade software issues and are free for all users (free download from Internet). As soon as a command has been transmitted from the PC program to the controller, this function will immediately be executed. While the controller is busy, the PC is free for other jobs. All controller functions may be tested on the target stage using the hardware debugger "DEMOSTEP.EXE". CNC Program With the standard CNC program PCT25, a turnkey control is immediately available. Executable drive programs according to the machine language DIN may be written with the integrated editor or with any other non-formatting editor and be saved on hard disk. Besides the basic positioning commands, many important functions are available in PCT25. These include the reference motion, manual control, teach-in control, a macro programming facility, tool radius correction, tangent control, I/O controls, subroutine processing, parameter calculation, parameter combination, timers, event counter, work piece counter, clipboard records for other running applications and much more. A 4

5 perfect syntax check avoids any program execution problems. The help system contains all necessary user instructions, facilitates a quick start-up and replaces completely any instruction manual. Program and help system may be installed in English, French or German language. All users who do not like the standard DIN/ISO commands may rename all commands according to their individual preference. This is achieved by means of an ALIAS table to be filled in the ini-file. Additionally, an intelligent format filter may be used to convert language items. It may even convert HPGL language into CNC language. DXF-files may be directly imported. DXF-files are generated by vector graphic applications and especially by CAD systems. The import feature uses parameters to select the line type, the layer and the colour. Further it contains a scale conversion. The import function converts into CNC language. Transparent Graphic Editor for the CNC Program The graphic editor CNCGraph is a very useful option for the CNC application PCT25. CNCGraph supplies a transparent drawing layer. The user must place it over an image or a drawing. First he has to select the scales pixels / mm or pixels / inch in X and in Y, then he may draw lines across the work piece, which are intended to be transformed into motion tracks within a processing program for PCT25. When the drawing is complete, the processing program can be created by a mouse click. This application is useful for dispenser machines, mini wave solder machines, welding machines etc. As a special advantage, the PCT25 program can be prepared on an extra computer, and does not need the installed CNC program PCT25. Operating Systems Loader, hardware debugger and the CNC program PCT25 are available for DOS, Windows 95, Windows 98 and Windows NT/2000/Me/XP. The controller families TURBO-STEP 45 PCI (PCI bus) and TURBO-STEP 45 USB are not supported under DOS. Planning your Machine Control The controller type TURBO-STEP 45 PCI suits for applications, which work with 1, 2, 3 or 4 axis and additional peripheral devices. It may also be used for up to 8 axis arranged in two groups of 4 axis. This controller issues asymmetric step pulses and direction signals, which can be jumper-selected for direct or isolated transmission. Up to 4 controllers may be installed in a single personal computer, to control a maximum number of 32 axis, including interpolation of up to 32 axis. Request our free project support if you are planning a system. We offer to create your special application software if required. The controller type TURBO-STEP 45 USB is compatible with TURBO-STEP 45 PCI. 5

6 Stand-Alone Controller Modules for Permanent Programs Powerful CNC Modules: Programmable in Personal Computers for Production Applications Properties These controller modules provide a simple, useful and very economic solution for controlling one-axis or multi-axis motion tasks predominantly in quantity production applications. The personal computer is not necessary for the machine control in the production plant, but only in order to develop the motion program. Once the program has been checked and is complete, the controller serves as a "black box" executing the program, which is stored within the module like "firmware". The controller may perform every motion from single axis motion up to multi-axis Spline interpolation with speed profile. This is how it works: Within the program development phase, this system displays its extraordinary flexibility. A new program may be created using a personal computer, with the board inside the module plugged into an ISA bus slot, and connected to the external system in the same way as from the module. The CNC compiler PCT25C is a CNC program and includes a firmware compiler. The user writes and checks the program, according to the machine language DIN When it is complete, he selects "Compile", which creates an INTEL HEX format file, which is used to burn an EPROM. He puts the EPROM into the controller and plugs it back into the module box, which is ready to go. All program features will be identical as checked before. Program selection, start, branching and program termination are controlled through the controller's input signals. The memory capacity may hold approximately 2500 instructions, which is very likely to be sufficient. Application for Step Motors and Servo Motors The module CNC 45S controls up to 4 step motor amplifiers or servo amplifiers with incremental inputs. Function The functional performance data correspond to those of the controller TURBO-STEP 45S. All motion commands from 1-axis motion up to 4-axis interpolation, described for this controller, are available. Applications Feeding devices, assembling devices, filling devices, test devices, etc. Consulting Use our manufacturer and programmer consulting. 6

7 TURBO-STEP 45D Step Motor Controller for 1 through 4 drives for High Step Frequencies Design: ISA board, to be plugged into computers Containing the ISA bus Control: Command and data bytes, Bi-directional transfer through the I/O-Bus Output Signals: 8 step and direction signals, TTL 4 free output port bits with TTL level Input Signals: limit signals, reference signals, Up to 10 free input port bits, Emergency stop For new designs select TURBO-STEP 45PCI Function When the controller is initialized, its firmware is loaded from the PC and the controller program is started. It contains linear interpolation in the plane X-Y, in the space X-Y-Z, and in the space X-Y-U, circular interpolation in the plane X-Y, tangent control with the axis U as turning axis, and all necessary parameter functions. In a second control mode, the controller performs independent motion of all axis' without interpolation and Spline or polygon interpolation for 2 through 4 axis with up to 2000 position vectors. During motion the actual position can be read by the controlling program and ports can be set and read. All commands and data are transmitted through the I/O bus of the computer. Commands Set the lower and upper ramp frequency for X-Y Set the lower and upper ramp frequency for Z Set the lower and upper ramp frequency for U Set the slope of the up going ramp for X-Y Set the slope of the up going ramp for Z Set the slope of the up going ramp for U Set the slope of the down going ramp for X-Y Set the slope of the down going ramp Z Set the slope of the down going ramp U Set the slope of the down going ramp for emergency stop Set the frequency range to 25/50 khz for XY Set the frequency range to 25/50 khz for Z Initialize the axis' X, Y and Z selectively and simultaneously at limit or reference inputs Initialize the axis U Set the logical levels of step / direction outputs Adapt to the logical levels of the limit inputs Set the actual position X,Y,Z,U in the controller Read the actual position in X,Y,Z,U Set the scale of U in steps per revolution Select the absolute/relative turning mode of U Tangent control of U on/off Linear motion to position X,Y, max 50 khz Linear motion to position X,Y,Z, max 50 khz Linear motion to position X,Y,U, max 50 khz Motion to position Z, max. 50 khz Motion to position U, max. 50 khz Circular motion with centre, arc and turning direction, max 50 khz Ramp setting and frequency divider for independent axis motion and Spline / polygon interpolators Independent motion of each axis up to 25 khz Transmit vectors for Spline / polygon interpolators Transmit speed profile for Spline / polygon interpolators Execute Spline / polygon interpolation Read / write ports during motion Read co-ordinates during motion Compatibility Manufactured since Full upwards compatibility with the discontinued type 25D. For new designs use the controller TURBO-STEP 45 PCI. Software Hardware debugger DEMOSTEP.EXE for Windows 95/98/NT/2000, DLL-driver for Windows 95/98/NT/2000. Option: CNC program PCT25 according to ISO/DIN (G-codes) for Windows 95/98/NT/

8 TURBO-STEP 45S Step Motor Controller for 1 through 4 axis' for High Step Frequencies For new designs select TURBO-STEP 45 PCI Design: ISA board, to be plugged into PC, XT and AT Control: Command and data bytes, Bidirectional transfer through the I/O-Bus Output Signals: 8 step and direction signals, 5-12V, 4 free opto-isolated output port bits with Darlington-stages Input Signals: limit signals, reference signals, Maximum 10 free input port bits, Emergency stop All inputs and outputs are isolated with optocouplers TÜV - certified CE. Function When the controller is initialized, its firmware is loaded from the PC, and the controller program is started. It contains linear interpolation in the plane X-Y, in the space X-Y-Z, and in the space X-Y-U, circular interpolation in the plane X-Y, tangent control with the axis U as turning axis, and all necessary parameter functions. In a second control mode, the controller performs independent motion of all axis' without interpolation and Spline or polygon interpolation for 2 through 4 axis with up to 2000 position vectors. During motion, the actual position can be read by the host program and ports can be set and read. All commands and data are transmitted through the I/O bus of the computer. Commands Set the lower and upper ramp frequency for X-Y Set the lower and upper ramp frequency for Z Set the lower and upper ramp frequency for U Set the slope of the up going ramp for X-Y Set the slope of the up going ramp for Z Set the slope of the up going ramp for U Set the slope of the down going ramp for X-Y Set the slope of the down going ramp Z Set the slope of the down going ramp U Set the slope of the down going ramp for emergency stop Set the frequency range to 25 / 50 khz for XY Set the frequency range to 25/ 50 khz for Z Initialize the axis' X, Y and Z selectively and simultaneously with limit or reference inputs Initialize the axis U Set the logical levels of step/direction outputs Adapt to the logical levels of the limit inputs Set the actual position X,Y,Z,U in the controller Read the actual position X,Y,Z,U Set the scale of U in steps per revolution Select the absolute / relative turning mode of U Tangent control of U on/off Linear motion to position X,Y, max 50 khz Linear motion to position X,Y,Z, max 50 khz Linear motion to position X,Y,U, max 50 khz Motion to position Z, max. 50 khz Motion to position U, max. 50 khz Circular motion with centre, arc and turning direction, max 50 khz Ramp setting and frequency divider for independent axis motion and Spline / polygon interpolators Independent motion of each axis up to 25 khz Transmit vectors for Spline / polygon interpolators Transmit speed profile for Spline / polygon interpolators Execute Spline / polygon interpolation Read / write ports during motion Read co-ordinates during motion Software Standard: loader for DOS and Windows 95/98/NT/2000. Hardware debugger DEMOSTEP.EXE with source files for DOS, hardware-debugger DEMOSTW.EXE for Windows 95/98/NT/2000, DLL-files for Windows 95/98/NT/2000 with script and HPGL-driver. Options: CNC program PCT25 according to ISO/DIN (G-codes) for DOS and Windows 95/98/NT/2000, the Windows version also with tool correction, all Windows software may be installed in English, French or German language. For new designs select the controller TURBO-STEP 45 PCI. 8

9 TURBO-STEP 45 PCI product no TURBO-STEP 45 PCI-1 product no TURBO-STEP 45 PCI (-1) Controller for step motors or servo amplifiers with incremental inputs, with high step frequencies up to 50 khz, controlling 1 through 8 axis Design: PC board for PCI bus Control: Command and bidirectional data transfer through the PCI bus Outputs: Step and direction bits, 4 free output port bits 24V / 1A 1 analogue output (only type 1) Inputs: 12 limit and reference inputs, 4 free input port bits 5-24V, emergency stop All logic signals isolated through opto-couplers Function When the controller is initialized, its firmware is loaded from the PC, and the controller program is started. The controller operates with 2 axis groups with 4 axis within each group. The axis group may be selected by a software command. The firmware includes linear interpolation in all planes and spaces up to 4 co-ordinates (X,Y,Z,U), circular interpolation in XY, Spline interpolation in all planes and spaces up to 4 co-ordinates (X,Y,Z,U) with up to 2000 vectors per individual curve, straight line, circular and Spline interpolation in XY with automatic tangent control of the axis U (for cutting application). Independent motion of each axis with individual speed and ramps is also possible. Port bits can be read or set during positioning motion of any axis. All these functions are available within both axis groups. Thus, 8 axis are available. Total number of instructions is more than 70. The controller TURBO-STEP 45 PCI-1 additionally supplies a programmable analogue output signal volts with reference to the GROUND potential of the personal computer. Generic Instructions Select axis group Select lower and upper ramp frequency Select ramp slopes Select slope of emergency / limit ramp Simultaneous reference motion of all axis with selectable limit actuators and logic levels Select logic levels of step and direction signals Select logic levels of limit signals Set actual position Read actual position Read inputs, set outputs Read limit inputs Execute single step Set scale of U in steps per revolution when used as turn axis with tangent control Select relative / absolute motion of U Select / deselect tangent control Interpolating motion commands, max. 50 khz Circle command (centre, arc length and direction), max. 50 khz Independent axis motion, max. 25 khz Set series of position vectors Execute Spline vector interpolation Set ramp profile for Spline motion Read / write ports under motion Read actual position under motion Software All software is running under Windows 95/98/NT/2000/Me/XP. Standard supply with loader and hardware debugger, supporting customer s own program development. The turnkey CNC program PCT25 (according to ISO / DIN 66025) is a very economic option. Accessories: A connection board for solder-free wiring to the external devices is available. This adapter allows signal level adaptation to single line or twin line (RS422) step/direction inputs of motor amplifiers. 9

10 Special Machine Control with TURBO-STEP 45 PCI-SPS (-1) Controller for 1 through 8 axis step motor drives or servo drives with incremental inputs with programmable SPS control Design: Control: Outputs: Inputs: PC board, for PCs with PCI bus, compatible with the controller TURBO-STEP 45 PCI, with SPS adapter for rack mounting Command and data bytes, bi-directional transfer through the PCI bus Step and direction bits, 16 free output port bits 24V / 1,5A each output has 7 different boolean functions with 2 inputs each 12 limit / reference inputs, 16 free inputs 5-24 V, emergency stop Function This system contains a controller derivative of the type TURBO-STEP 45 PCI, plugged into the PCI bus of a PC, and an adaptor unit on an aluminium plate to be mounted into a rack. The basic functions are a compatible extension of the functions of the controller TURBO-STEP 45 PCI. Additionally this control contains 16 logical bit inputs (0 or 24 V) and 16 power outputs (24 V / 1,5 A). Using controller commands, the user may create up to 7 logic functions to be assigned to each of the 16 outputs. The logic functions may even be changed within a fraction of a millisecond while a program is running. This system is dedicated to execute numerous motion and control tasks with compact and economic hardware. Besides intelligent motion control this includes controlled hydraulic or electrical feeding motion to a limit switch, interlocking of control elements, detecting extremely short events etc. All inputs and outputs are isolated through opto-couplers. The SPS adapter is connected to the controller through 2 SUB-D cables. The type -1 additionally contains an analogue output port (see type 45 PCI-1). Functions of the SPS-Adaptor 16 logical inputs are available. They can be read through controller commands. 16 switching outputs (24V / 1,5 A) can be directly operated by controller commands or be activated to perform special boolean functions with 2 successive inputs each. A macro cell is assigned to each output Qn, allowing to gate this output with 2 inputs In, In+1 and with the activation signal Sn, performing a selectable logic function. The following logic functions may be selected: Qn=Sn Qn=Sn AND In Qn=Sn AND In AND In+1 Qn=Sn AND (In OR In+1) Qn=Sn AND (NOT In ) AND In+1 Qn=NOT(Sn AND In) Qn=NOT(Sn AND In AND In+1) Qn=NOT(Sn AND (In OR In+1)) Software Running under Windows 95/98/NT/2000/Me/XP. The CNC program PCT25 (G-commands according to ISO / DIN 66025) is included. Extensive documentation for individual program development. 10

11 SPS-Adaptor II Product no KUNDLER CONTROLLERS The instructions of this extended SPS-adaptor are compatible with the standard adaptor. The following features have been added: Input Ports The voltage levels of the input ports range from 5 through 24 volts dc. The input ports to which logic combinations can be assigned, may be configured by inserting jumpers. These are the configuration options: 1. Inputs driven by a npn transistor, operating on a pull-up resistor 2. Inputs driven by a pnp transistor, operating on a pull-down rsistor If contacts are used to switch the inputs, an open switch reads high in case (1.) or low in case (2.) This selection may be chosen for the inputs 1 through 8 and differently for the inputs 9 through 16. the nine remaining inputs may be configured individually. All selections are made by jumpers. Output Ports The 16 logical outputs may be reversed by a jumper. Normally, the initial state of all outputs is low (0 volts). If the outputs are reversed, the initial state will be high instead (24 volts). If the program executes a switch-on command, the output normally goes high. However, if the jumpers have been selected for reversed outputs, it will go low. Thus, the device can be correctly adapted to the control environment. To adapt the output to the loads, the following additional options may be selected. Selection for the outputs 1 through 8 may be different from selection for the outputs 9 through 16. These are the options: 1. When the output goes high, it will be pulled to high by a CMOS high-side switch. When the output goes low, the high-side switch will be open. In both cases, the low-side switch remains open. 2. When the output goes low, it will be pulled to low by a CMOS low-side switch. When the output goes high, the low-side switch will be open. In both cases, the high-side switch remains open. 3. When the output goes high, first the low-side switch will open. Then the high-side switch will switch on. When the output goes low, first the high-side switch will open. Then the low-side switch will switch on. The timing ensures that no short circuit glitches will occur. The CMOS switches are designed for maximum 1.6 amps. They are short circuit proof and safe against overheating, switching off by overload. After removing the supply voltage, the outputs are ready again. The option no. 3 allows to reverse the polarity of a voltage to a load, for instance in order to reverse a dc motor. If a dc motor is used for one direction only, the half-bridge output causes a quick stop by shorting the motor. The SPS-Adaptor may also be used with TURBO-STEP 45 USB. 11

12 For USB Connection: TURBO-STEP 45 USB 1-through 8- axis controller for step motors or servo systems with incremental control with high step frequencies (max. 50 khz) Design: Al-box for rail mounting Control: USB connection to computer bidirectional transmission of commands and data through the computer s USB Output signals: Step and direction bits, 4 free output port bits 24V / 1A Input signals: 12 limit and reference inputs, 4 free input port bits 5-24V, emergency stop All logic inputs and outputs are opto-isolated Power supply: 9 V plug supply for VAC Commands and connections are compatible with the controller TURBO-STEP 45 PCI. Function When the controller is initialized, its firmware is loaded from the PC, and the controller program is started. The controller operates with 2 axis groups with 4 axis within each group. The axis group may be selected by a software command. The firmware includes linear interpolation in all planes and spaces up to 4 co-ordinates (X,Y,Z,U), circular interpolation in XY, Spline interpolation in all planes and spaces up to 4 co-ordinates (X,Y,Z,U) with up to 2000 vectors per individual curve, straight line, circular and Spline interpolation in XY with automatic tangent control of the axis U (for cutting application). Independent motion of each axis with individual speed and ramps is also possible. Port bits can be read or set during positioning motion of any axis. All these functions are available within both axis groups. Thus, 8 drives are available. Total number of instructions is more than 70. Generic Instructions Select axis group Select lower and upper ramp frequency Select ramp slopes Select slope of emergency / limit ramp Simultaneous reference motion of all axis with selectable limit actuators and logic levels Select logic levels of step and direction signals Select logic levels of limit signals Set actual position Read actual position Read inputs, set outputs Read limit inputs Execute single step Set scale of U in steps per revolution when used as turn axis with tangent control Select relative / absolute motion of U Select / deselect tangent control Interpolating motion commands, max. 50 khz Circle command (centre, arc length and direction), max. 50 khz Independent axis motion, max. 25 khz Set series of position vectors Execute Spline vector interpolation Set ramp profile for Spline motion Read / write ports under motion Read actual position under motion Software Running under Windows 95/98/NT/2000/Me/XP. Standard supply with loader and hardware debugger (all running under Windows 95/98/NT/2000/Me/XP for customer s own program development. The turnkey CNC program PCT25 (according to ISO / DIN 66025) is a very economic option. Accessories: SPS-Adaptor for extended peripheral devices and for solder-free connection to all devices. Unipolar or bipolar (RS422) amplifier inputs can be connected. Many additional isolated input ports and power output ports are available. 12

13 TURBO-STEP 45 USB-V USB-Controller with Distributor Board and RS422-Drivers Extended Controller TURBO-STEP 45 USB with distributor board mounted on the box Function The functional description corresponds to that of the controller TURBO-STEP 45 USB together with the distributor board. This device represents a compact controller unit for 8 drives with a minimum of cabling. 13

14 Controller Module CNC 45S CNC Motor Controller for Permanent Programs for up to 4 Step Motor Axis', with interpolators (straght line, circle, spline) May be used for interpolation or independent motion of each axis Design: Controls: Module in Al box, LxWxH: 341x44x238 mm, weight: 1,5 kg Logical inputs with 24 Volts level Logical outputs with 24 Volts / 1,5 Amps max Motor Drive Signals: 1 step and 1 direction bit for each axis, Level: TTL through 12 Volts Input Signals: 8 limit inputs, 8 free input port bits, stop input Output Signals: 4 Darlington outputs 24 Volts / 1,5 Amps Power Supply: 24 Volts DC, 250 mamps All Input and Output Signals are Opto-Isolated Function The controller module serves to control programmed motion of up to 4 drives of one ore more machines within industrial environment. If used for one machine, a number of interpolators is available to create practically any complex motion even with selectable speed profile. If more than one machine is controlled by this module, each individual axis may be separately controlled, in this case without interpolated motion. The program is created in CNC language according to DIN using a personal computer. While being developed, the program may be tested with the target machine. For this purpose, the controller may be removed from the box and simply be plugged temporarily into the PC. Preferably you may use a separate controller board to be permanently installed within the PC for programming purposes. As soon as the CNC program is complete, it will be compiled, whereby an INTEL HEX format file will be created, which is ready to be loaded into an EPROM. After putting this EPROM into the controller board, plug the board back into the module and the controller module is ready to work. All programs may be saved on storage media as usual. Generally, program execution is started, controlled and terminated by external switches, push-buttons or any other events entered through the controller's input bits. Activating the emergency stop input terminates immediately each motion and de-activates the controller until it will be restarted. The instruction set is identical with that one of the controller TURBO-STEP 45S. Connection to Amplifiers and Peripheral Devices For these connections, it is recommended to use the System Box. It facilitates cable branching to the various external devices, such as amplifiers, switches, magnetic valves, limit actuators etc. Contents of Delivery Module with 24 Volts power supply cable, 1 m, instruction manuals, CNC program / compiler PCT25C according to DIN The EPROM programmer is not included. We create your application program on request. 14

15 System Box for TURBO-STEP 45S or CNC45S Connector Box with two Cables with Sub-D Connectors Connects the controller to the motor amplifiers, limit actuators, switches, magnetic valves, etc. Design: Al-box with printed circuit board inside, dimensions: LxWxH: 185x44x238 mm, weight: 0,75 kg, 16 cable outlets (5 mm diameter), 2 Sub-D- connetor cables, length: 1m, 15 and 25 pins Optional design: p.c.b. mounted on an aluminium plate Fig.: System Box 1 2 types with different functions Application This box facilitates the connection of the controller connectors to the motor amplifiers, switches, pushbuttons, limit switches, the emergency stop switch, the magnetic valves, e.t.c. When putting into operation the system, no soldered connection must be made. All connections will be screwed. Two different types are available: System Box 1 For all step motor amplifiers with opto-isolated inputs. The step and direction signals are transmitted through one line each, going low and high with reference to GND or to a positive common voltage. This option is used for instance for the amplifiers of the following manufacturers or suppliers: SIG-Positec Phytron Yaskava servo amplifiers System Box 2 For all step motor amplifiers or incremental servo amplifiers whose inputs are symmetrical line receivers (RS422-receivers). Each step and direction signal is transmitted through a pair of lines switching low and high with symmetric levels. This option must be used for the power amplifiers and incremental servo amplifiers of the following manufacturers: Berger Lahr Positec (Twin Line) Bosch-Rexroth-Star Phytron Contents of Delivery System Box, 1 Sub-D cable 15p (m-f 1:1), 1 Sub-D cable 25p (m-f 1:1), length: 2m, circuit diagram. Customer-specific cables to the power amplifiers Please request our special cables to the power amplifiers of your choice. 15 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

16 Connection Board for TURBO-STEP 45 PCI Connection board with 2 SUB-D cables Used for safe and solder-free connections of the controller to the amplifiers, limit actuators, switches, solenoids etc. Design: printed circuit mounted on an aluminium board 260 x 125 mm, or on an angle support Selectable signal levels to adapt to the inputs of the motor amplifiers Product no Application This connection board is an accessory of the controller TURBO-STEP 45 PCI. It serves to facilitate the connections to the motor amplifiers, limit actuators, switches, solenoids, emergency stop etc. System wiring does not need any soldering because of screwed terminals. This device is used for motor amplifiers which may need either asymmetrical or symmetrical (RS422) input signals. The user may decide by setting appropriate jumpers, whether the original asymmetrical signals are fed to the amplifiers or are converted into symmetrical signals previously. By this feature, step and direction outputs of the controller may be adapted to all unsymmetrical levels with 5 through 12 volts of t symmetrical levels of 5 volts. Unsymmetrical signals are used with amplifiers with opto-coupler inputs or with current controlled inputs. However, symmetrical signals are used with amplifiers which have line receivers or differential amplifiers. Please refer to the supplier s documents. In case of doubt refer to us. Both unsymmetrical and symmetrical signals may be transmitted either with reference to PC GROUND or isolated from GROUND through opto-couplers. Supplied Items Electronic board, mounted on an aluminium plate, 1 SUB-D cable 15p, 1 SUB-D cable 25p, length 2m, circuit drawing with wiring instructions. User Specific Cables for Motor Amplifiers Please ask us for user specific cables for Motor Amplifiers of your supplier. We manufacture special cables for your application also in unity quantity. Connect the plugs and switch on Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

17 Power-Controller Type *** all inclusive *** Intelligent 3-axis Servo Controller with 3 Servo Amplifiers for Complex Motion Control through the Serial Port of a PC Design: corrosion-free steel box, Under table mounting, dimensions: 425 x 410 x 90 mm weight: 15 kg instructions and data Control: transmitted through PC serial port Motors: DC commutation motors with incremental transmitters nominal power: 150 W, max. 380 W Output Signals: 4 free output bits with Darlington amplifiers Input Signals: 2 free input bits, TTL level Emergency Stop Button, CE conformity Program CNC "PCT25" for Windows 95/98/2000/NT is included Function This box includes an intelligent motion controller commanded by an allocated PC, 3 servo motor amplifiers and the power supplies for 115/230 50/60 Hz. Applications >>> Control system, ready to use, according to standard DIN/ISO, operating with PC >>> Extremely powerful motion control, including linear, circular and Spline interpolation >>> Drives with incremental control, operating very smoothly >>> Positioning, assembling, cutting, engraving, dosage, including automatic tangent control >>> Easy to use when creating a program surface under Windows instead of using CNC >>> Brings along software sources and DLL for this purpose Technical Specification: Power supply: 230 / 115 volts, +10% / Hz, 1kVA Design: corrosion-free steel box, under-table mounting Dimensions: 425 x 410 x 90 mm / x x 3.54 inch Weight: 15 kg Front face controls: power switch, operation lamp, emergency stop button Rear face controls: voltage selector switch 230 / 115 volts, reset button, 4 Sub-D-connectors for communication, auto-check, I/O signals, incremental feed-back, motor cable plugs Nominal motor voltage: 24 volts DC Nominal motor power: 150 W Maximum motor power: 380 W Incremental feed-back: 200 through 500 increments per revolution, signals a-b, TTL level Incremental resolution: 1 x, 2 x or 4 x Referencing method: precise referencing at the axis stops with reduced torque without using any sensors Selectable current threshold for automatic switch-off on excessive motor current 17 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

18 PCT25 the Powerful Universal CNC-Program The first release of this CNC program, based on personal computers with KUNDLER CONTROLLERS devices dates back to Meantime it has permanently been improved to meet the requirements of our customers, when designing machinery with intelligent features. It is not only selected to control tool machines, but also for special machines for manufacturing and manipulation, feeding, filling, printing as well as for all sorts of robotic machinery. The EURO Version in 3 Languages The complete Windows software related to TURBO-STEP presents itself in 3 selectable languages, to meet the needs of the growing economic activities within the European Community. The language of menus, messages and the help system will be switched to English, French or German either by selection in the install program or by detecting the system language. The help system is so extensive that no hardcopy description is required for PCT25. Set of Commands According to the Standard DIN The commands to be executed by PCT25 will be typed into an integrated editor. The command files may be saved on any data media. The command format corresponds to the standard DIN 66025, but many special commands, which are not defined within the standard, have been added. This applies for instance for the reference motion, especially necessary for step motor drives or servo drives with incremental feedback. The user will find a very detailed description of every command within the help system. The following groups of commands are available: 1. Fast Traverse Motion Command G00 Single axis motion or linear interpolation with fast speed parameters, usually executed between successive processing motions or actions 2. Working Speed Motion Commands G01, G02, G03, G20, G21, G22, G23, G25, G40, G41, G42, G80 G01 is the single axis or interpolating multi-axis motion command for work piece processing (e.g. milling, engraving, welding, dispensing etc.). G02 and G03 are the circle commands (cw and ccw, respectively). G20 through G23 activates and de-activates the tangent control for the axis U, G25 provides a set of reference motion commands with different features, G40 through G42 are radius correction commands, and G80 controls polygon or Spline interpolation for series of maximum 2000 position vectors. 3. Commands for Speed Control G61 through G67 The commands G61 through G67 perform the speed settings for working motion and fast traverse, as well as for speed profiles within working speed motion and for the emergency and limit stop ramps. 18 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

19 4. I/O-Commands G11, G12, G13 The commands G11 and G13 are used to read input ports or to wait for a specific state of an input port. G12 serves to set the output ports and to adjust the value of the analog output (types TURBO-STEP 45 PCI-1 and TURBO-STEP PCI-SPS-1 only). The number of ports depends on the type of controller. 5. Timer Commands SETTIMER, TIMER The command SETTIMERn is used to start on of 10 available timers. The counted time value will be set to zero. When the command TIMERn.mmm has been detected, the actual program will wait until the time mmm will have elapsed since the timer n has been started. The actual timer values may also be picked up for program branching. 6. Program Control Commands G30, G31, Lnn, M17, M00, M02, M20-M22, M24, M25, M30 These commands serve to control program branching, program stops and the program termination. G30 controls the conditional jump after evaluating a comparison. Co-ordinates, parameters, timer values and logic states may be used within a comparison. G31 executes the unconditional jump. Lnn and M17 include the call, the start label and the termination of a subroutine. M02 terminates the program execution and M30 terminates the program text. With the PCI controllers, M20 and M21 control selection of axis groups including the switching mode. The commands M00, M24 and M25 are used to control program stops: M00 executes a programmed stop, whereas M24 and M25 are used to select, which output ports have to be changed automatically on a program stop released by an emergency stop input. 7. Calculation with Parameters 100 parameters may be used within a program. They may contain variables for arithmetic or logical operations. The contents may be evaluated for branching, to calculate target coordinates and be transferred to output ports. 8. Expert Commands G78 and G79 Several very special generic commands of the controller do not have any correspondent command within the set of CNC commands. The expert commands are used to issue anyone of these original controller commands to the controller. 19 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

20 PCT25 user form with open help page Control Options within the ini-file The ini-file offers a large variety of options for the individual user. First, this includes the connection of several controllers to the program. Then, scales and dimensional units as well as decimal formats of numbers can be adjusted. The buttons for manual controls may be labeled with individual meaningful names. Also those users, who do not like the CNC language, will find a solution: they may modify the command syntax and rename commands. For example the working speed motion command G01 may be renamed with MOVETO. Another editing help is the macro feature: the user may write down named macro text blocks which occur repeatedly within the program. Placing the macro name at the target locations within the text will then automatically insert the referenced text block, when the MACRO EXPAND button is clicked. The background procedures ACTIVATE and PASSIVATE are very popular tools. They are used to complete executable programs which have been automatically created with CAD software, thus avoiding, that the user must do a painful job and insert activating instructions 20 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

21 at the start of each working speed motion and passivating instructions at the end. In many cases the drawing program just generates operating and idle motions, not knowing if this program will be used to dispense glew, to weld along programmed lines or to guide an observation microscope. Each of these processes will need different activation and passivation commands. The relative command strings are only once stored within the sections ACTIVATE and PASSIVATE in the ini file and will automatically be inserted at the respective transitions. Within a welding application, the activation command string would include first the vertical positioning, then ignition, the burning check, the pre-heat period and finally the begin of motion. The passivation command string would include extinguishing the burner jet, then vertical retraction of the jet and finally the fast motion to the next start position. An additional feature in the ini-file is the file filter. It serves to adapt dialect expressions in a CNC file according to DIN 66025, which are not understood by PCT25. For instance the decimal separator may be changed from comma to point with a single mouse click within a large program. Finally, the ini-file contains a very important section, delimited by the keywords INIT BEGIN and INIT END. The sequence of commands, which is placed within these delimiters, will be executed when opening the program PCT25. This is the location to place all configuration commands which are assigned to the machine under control. Such parameters as the direction of the axis, the active level of the step pulses, the logical sense of the limit inputs should range under these configuration commands. 21 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

22 The Transparent Graphic Editor CNCGraph This program requires Windows 2000 or higher. Any lower Windows versions cannot supply the transparent drawing form. CNCGraph supplies a transparent drawing form. The user opens the program over the image or a drawing of the work piece and adjusts and extends it over the area to be treated. He draws lines along which the treatment has to be executed. When the drawing is complete, it will automatically be converted into an executable file for PCT25. Typical applications are dispensing, mini wave-soldering, welding etc. The following parameters are selected to achieve a proper adaptation: - the X scale in pixels per mm (or inch) - the Y scale in pixels per mm (or inch) - the number of decimals of the CNC co-ordinates The transparent graphic editor is positioned over the work piece image. Then, the lines are edited, along which a treatment in the CNC program is to be executed. 22 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617

23 Pin Assignments All connectors are Sub-D type with pins. PCI and USB pinning are identical. Pin name translations: RICHTUNG = direction ENDLAGE = limit input SCHRITT = step EXTERN NOT HALT = external stop 23 Dipl.-Ing. Walter Kundler Moltkestraße 26 D Waldkirch Tel Fax 23617