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Power Automation America, Inc.
 The new generation of CNCs - PC Based and Open Architecture
 

Power Automation America, Inc.

Connections

Power Automation America, Inc. offers a complete line of CNC controls and common accessories for a complete automation solution from one source. Even though a particular application might require a different combination of standard and optional hardware items, Power Automation America, Inc. provides the interface hardware (cables and adapters) to support the integrator to bring it all together. The various connections to the Power Automation CNC and its accessories are described below.

 


 

Page Index:

CNC Models

Front Panels

Inputs and Outputs

SERCOS (Digital) Drives

Analog Drives

Machine Tool Builders Panels

Auxiliary Panels

Handheld Operator Station

Manual Pulse Generators

Power Supplies

Miscellaneous Buttons and Switches

 


 

CNC Models

 

The standard LW models include a built-in interface to 4 analog servos (4 encoder inputs, 4 analog outputs; this is called the 4AXLX module) and a built-in interface to a number of 24V discrete input and output signals: 48 inputs and 32 outputs (two 2416LX modules are built-in). These systems are expandable with access to more servos by adding one external 4ENC4A module (M149, up to 8 axes total), and with access to more IO signals by adding the external 2416 module(s), as needed (MM77, each module has 24 inputs and 16 outputs).

  

The standard eCNC analog models include an interface to 4 analog servos (using the 4ENC4A MIO, M149) and an interface to a number of 24V discrete input and output signals (using the 2416 MIO, MM77). These systems are expandable with access to more servos by adding the 4ENC4A module(s), as needed (up to 64 axes), and with access to more IO signals by adding the 2416 module(s), as needed.

 

The standard eCNC SERCOS models include an interface to 8 digital servos on a single fiber optic ring (using a SERCOS master in the control) and an interface to a number of 24V discrete input and output signals (using the internal 2416 connector and an external 2416 MIO, MM77, when more than 24/16 are provided). These systems are expandable with access to more servos by adding another ring, as needed (up to 32 digital axes), and with access to more IO signals by adding the 2416 module(s) as needed. The SERCOS system can also interface to analog servos by adding the 4ENC4A module(s), as needed (up to a maximum total of 64 axes of both types). 

 


 

Front panels

 

For each CNC model above, there are two cables available between the CNC industrial PC (IPC, in a CE-rated stainless steel shell) and the operator panel. The first is the keyboard cable (when the front panel has a keypad; the front panels with the 15" touch screen do not) and the second is the VGA cable (IPC has VGA card with standard VGA 15-pin high-density connector). These cables can be up to 10meters (about 30feet) which is the limit for the VGA signals. This is standard PC technology and a number of vendors offer a commercially available KVM-extender (keyboard, video, mouse) that transmits these signals via a high-speed Ethernet connection over very long distances.

 

For the touch screen option (available for either the 12.1” or 15” color displays) for the operator front panels, there is an additional cable provided to support the touch screen. It connects the touch screen to the IPC at both the PS/2 mouse connector and the COM1 serial port.

 

There is also a comprehensive front panel option (M268) that includes the 15” TFT touch display, the Machine Tool Builder’s Panel hardware (M309) and a Manual Pulse Generator (M318) all in one panel.

 


 

INPUTS & OUTPUTS:

 

SERCOS Built-in IO (24Volt Discrete Inputs and Outputs)

 

The SERCOS servo model of the Power Automation CNC offers a 50-pin D-shell connector with 24 24VDC input signals and 16 24VDC output signals. This connector is pin-compatible with the 50-pin D-shell connectors for the MTBP models and the Auxiliary panel.

 

If these discrete IO signals are required without one of those front panel accessories, then a breakout card (M314) with a standard 50-pin IO cable (available in many lengths; MM82 for 2meters) can be obtained from Power Automation to convert the 50-pin D-shell connector to terminal strip connections. The discrete wires from the breakout are connected to the modular IO connectors as needed.

 

 

24Volt Discrete Inputs and Outputs

 

The connection of the discrete logic signals from the machine and/or control to the Power Automation CNC is rather easy. The connections on the 2416 Modular IO (MM77) and on the 2416LX built-in IO module (LW CNC or L2 analog CNC) use pluggable terminal strips (MM80). Up to eight signal wires are wired to a single 8-pin connector, using a flat-blade screwdriver and the stripped end of the wires. Five connectors are provided for the three input bytes and the two output bytes per module.

 

If other IO bus technologies such as a field bus (e.g., DeviceNet, Interbus, Profibus, CAN bus) are used, then the type of connections depend on the hardware being used.

 

 

10Volt Analog Inputs and Outputs

 

The connection of the analog signals (from –10VDC to +10VDC) from the machine and/or control to the Power Automation CNC is also rather easy. The connections on the 4AD4DA Modular IO (M148), the 4ENC4A Modular IO (M149) and on the 4AXLX built-in IO module (L2 analog CNC) use pluggable terminal strips (M183 for 4AD4DA; M181 for 4ENC4A; M186 for 4AXLX). Up to eight wires (for four pairs of analog signals) are wired to a single 8-pin connector, using a flat-blade screwdriver and the stripped end of the wires. One connector has 4 channels (each channel is one signal pair) of either analog inputs or analog outputs; no signal mixing of inputs and outputs on one connector is allowed.

 

 

Relay Outputs

 

The connection of the normally open contacts (for PLC controlled relays) to external electrical circuits from the Power Automation CNC is also rather easy. The connections on the 16RO Modular IO (MM72) use pluggable terminal strips (MM74). Up to eight wires (for four pairs of wires to each contact) are wired to a single 8-pin connector, using a flat-blade screwdriver and the stripped end of the wires. Each connector has 4 contacts for 4 relays (each relay has one wire pair for its contact); four connectors are provided for the 16 relays per module.

 

 

Encoder Feedback Inputs

 

The connection of the encoder feedback signals (5VDC differential (TTL square wave) incremental encoder signals, with two signal pairs for the position feedback (A, /A, B, /B) and one signal pair for the marker pulse (I, /I) are expected) from the servo drive and/or motor to the Power Automation CNC is also rather easy. The connections on the 4ENC4A Modular IO (M149) and on the 4AXLX built-in IO module (LW CNC or L2 analog CNC) use standard 15-pin D-shell connectors. Power Automation offers a flying lead cable (M182) with the 15-pin D-shell connector, in a 3-foot length, to make this connection easier. Alternately, a 15-pin D-shell connector can be pinned and individually wired with commercially available parts. The flying lead wires are wired to a terminal strip at the drive or to a nearby terminal strip where the encoder signals from the motor (or drive) are connected. If the drive has a pinned connector, then the wires can be attached to the appropriate pins on the appropriate connector for that drive.

 

Alternately, a breakout card (M315) can be obtained from Power Automation to convert the 15-pin cable connector to terminal strip connections when the integrator obtains a cable with 15-pin D-shell connectors on both ends. The encoder is wired to the breakout terminal strip.

 


 

SERCOS (Digital) Drives and Motors  

 

The connection of the SERCOS drives (and their motors) to the Power Automation CNC is rather simple, given the SERCOS architecture.

 

The fiber optic ring includes a fiber optic cable from the CNC to the first SERCOS drive on the ring, another cable from one drive to the next (typically very short, when all drives are mounted adjacent to each other) and a cable from the last drive back to the CNC. For shorter distances, plastic cables can be used; for longer distances, glass cables are used (as glass has less effect on the transmission of the light signal than plastic). Typically these fiber optic cables are provided by Power Automation only with the drives/motors package, rather than available as a separate part number. The SERCOS drive manufacturer will also support these cables for their drives (either new or replacement).

 

The motor feedback is wired only to the drive. No connection of the position feedback from the motor to the CNC is required in a SERCOS system since the position loop is closed in the drive and the CNC gets the position information over the SERCOS fiber optic network. This SERCOS architecture enables a variety of feedback technologies to be applied without affecting the CNC (such as an absolute or incremental encoder, resolver, etc.).

 

The axis home switch is wired to the drive; whether this connection is done via terminal strip or pinned connector depends on the particular drive manufacturer. The axis overtravel switches are wired to 24V input signals to the CNC (as discrete input signals, described above).

 


 

Analog Drives and Motors

 

The connection of the analog drives (and their motors) to the Power Automation CNC is described above, with the speed control accomplished with the 10V analog output connection and the position feedback accomplished with the encoder feedback input connection.

 

The axis home switch and the axis overtravel switches are wired to 24V input signals to the CNC (as discrete input signals, also described above). Other possible drive signals (e.g., drive enable and drive fault) are similarly wired as discrete IO signals.

 


 

SERCOS CNC Status

 

The SERCOS servo models of the Power Automation CNC (L2 or eCNC) offer a high-density 15-pin connection for two status indicators, supported by two hardware relays. The individual relays indicate that 1) the CNC power is valid and 2) the CNC software is running. These two relay contacts can be wired into the control’s electrical system as required. Typically, the first (power ok) is wired into a ‘control on’ circuit while the second (CNC ok) is wired into an emergency stop circuit. To expedite this connection, a cable (15-pin high-density to 15-pin D-shell; M323) and a breakout card (M315) can be obtained from Power Automation to convert the 15-pin high-density cable connector to terminal strip connections. Alternately, a 15-pin high density connector can be pinned and wired from commercially available parts. The discrete wires from the breakout are connected to the electrical system as needed.

 


 

Analog CNC Status

 

The analog servo models of the Power Automation CNC (LW, L2 or eCNC) offer a 6-pin connection pluggable terminal strip for two status indicators, supported by two hardware relays. The individual relays indicate that 1) the CNC power is valid and 2) the CNC software is running. These indicators are the same as for the SERCOS servo model. These two relay contacts can be wired into the control’s electrical system as required. Typically, the first (power ok) is wired into a ‘control on’ circuit while the second (CNC ok) is wired into an emergency stop circuit. The discrete wires from the pluggable terminal strip are connected to the electrical system as needed.

 


 

Machine Tool Builder’s Panel  (MTBP)    

 

The Power Automation MTBP (Machine Tool Builder’s Panel) can make the operator’s panel design and implementation easier. The MTBP has the common operator switches for many CNC applications. The MTBP has two sizes to match the corresponding CNC front panel configurations, either 19” rack mount (M319) or the slim line (M309). The different layout for the slim line model allows for an additional four general purpose push buttons (M319 has 8; M309 has 12); each of these push buttons has a programmable LED. Both models are only a few inches deep, just like the front panels with Windows 2000 based CNC models. Different cable lengths are available for its 50-pin connector.

     

When using the SERCOS CNC, the MTBP’s included 2-meter cable is pin-compatible for an easy installation. By connecting the cable from the MTBP to the SERCOS control’s built-in IO connector (and loading the PLC application template for the MTBP I/O), it takes just a few moments to be running with the MTBP.

 

Alternately, if the built-in IO connector is not used, a breakout card (M302) can be obtained from Power Automation to convert the 50-pin D-shell connector to terminal strip connections. The discrete wires from the breakout are connected to the input and output bytes of an IO module.

Any of the general purpose push buttons on an MTBP (on M309, M319, M293, M295) can be custom engraved for a nominal charge (M305).

 


 

Auxiliary Panel

 

For the 19” rack-mount CNC front panel configuration, an Auxiliary Panel is also available. This panel has the same size as the 19” MTBP but it includes just 16 general purpose push buttons (each with an LED) and a handwheel (also called a manual pulse generator or MPG). The handwheel in these Auxiliary Panels comes in either 5V encoder (M295) or 24VDC input (M293) models.

 

A breakout card (M302) can be obtained from Power Automation to convert the 50-pin D-shell connector (at the end of the included 2-meter cable) to terminal strip connections. (Alternately, a 50-pin D-shell connector can be pinned and wired with flying leads from commercially available parts.) The discrete wires from the breakout are connected to the input and output bytes of an IO module. If the 5V encoder MPG model is provided rather than the 24VDC input model, the encoder signals are provided from a terminal strip on the back of the unit (rather than within the 50-pin connector) to enable an easier connection as an encoder input (such as the flying lead cable described above (M182) with the encoder feedback input).

 

Any of the general purpose push buttons on an MTBP (on M309, M319, M293, M295) can be custom engraved for a nominal charge (M305).

 


 

Handheld Operator Station

 

The handheld operator station provides a simple solution to the requirement for remote operator activities. This rugged pendant includes the handwheel (in either a 5V encoder model, M316, or a 24V input model, M300) with several buttons and switches. The cable comes with its bulkhead connector. Models with longer cables are also available (M336, M337) with the same bulkhead connector.

 

The discrete wires from the round 26-pin connector are connected to the appropriate input and output bytes of an IO module. If the 5V encoder handwheel is present, the flying lead cable (described above with the encoder feedback input) can be used.

 


 

Manual Pulse Generators

 

Each manual pulse generator (MPG) comes with a handwheel with 100 positions. The back of the MPG has a 6-pin terminal strip: 2 pins for the input of the power supply (either 5V (M317) or 24V (M318), depending on the model) and then 2 pins each for the output of the A and B phases. With the 5V model, the wire pairs provide the differential signal for the encoder. With the 24V model, only one of each pair is used for A and B because the 24V logic is not differential.

 

 


 

Miscellaneous Buttons and Switches

 

The CNC operator panels have a number of holes predrilled that are covered by the front panel foil. They enable the mounting of operator push buttons on the CNC front panel itself. For some applications with minimal operator button requirements, the buttons could be placed on the front panel avoiding the cost of additional operator panels. Alternately these buttons and switches can be mounted on any operator panel. A 24-position rotary gray-code switch (M165, used for a feedrate override or a spindle speed override) is available, as well as the cycle start and cycle stop push button pair (M166, both can be illuminated) and the jog plus and jog minus push button pair (M167, both can be illuminated). No wires are provided with these switches; they would be individually wired to an IO module as discrete inputs and outputs.

 


 

More information with pictures is available online for our CNC Controls  and Accessories.

 

For more information, please contact us:

 

Power Automation America, Inc.
8601 Jameel Road Ste 140
Houston, TX 77040

Phone: 713-263-9400

Fax: 713-686-9301

Email: sales.america@powerautomation.com

 

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