Sections:

Physical Layout

Power Supply

Opto and Digital Outputs

Step Outputs

Recommended Driver Connections
Dual X-axis

Limit and Special Inputs

Recommended Limit Cabling
Input Noise Filtering
Input Status LED Array

Encoder Inputs

Analog Outputs

15 Isolated Inputs

Field Serviceable Components

Ordering Information

M40-M41K Differences

Physical Layout

The M41K is ExtraTech's main interface board.  The M41K comes in 3 flavors,  the T2 , T3 and T4.  All types/flavors have some common components and features such as. . .

8 Optically Isolated Solid State Relays 8 Optically Isolated Limit Inputs Ribbon cable (HPR01) for interfacing into the M60. Board Shape, size and software interface.

All M41K's also support Step and Dir signals, however, the method is controlled by the type.

For applications that converting from the M40 to the M41K, see the additional notes at the bottom of this document.

T2	This is the more generic flavor that is intended to be and easy upgrade from the M40. On the T2, all terminal connectors are vertical and Step and Dir are supported through 2 terminal blocks and the M60 ribbon cable. The T2 can be sandwiched between the M60 and the controller board, however, due to the fact that some of the connectors are vertical, the over all board height will be taller than a T3. Power input is handled via the terminal connector P1 or the M60 ribbon cable.
T3	T3 is a higher end board designed to minimize overall stack height when used with a M60. The T3 is a fully populated and more expensive version of the T1. All connectors on the edge of the board are horizontal and all connectors towards the center are vertical. Terminal blocks are supplied for step and dir signals for use if the application doesn't use an M60, or if the application calls for more than 4 motors. The analog portion of the circuit is populated, which supplies an isolated 0 to 5 volts, or 0 to a variable voltage up to 10 Volts.  This output can be controlled by the DAC software port, or by the laser control circuitry (for running analog lasers.)
T4	Type4 is a fully populated board like the T3, with all connectors vertical (like a Type2).

Power Supply

Only a +5V (2.0A) power supply is required. The power supply voltage(s) are brought to the board at header P1 ( On T2 and T3 boards ). P1.2 and P1.1 are the primary power input pins, the rest of the +5 volt and Ground references are there for wiring convenience, and are intended as outputs only.

If the application uses an M60, the power supply requirements are met by the M60 and no other supply is necessary.

Feed rate override is an option that must be ordered when the system is purchased.

The current usage listed is only for on-board requirements; off board requirements through the motor and I/O headers can raise the current requirement.
 

Opto and Digital Outputs

The M41K  supports 8 Optically Isolated Outputs. The boards normally come populated with PVG612 outputs that will allow the user to switch 0-60V AC or DC at up to 1 amp.  Other outputs chips are available.  Please contact ExtraTech for information.

Through the HPR01 Ribbon Cable, the M41K also supports a MODULAR DRIVE ENABLE BIT.  This bit is at location PORT 107:1. When this bit is set, the modular drives are enabled.  The output, as well as the above outputs reset into an off state.

The M41K also supports 2 other digital outputs.  The outputs are located on header JP2, in the lower right corner.

    IO-1 is controlled by Port 107:2
    IO-2 is controlled by Port 107:4

Each output must be limited to 2mA.
 

Step Outputs

The M41K supports two X's, two Y's, three Z's and 1 theta / Q axis  (T2 and T3).  Each of the step outputs has a software switch, and each step output and each dir output has an individual driver.  When the 74ALS1034 driver is used, the normal state of the step output is high.

! Use only shielded cable for the step and direction lines, and shield the cable only at the M41K board.

The system builder must also make sure the pulse width is properly set for the motor drives. Use the command set_pulse_width to set the pulse setup time and pulse width of the output pulse train. Refer to your motor driver manual for the proper value. Refer to the Programmers Reference WinHelp File on our download page for a complete reference on the uCito programming language for our controllers.

WARNING: If the user wants to attain the maximum speed for any particular pulse width setting, the system builder must insure that the motor driver has no direction-line hold time requirement and that the driver steps off the leading edge of the step pulse.

WARNING: If the programmed pulse width is below the actual value needed for the motor driver, motion will appear to drift on the machine tool.

WARNING: If step-delay is turned on, the output step pulses will ony be 1.5uS wide. If turned off, then the pulse width from the controller will be passed on unchanged.

Recommended Driver Connections

Use a 3 conductor shielded cable.  Shield the cable at the M41K board only.   On the driver,  connect +5,  or  (Step + and Dir +)  to  S1.11 or S2.7 on the M41K board.  When the driver has both  Step + and Dir + instead of +5 volts,  connect  Step + and Dir + together and use the same conductor in the shielded cable.    Connect step or step (-)  to the correct step line on S1 or S2.   Connect  dir or dir (-) to the correct dir line on S1 or S2.

Dual X-axis

Output provisions for a second X-axis motor are provided on S1.9 and S1.10.  Also see pulse_enable in the Programmers Reference WinHelp File which enables bits for each axis which are mapped to OP117.1 and OP117.2.
 

Limit and Special Inputs

All M41K boards have 8 inputs, an ESTOP , a Pause and 5 more Special (miscellaneous) inputs.  All inputs are PNP type. This means that in order for an input to be on, 12V (with 2.2k resistors) or 24V (with 5.6k resistors), in reference to Limit Ground, must be supplied to that input pin.  Typically, normally closed mechanical switches or PNP proximity switches are used for limit inputs.

MAKE SURE   that Limit Common L1:9, L2:8 or L2:9 is connected to the ground of the power supply that is running the limits.   Otherwise, the limit system will not function.

Be aware that the limit system is optically isolated from any other part of ExtraTechs control system, and should be treated as an independent system, given its own power supply, in order to obtain the highest noise immunity possible.

Limits may be read from Input Port 2 or Port 109.  To Enable a Limit Input to activate a Limit Detect, the corresponding bit in the Limit Mask, Output Port 109 (OP109),must be set high. For example, to enable the first four limit inputs as over travel switches, write the value 15 to OP109.

The E-STOP, PAUSE, and  special (miscellaneous) inputs also enter via optically isolating receivers, in which the current limiting resisters are also RP1. Special Inputs may be read from Input Port 1 or Port 111.

NOTE:  That IP1.1 (1) is LLAT (Limit Latched), this flag states whether or not the information read from Input Port 2 (IP2), the limit inputs, is latched or real-time.   Input Port 1 (IP1) is mirrored at IP111; Input Port 2 (IP2) is mirrored at IP109.

NOTE:  To use onboard laser functions, SPECIAL INPUT 4 is a DOOR-INTERLOCK for the laser.  The "SPCL IN 4" input must be ACTIVE (GREEN LED ON) for the laser to function.

Recommended Limit Cabling

The following table shows the recommended limit switch line connections.  The standard X-axis is called the XA axis, when a second X-axis motor is present it is called the XB motor. A single limit switch for the XB motor is provided for auto-squaring the table.The Limit Input lines are abbreviated "LI".

NOTE:  The limit inputs lines are noise sensitive.  On the machine tool the limit cables must not be run in the same conduit as (or along with) the cable going to the motors. Keep the limit cables away from any cable with high current or fast voltage swings; also, use shields for the limit cables.

NOTE: To conform with the ANSI Robotics standard, the E-Stop, PAUSE and (enabled) limit input lines,  must be a closed circuit for the controller to function. Open-circuits on any of these controls will cause the input line to be triggered.   When the circuit is closed and current is flowing, the related LED on the M41K board will be GREEN.

When using "mechanical" switches,  connect the switch between the positive limit power supply and the limit input line.
When using proximity limit switches, make sure you use PNP types and wire as directed.
 

Input Noise Filtering

A digital filter is being used in the M41K circuitry to prevent false triggers. This filter will reject ALL input pulses less than 8mS wide, and will filter out SOME pulses up to 16mS wide.    All pulses wider than 16mS WILL be detected.
 

Input Status LED Array

The LED Array contains two green LED bars used to indicate active input status. The LED bars are aligned with the L1 and L2 input connectors. These LED's indicate a valid connection in the input line. In other words, when a voltage difference (current flow) is present, that channel's LED illuminates.  The normal status for a limit input is for that channel to be GREEN.
 
 

When limits_off,   reading from 109  gives raw and unfiltered data.
When limits_on,    reading from 109  passes raw and unfiltered data UNTIL a limit is detected.
                                At that point, only the offending limit is passed to port 109.  This data is held at port 109 until
                                a limits_off command is sent.  Only limits that are masked can cause a limit detect.
 

The Inputs are as follows.
 

Encoder Inputs

If the encoders do not have complementary signals (A/ and B/), jumper Encoder Inputs A/ (PVx.4) and B/ (PVx.6) to Voltage Ref (PVx.7).  Otherwise, Voltage Ref should remain unused.
 
 
 

Analog Output

The M41K  T3  comes with one  Analog Output.  The output range is selectable from 0V to 5V, or 0V to ADJ..
    *  AD is short for ADJUSTABLE.   The M41K T3 has a jumper that allows the maximum output to be scaled via an on board variable resistor.

The analog output port is Port 121. In uCito, the way to send DAC data is
121 dup 1com pset_bits
Note the "dup 1com" clears unused bits. The DAC write state-machine takes 4uS to cycle so back to back pset-bits in macros to Port 121 should be avoided.
 

Field Serviceable Components

The following table lists which components are in sockets and can be changed in the field to fix a particular failure.
 

Ordering Information

Please refer to the list below for ordering information

        M41K-T2-12V        ( Type 2,  limits set at 12 Volts)
        M41K-T2-24V        ( Type 2,  limits set at 24 Volts)
        M41K-T3-12V        ( Type 3,  limits set at 12 Volts)
        M41K-T3-24V        ( Type 3,  limits set at 24 Volts)
        M41K-T4-12V        ( Type 4,  limits set at 12 Volts)
        M41K-T4-24V        ( Type 4,  limits set at 24 Volts)
 

M40-M41K Differences
 

* If the M41K application is an old M40 application, check the code / init file for the following ports.  These bits are no longer supported in order to eliminate potential coding bugs.  (Driving the same output bit from 2 different control ports will cause erratic behaviour.)

The following Output Ports no longer supported on the M41K board

    Port 1 - bit value 4 and 8 (Xa and Xb enable bits) is now supported only at Port 117
                    The old Port 1: bit 4 is now only located at 117:1
                    The old Port 1: bit 8 is now only located at 117:2
    Port 2 - all bits   (runs the solid state relays)   is now Port 101 only  (both were supported in the M40s)
    Port 3 - all bits   (DAC port)  is now Port 121 only (both were supported in the M40s)
    Port 6 - all bits   (Z1, Z2 and Z3 enable bits) is now supported only at Port 119