Physical Layout
The purpose of the M54 interface board is to provide a complete I/O interface with fully
integrated step motor drivers. The M54 board measures 7 1/4 inches by 8 inches. It mounts on top
of the controller board by 8 mounting holes on top of stand-offs. The
controller and I/O board stack mounts to an aluminum plate which has 4 holes for mounting in an
enclosure. The I/O interface for the controller board comes through a 64 pin DIN connector and
ribbon cable.
M54R5 Schematics for I/O circuits:
M54R5 Brains
M54R5 PowerHeaders
M54R5 Sub D's
M54R5 Limit Isolator
Power Supply
The M54 board stack requires a rectified, unfiltered D.C. supply, between 24 and 42 volts DC.
Other voltages used (+5, +12) are derived from the high voltage (24V - 42VDC), which
comes in on Header H2. The D.C. supply must not exceed 42 Volts or permanent damage to the
board will occur. We recommend ExtraTech's 6061-X0-00 transformer and 25 amp bridge
rectifier.
| PIN | DESCRIPTION | CURRENT |
| H2:5 | Ground for D.C. Supply | 10 A |
| H2:6 | Positive D.C. Supply | 10 A |
| PIN | DESCRIPTION | CURRENT |
| H1:1 | logic common (LCOMMON) | |
| H1:2 | Feed rate override pot * | 1K Ohm pot |
| H1:3 | logic +5V Out *!* | |
| H1:4 | E-stop In -- (See Misc/Special Inputs) *E* | |
| H1:5 | E-stop Out -- (See Misc/Special Inputs) *E |
| * -- |
Feed rate override is an option that must be ordered. |
|
| *!* -- |
The +5 Volt and +12 Volt terminals on the M54 board are voltage OUT points. DO NOT FEED POWER TO THESE PINS ! | |
| *E* -- |
Decoding EStop -- If Port 1 or 111, bit value 4 is HIGH, the system is in E-STOP. If Port 2, value 128 is LOW, then E-Stop wired to header H1:4/5 is causing a problem. However, this bit being low does not exclude a problem also at H3:12/13. |
Motor Outputs
The M54R5 supports up to 4 motors. Each motor driver has short circuit protection, both
Phase to Phase and Phase to Ground. With 3 motors the axes can be software re-configurable.
With 4 motors the axes must be hard wired.
Please see the ESTOP section on detection of the ESTOP / Short Circuit signal.
Motor 1 is always Xa. To power any drive, bit 64 at port 2 must be set. (this is a global drive enable
bit) Upon request, ExtraTech will provide some macros that can be included in your init file to
simplify your code.
Motor Selection All four motor outputs are located on Header H3, a DB-25F connector. The power-up default
configuration is shown below.
Motor 2 is always Ya.
Motor 3 can be configured as Xb, Yb, Z, or Q
Motor 4 can be configured as Yb, Z, Z2 or Q
The power to Xa and Ya can be reduced to 1/4 power by setting bit 128 at port 157.
Full power to Xa and Ya is restored by clearing bit 128 at port 157.
The pulse train to XA/XB can be controlled with the Pulse Enable command.
The power on motor 3 can be configured as Off, Quarter Power or Full Power
The pulse train to Yx, Z or Q can not be controlled by the M54.
(Multiple Y's, Z's and Q's move together unless they are turned off.) ID24
Current -- The motor must be rated for at least 4 amps.
Phase Inductance -- 1.5mH or LESS, above this level, resonance's and stalling can become a
problem
Phase Resistance -- 0.24 ohms or LESS
Configuration -- Series or Parallel, however the 3 above conditions must be met.
| PIN | DESCRIPTION | PIN | DESCRIPTION |
| H3:1 | Xb A special use axis | H3:14 | Xa axis Phase A (1) |
| H3:2 | Xb AA special use axis | H3:15 | Xa axis Phase AA (1) |
| H3:3 | Xb B special use axis | H3:16 | Xa axis Phase B (1) |
| H3:4 | Xb BB special use axis | H3:17 | Xa axis Phase BB (1) |
| H3:5 | EARTH GND | H3:22 | Z axis Phase A (3) |
| H3:6 | EARTH GND | H3:23 | Z axis Phase AA (3) |
| H3:7 | EARTH GND | H3:24 | Z axis Phase B (3) |
| H3:8 | Y axis Phase A (2) | H3:25 | Z axis Phase BB (3) |
| H3:9 | Y axis Phase AA (2) | ||
| H3:10 | Y axis Phase B (2) | ||
| H3:11 | Y axis Phase BB (2) |
Look at a Motor Wiring Diagram.
Third Axis Configuration
If the default configuration does not suit your needs, the below table contains the information
necessary to reconfigure the third and fourth axis.
| DESCRIPTION | Port : Controlling bits |
| Motor 3 Tandem Xb | 160:xxxx xx00 |
| Motor 3 Tandem Yb | 160:xxxx xx01 |
| Motor 3 Z-axis | 160:xxxx xx10 |
| Motor 3 Theta / Q | 160:xxxx xx11 |
| Motor 3 OFF | 160:xxxx 0xxx |
| Motor 3 ON at Full Power | 160:xxxx 10xx |
| Motor 3 ON at Quarter Power | 160:xxxx 11xx |
Limit and Special Inputs
Limit input switches are connected to header H5. The H5 header is a DB-15F connector for
use with the machine. Current must flow through the inputs for motion to occur (limit
switches are normally closed). An open circuit will cause a limit detect. Current
flow is established by connecting a limit to Limit Vcc, through a normally closed limit switch.
The Green Led Bar will glow green when current is flowing through the limit
circuit. (Green is good). Bar 1-6 are limits, 7 and 8 are misc and E-Stop,
bar 9 is not connected and bar 10 indicates +12 on the limit system. The M54 like all
other interface boards, latches non-masked inputs on a limit detect. It is important to
read the limit register before turning off the limit detect system with a "limits_off" command.
Once the limits have been turned off, the init file can only read the current, non masked
condition of the limit inputs and not the history.
| Input Name | Header | HCPL2630 | LED Bar | Port : bit |
| Limit 1 Xa Home | H5:14 | U17a | Bar : 1 | 109:1 |
| Limit 2 X over travel | H5:7 | U17b | Bar : 2 | 109:2 |
| Limit 3 Y Home | H5:15 | U18a | Bar : 3 | 109:4 |
| Limit 4 Y over travel | H5:11 | U18b | Bar : 4 | 109:8 |
| Limit 5 Z Home | H5:8 | U19a | Bar : 5 | 109:16 |
| Limit 6 *P* Xb Home | H5:13 | U19b | Bar : 6 | 109:32 |
| Limit VCC *!* | H5:6 | - - - | Bar : 10 | - - - |
| Limit Gnd *!* | H5:9 | - - - | Bar : 10 | - - - |
| * -- |
The light text indicates recommended limit position. |
| *P* -- |
This input is an optional pause input. Setting port 157, bit 64 will enable this
input as a pause As in the case of limits, current must normally be flowing through this loop (normally green). |
| *!* -- |
Limit VCC and Limit Gnd are power pins that have internal supplies. DO NOT FEED POWER TO THESE PINS ! Power from this supply is limited and must not exceed 84mA total. If all 6 limit inputs are used, only 36mA is available. |
| Input Name | Header | Location | LED Bar | Port : bit |
| Misc. Input 1 * | H5:12 | Sub D 15 | Bar : 7 | 109:64 |
| Misc. Input 1 | H5:9 (Limit Gnd) | Sub D 15 | - - - | - - - |
| E-Stop Input (-) *!* *E* | H3:12 | Sub D 25 | Bar : 8 | 109:128 |
| E-Stop Input (+) *!* *E* | H3:13 | Sub D 25 | - - - | - - - |
| E-Stop Input (-) *!* *E* | H1:4 | Machine | - - - | - - - |
| E-Stop Input (+) *!* *E* | H1:5 | Machine | - - - | - - - |
| * -- |
Misc Input 1 is a low-side input. In order for current to flow, H5:12 must connect to H5:9 (limit ground) through a switch or limit. |
| *!* -- |
Both E-Stop inputs must be wired to a normally closed switch or circuit. |
| *E* -- |
Decodeing EStop -- If Port 1 or 111, bit value 4 is HIGH, the system is in E-STOP If Port 2, value 128 is LOW, then E-Stop wired to header H1:4/5 is causing a problem. However, this bit being low does not exclude a problem also at H3:12/13. |
ESTOP
If a short circuit condition occurs, then an ESTOP will be generated. At that point the
cause of the Estop can be tracked, by searching for abnormal bits. Below is a list of the
possible causes of an estop.
When checking for the source of and estop detect -- check the NME bit FIRST. If the
LIMIT SYSTEM detects a short circuit, it shuts down and clears the NME bit, it also causes the
LLAT and Ext-EStop signals to set. Without checking the NME bit first, a false cause
may be isolated.
LLAT
111
Normally 0
Caused by a limit detect
Ext-LeStop
111,4 & 2,128
Normally 0
Typically an External EStop switch
Ext-EStop
111,4
Normally 0
The ESTOP loop located at the Motor Cable
StlM12
137,1 & 2
Normally 0
A short circuit detect on the X or Y axis
StlM34
137,4 & 8
Normally 0
A short circuit detect on the Z/3rd axis
NME
157,8
Normally 1
A short circuit detect on the Limit System
Outputs
The M54 interface board supports two solenoid/relay coil outputs, one mechanical relay output K2,
two isolated open collector transistor outputs Aux1 and Aux2, and one isolated Opto22 output
ISO1.
Aux1 and Aux2 will sink to AuxCommon when enabled. These lines are not fused and are
limited to 30mA / 24 volts.
| Output Name | Header | Port : Bit |
| K2 Relay Output (mechanical relay) * ** | H2:1 | 2:1 |
| K2 Relay Output (mechanical relay) * ** | H2:2 | - - - |
| IS01 Output + (polarity for DC opto22) | H2:3 | 2:2 |
| IS01 Output - (polarity for DC opto22) | H2:4 | - - - |
| AUX 1 + | H5:10 | 1:16 |
| AUX 2 + | H5:3 | 1:32 |
| AUX Common | H5:2 | - - - |
| * -- | J1 controls if K2 is normally closed or open J1:1 and J1:2 shorted = Normally Closed J1:2 and J1:3 shorted = Normally Open (factory setting) |
| ** -- | This output is AND'ed with ESTOP/ HALT. The relay will shut off and return to is "normal" state on ESTOP, then will resume it's last commanded state on removal of an estop or halt, unless otherwise specified in the init file. |
| Solenoid Output Name | Header | Port : Bit |
| Solenoid / Relay Output 1 -- *!* | H3:18 | 124: 0 to 255 124: 0 to 2.35 amps |
| Solenoid / Relay Output 1 + *!* | H3:19 | - - - |
| Solenoid / Relay Output 2 -- *!* | H3:20 | 125: 0 to 255 125: 0 to 2.35 amps |
| Solenoid / Relay Output 2 + *!* | H3:21 | - - - |
| NOTE: -- | The solenoid / relay coil #1 should be connected between H3:18 and H3:19. The solenoid / relay coil #2 should be connected between H3:20 and H3:21. Any deviation from this will damage the board ! DO NOT use diodes! across the coils, the necessary diodes are internal. |
| *!* -- | Do not mix control technologies, use either port 124 and 125 to control the outputs, or use the older commands, but do not mix the two. |
Field Serviceable Components
The following table lists which components are socketed and can be changed in the field to fix
a particular failure.
| LOCATION(S) | IC TYPE | SIGNAL DESCRIPTION |
| U18--U21 | HCPL2630, 2631 | Input Isolated Receiver |
| U15, U16 | 4N32 | Aux Signal Isolated Driver |
| ISO1 | G4ODC5 or G4OAC5 | Isolated Output Switch |