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MachBob2 (MB2) Owner Instruction manual Doc E1.2 (22/03/59) www.CNCRoom.com Page 1

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MachBob2 (MB2)

Owner Instruction manual

Doc E1.2 (22/03/59)

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Introduction

It is known that the environment in the industry often have interference from electrical power such as motors, welding machines, magnetic contactor, etc. These signals interfere personal computer and control board. Bringing personal computer to this environment is a challenge. We can improve the environment by placing the devices in the control cabinet in the correct manner. Including installing noise reduction, such as installing Noise filter, Isolated transformer, etc. However, using computers and control board designed for industrial applications is more important. MachBob2 (MB2) is designed for industrial applications. MB2 is designed to work with ESS the excellent motion controller for Mach3 and Mach4.

Specification and Features

• With ESS, Ethernet connection helps controller and drives located away from PC and has more noise resistant than USB and parallel port connection.

• Run on Mach3 / Mach4 with Windows XP, Win7, Win8 both 32 and 64 bit, on both desktop and notebook computers.

• New! Utilizes All 3 ports of ESS. • New! Motion command signal can be selected between Pulse/Sign, CW/CCW, and Quadrature.

Frequency can be selected from 32 kHz to 4 MHz. • New! Differential line driver for motion signals makes a longer wiring with more resistant to

interference when comparing to TTL open end. • New! Single 24Vdc Power supply is needed. On the board consist of 5Vdc isolate and non-

isolate dc2dc converter, thus saving installation space and wiring. • New! OSSD outputs and safety circuit are implemented. When a peripheral device such as

servo motor drive and/or spindle VFD causes alarm. Safety Circuit will disengage OSSD output. This method is used in big CNC machine to cut power out off the drives.

• New! LED status for all inputs and outputs including motion control signals. Makes it easy to diagnose the problem.

• Isolated power and ground between PC, ESS, I/O, which eliminates crossover noise and ground loop problem.

• New! Polarity and over voltage protection (in conjunction with fuse) for 24Vdc power supply. • AnaSpeed circuit is implemented - the circuit is isolated from MB2 itself, But be a part of VFD

inverter and acts as a digital VR. High voltage noise of inverter cannot interfere through this connection.

• A charge-pump signal is provided. This helps users to form a safety interlock condition among controller and devices.

• 22 isolated input points, consist of 17 points of NPN and 5 points of PNP type. • 14 NPN isolated output points, sinks current up to 100mA for each channel (up to 500 mA per

group). • 2 relay, with both NO, NC contact. • Spring terminal for quicker connecting and disconnecting cable and resistant to vibration. No

more screws loose and tightening forgotten.

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Precaution

• Take static discharge before touching any part of ESS/MB2. Grounding your body by wearing grounding strap or frequent touching the metal chassis of earthed to release electrostatics.

• Make sure that no high voltage leak from solder iron when soldering solder-bridge – the safe way is to unplug solder iron off the power socket when it builds up enough heat for melting lead solder. Hi voltage leaking of most cheap solder irons can potentially damage the integrated circuit (IC) on MB2 board.

• Beware of Fragile, do not drop electronics board. • Heat could build up if many of inputs and outputs are on at same time. In some

circumstances a cooling fan is needed to ventilate heat to the ambient air.

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Quick Reference

L L L L L L L L L L L L L L

24Vdc

Power Supply24Vdc

VFD Inverter

Anal

og v

i

Fow

ard

(b)Single endconnection

(a)DifferentialconnectionDrive

Drive

Ports and Pins meaningX110 = input, port 1, pin 10Y301 = output, port 3, pin 01

Figure 1 MB2 Overview Connection

Figure 2 Summary Tables for Ports and Pins

Quick Reference is a summary for experience users. Figure 1 is a shrinkage view of MB2 board. It shows a connection of inputs/outputs, power supply, analog output for VFD and axis signals including differential and single end connection. Suggest that you should try figure (a) first, the differential connections are more noise resistant than single end connection, figure (b) – Figure 2 is summary table of ports and pins reference number. For example X110 meaning X is input, first digit is port number, last 2 digits is pin number.

Precaution, Heat could build up if using many of inputs and outputs. In some circumstances a cooling fan is needed to ventilate heat to the ambient air.

Pin I/O Term Name Description Pin I/O Term Name Description Pin I/O Term Name Description1 O SPD Sink output 1 O NO1 Relay 1 O Y301 Sink output2 O XS Axis step 2 I - OSSD feedback 2 O Y302 Sink output3 O XD Axis direction 3 I X203 NPN input 3 O Y303 Sink output4 O YS Axis step 4 I X204 NPN input 4 O Y304 Sink output5 O YD Axis direction 5 I X205 NPN input 5 O Y305 Sink output6 O ZS Axis step 6 I X206 NPN input 6 O Y306 Sink output7 O ZD Axis direction 7 I X207 NPN input 7 O Y307 Sink output8 O AS Axis step 8 I X208 NPN input 8 O Y308 Sink output9 O AD Axis direction 9 I X209 NPN input 9 O Y309 Sink output10 I X110 NPN input 10 I X210 NPN input 10 I X310 PNP input11 I X111 NPN input 11 I X211 NPN input 11 I X311 PNP input12 I X112 NPN input 12 I X212 NPN input 12 I X312 PNP input13 I X113 NPN input 13 I X213 NPN input 13 I X313 PNP input14 O CP ChargePump 14 O NO2 Relay 14 O Y314 Sink output15 I X115 NPN input 15 I X215 NPN input 15 I X315 PNP input16 O BS Axis step 16 O CS Axis step 16 O Y316 Sink output17 O BD Axis direction 17 O CD Axis direction 17 O AO Analog output

Port1 (output) Port2 (Pins 2-9 as input) Port3 (Pins 2-9 as output)

*Output can sink current up to 100mA and up to 500mA per group of 8 pins

Shrinkage part

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MB2 Layout.

8–9mm

18-24 AWG

Figure 3 MB2 Board Layout

Input (CN1) – Input terminals, consist of 18 channels of NPN type and 5 channels of PNP type Axis (CN2) – Axis signal terminals, consist of 6 axes, naming X, Y, Z, A, B, C Output (CN6) – Output terminals, consist of 14 NPN sink outputs, Analog signal, 2 Relay’s

NO/NC and inlet for 24Vdc power supply LPT1-3 (CN3-5) – Connectors for ESS JP1 – Charge Pump override RJ-45 – Communication connector, part of ESS board

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ESS and MB2 piggyback

MB2 Connection Diagram

Figure 4 Connection Diagram

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Hardware Connecting The SmoothStepper to Your PC

This part is taken from

http://www.warp9td.com/index.php/documentation/doc-ess#Connecting

The best way to connect your ESS to your PC is to use the Direct Connect method: hook the Ethernet cable directly from your ESS to the network adapter in your PC. This will make trouble shooting easier since there are no switches or routers between the ESS and your PC. (A switch should be fine since it only operates in the lower 3 layers of the TCP/IP stack, but why add extra equipment if you don't need it. A router should be fine if you only have your ESS and PC connected to it, but this will require more work to configure and setup. As a result we highly recommend the direct connection, which is what the SCU [System Configuration Utility] expects.)

If you don't have an Ethernet Adapter on your PC, we recommend using a a PCI or PCI Express Ethernet Adapter -OR- a USB 2.0 or USB 3.0 Ethernet Adapter. Quite a few people use these alternatives successfully, including myself.

We STRONGLY discourage using a wireless connection to communicate with your ESS. There can be much more latency or delay involved with wireless communications, along with a much higher risk of dropped packets. The ESS needs a fast, stable, and consistent link to your PC.

Many people use a second Ethernet connection or their wireless connection on the PC so they may easily connect to the internet, which is fine.

While you are running Mach and your CNC system, we recommend that you refrain from browsing the internet, gaming or streaming music or videos. This can cause your computer to take too much time away from Mach which could cause lost communications with your ESS (which can ruin your project).

We also recommend that you disable power saving options (monitor sleep and power off timers, hard drive sleep timers, and computer sleep timers); these have been know to cause lost communications with your ESS.

We also recommend that you set Windows Update to notify you that there are updates available instead of automatically installing them on its own.

We also know of cases where antivirus and anti-malware software have caused problems. We recommend that you disable them while you are running Mach, IF your PC is not connected to the internet.

Note that you do not need to assign a static IP address to your computer if you program the ESS to use an address that is in the same subnet as your computer. The subnet is the same if the first 3 groups of numbers in the IP addresses are the same. Quite often Internet routers will assign addresses in the 192.168.0.x or 192.168.1.x ranges. If you wish to use a DHCP server for your

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computer, you can do that but the ESS still needs to use a static IP address in the same subnet. A direct connection to the ESS is the preferred way to go because there is no question as to whether there is enough bandwidth available to run your machine reliably.

We STRONGLY RECOMMEND THAT YOU DO NOT hook your ESS up to the same Ehternet adapter that you connect to the Internet with. There is no telling how much CPU and Ethernet bandwidth is being used up by other applications or other devices on the network. It is therefore officially discouraged. You are on your own if you wish to mix the Internet with your CNC data. However, if you wish to change the IP address of the ESS, you may do so with the Configurator Utility.

If the remainder of this section confuses you, don't worry. The SCU in the next section will do all of the work for you in just a few mouse clicks! The remainder of this section is just to document what the ESS uses and needs, you may skip to the SCU section.

The ESS comes configured from the factory with a default static IP address of 10.9.9.9 With your ESS at 10.9.9.9, you will need to assign your network adapter to use 10.9.9.2 or another valid and unused address in the subnet. We recommend that you keep the 10.9.9.9 IP address assigned to your ESS, since all of our documentation and videos will use that value. In fact MOST users keep this value assigned to their ESS. However, if there is a need to change it, you may do so with the Configurator Utility.

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Axis Connection X, Y, Z, A, B, C

AXIS CN2 terminal supplies motion command for drives.

VCC

Dir+

Step+

Dir-

Step-

optocoupler

XD-

XS-

(a) differential connection

(b) single end connection

XD+

XS+

Dir+

Step+

Dir-

Step-

*grounding at drive side

XD-

XS-

Line Reciever

XD+

XS+

Dir+

Step+

Dir-

Step-

Optocoupler

XD-

XS-

*grounding at drive side

Figure 5 Axis command terminal and various connection mode

There are two modes to make connection to CN2.

(a) Differential mode is best noise immunity. Recommended to use differential mode if possible.

(b) Single end mode is used if drive is not compatible with differential mode. There are two points of VCC to share with all axes.

MB2 Cable Drive Input

Twisted pair

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Inputs

Figure 6 Input terminal

Figure 6 shows 22 points of inputs. There are 17 points of NPN type which are X110-X115, X203-X215 and 5 points of PNP type which are X310-X315. There are solder-bridges underneath of MB2 board for user to bridge input status of X203 – X210 to safety circuit. The OVR input is override signal for the circuit. Safety circuit will form AND logic for all involved signals. This helps user to eliminate extra effort to build separately circuit.

0V

X211

24V

Figure 7 Connection of NPN inputs, it references to 0V

Figure 7, shows conventional way to connect a switch to NPN input, X211 with 0V

MB2 NPN inputs connect to 0V

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X310

24V

0V

X31024V

0V

0V

24V

(a) external supply

(b) internal supply

COM-

COM-

24V

0V

Figure 8 Connection of PNP inputs, it refer to 24V

Figure 8, (a) shows the way we connect PNP input to external source. This connection is totally isolated from any part of MB2 circuit. The external circuit is maybe fault output of VFD drive or servo drive. Figure 8, (b) shows conventional way we connect PNP input to internal source.

0V

X211

24V 24V

X310

24V

COM-

0V

0V

(a) NPN connection

(b) PNP connection

0V

24V

Figure 9 Sensors connection

MB2 NPN type connection

Brown

Black or white

Blue

MB2 PNP input connect to external source

MB2 PNP inputs connect to internal source

MB2 PNP type connection

Brown

Black or white

Blue

Jumper wire connect to nearby terminal

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Figure 9, (a) shows connection of NPN type of sensors. This connection is applied for X110-X115 and X203-X215 inputs only.

Figure 9, (b) shows connection of PNP type of sensors. This connection is applied for X310-X315 inputs only.

X203

X204

Y Home Z HomeX Home

X+ Limit X- Limit Y+ Limit Y- Limit Z+ Limit Z- Limit

E-Stop

X211

0V

Figure 10 an example of E-STOP, LIMIT and HOME connection

Figure 10, shows conventional way to connect Estop, Limit and Home switches. This will form a AND circuit. Notice that all use NC contact (normally close).

Output

Figure 11 Output terminal

Figure 11, show 14 points output, each output can sink current up to 100mA and cannot sink more than 500 mA per one group of 8 as shown in Figure 1.

นอื มสเ ทุ พ์ทาอเ ร จงวVCC

100 mA (max)

LหรือL *

0V

24V

Ynnn

Figure 12 Connecting various load to Y output

MB2 external circuit

External power supply 5-30Vdc

* a diode is needed to parallel with coil

MB2 External circuit

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Analog

MB2

AH

AO

AL

CM2

NO2K2

+

-Ana

Spe

edci

rcui

t

Figure 13 VFD connection

AnaSpeed circuit converts PWM signal into analog signal. The maximum voltage level is depending upon external power supply. For example connect to 0-10V analog input of VFD, it demands 10Vdc from VFD as well.

AnaSpeed has about ± 0.2V top and bottom margin. It is able to generate voltage up to 9.8V only (10V-0.2V) when given external power supply at 10V. Compensation of this margin can be done in VFD’s parameter.

Normally, VFD need forward command to rotate the motor. Thus, any NO contact of K1 or K2 can be used for this purpose.

OSSD Output and Safety Circuit

MB2 has an OSSD (Output Signal Switching Device) output for users to form a simple safety circuit in their system. MB2 energizes OSSD output if there is no any error feeding in and it will de-energize OSSD output if there is an error occurred.

Most drives will give an OK signal or “Servo Ready” or similar meaning by energizing its output and external devices will take this status. In this case, MB2 collects OK signals from various devices thru X203-X210 inputs and send out OK signal to the next device.

However, if there an error feeding in, MB2 will send out “Not OK” signal by de-energize OSSD output and external safety circuit will stop the hazard.

It is simply to use magnetic contactor as external device to disconnect power supply from drives or VFD. Override input also provided for temporary energizing the magnetic contactor which lets machine operator to recover the error.

Figure 14 shows safety circuit block and relevant I/O including, inputs, solder-bridge, an override input and outputs

Warning. MB2 has used a simple safety circuit. There is no guarantee of failure. Thus, users MUST always check the functioning of the circuit.

Connect to Analog Input of VFD

Connect to Forward input of VFD

5V or 10 V

Analog Output

0V

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Safety Circuit

X203X204X205X206X207X208X209X210

Safety OVR (override)i202

OSSD

Figure 14 On board safety circuit

Power Supply

MB2 needs only single 24Vdc power supply to operate the board. The Figure 15 shows input terminal for 0V and 24V.

There is a non-isolate step down switching regulator converts 24V (12-24Vdc) down to 5V to power most parts of circuit including inputs and output. However, there is also a special isolated DC2DC convertor generates 5V for only ESS board.

On board has a small fuse protection against over voltage and polarity reversal.

Figure 15 Power supply connection

24Vdc0V

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Modification

MB2 has a number of places where users can conduct modification. Instead of using pin jumper, the solder-bridges are implemented to save cost and space. Users need to solder or de-solder these bridges to archive their purpose.

*1. Safety circuit inputs; primary function of X203-X210 are normal inputs just like the others. But these inputs are chose to be inputs for the safety circuit by soldering the bridge.

*2. Pin for PWM Analog, let users choose between Y101 and Y317 (set to Y317 by default)

*3. DC converter – Soldering the bridge to use onboard 5V isolated DC2DC converter (default). In some cases there are necessary to use external 5V power supply instead of using a tiny converter. This bridge has to be de-soldered then connect external 5V power supply to VCC channel at AXIS CN2 terminal.

*4. Free terminal – In some circumstances, users need few extra terminals for their work. User needs to free terminal by de-solder the bridge. These free terminals are meant to use with low voltage signal only, not over than 24V.

Figure 16 underneath layout of MB2

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Software

Users can obtain up to date software, plugins and tutorials from following link.

http://warp9td.com/index.php/sw

http://www.youtube.com/channel/UCpg3EROtW8xA_KzrFHgn4ZQ

User also can obtain MB2 pre configuration file from product link below.

http://www.cncroom.com/index.php?main_page=product_info&cPath=7&products_id=209

Mach3 Configuration

Users can obtain pre configuration XML file and copy to their system. However, there are some value needs to be set to suite for user’s application.

After downloading and extracting pre configuration profile. You will find MB2.xml that need to be copied and pasted into C:\Mach3 which is shown in picture below. Run Mach3 Loader and choose MB2 profile.

Figure 17 Copy and Paste MB2 pre-configuration

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Figure 18 Mach3 first screen

Menu Config > Ports and Pins

Figure 19 Mach3 Ports and Pins dialog

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Figure 20 Motor output tap

Specify value as shown in the picture.

Figure 21 Mach3 Input tap

Users need to set suitable value by themselves

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Figure 22 Mach3 Output tap (1/4)

Users need to set suitable value by themselves

Figure 23 Mach3 Output tap (2/4)

Specify Charge Pump value as shown in the picture.

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Figure 24 Mach3 Output tap (3/4)

Specify value as shown in the picture.

Figure 25 Mach3 Output tap (4/4)

Specify value as shown in the picture.

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Figure 26 Mach3 Spindle tap

Spindle Setup

Menu Config > Motor Tuning

Figure 27 Mach3 Motor tuning dialog

Motor Tuning and Setup, Users need to set suitable value by themselves

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Menu PlugIn Control > ESS-v10r2d1d Config

Figure 28 ESS General Configuration

Mach4 Configuration

Users can obtain pre configuration profile from product link above. However, there are some value needs to be set to suite individual system.

After downloading and extracting pre configuration profile. You will find a folder name MB2, let copy and paste this folder into C:\Mach4Hobby\Profiles as shown in picture below. Run Mach4 loader, then pickup MB2 profile.

Figure 29 Copy and Paste Mach4 pre- configuration

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Figure 30 Mach4 fist screen

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Menu Configure > Select Motion Dev…

Figure 31 Mach4 Select motion device

Menu Configure > Plugins…

Figure 32 Mach4 Configure Plugins dialog

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At Configure Plugins dialog,

ESS- Warp9 Tech… need to be ticked then close and reopen Mach4 before clicking on Configure… button

Figure 33 Mach4 ESS Configuration – General tap

In General tap, specify IP Address of ESS board

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Figure 34 Mach4 ESS Configuration – I/O tap (1/4)

I/O tap (1/4), specify as shown in the picture.

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Figure 35 Mach4 ESS Configuration – I/O tap (2/4)

I/O tap (2/4), specify as shown in the picture.

Figure 36 Mach4 ESS Configuration – I/O tap (3/4)

I/O tap (3/4), specify as shown in the picture.

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Figure 37 Mach4 ESS Configuration – I/O tap (4/4)

I/O tap (4/4), specify as shown in the picture.

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Figure 38 Mach4 ESS Configuration – Homing tap

Homing tap, users need to specify by themself

Menu Configure > Mach…

Figure 39 Mach Configuration – General tap

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General tap, Users need to set suitable value by themselves.

Figure 40 Mach Configuration – Axis Mapping tap

Axis Mapping tap, specify as shown in the picture.

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Figure 41 Mach Configuration – Motors tap

Motors tap, Users need to set suitable value by themselves.

Figure 42 Mach Configuration – Homming/SoftLimits tap

Homing/ SoftLimits tap, Users need to set suitable value by themselves.

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Figure 43 Mach Configuration – Input Signals tap

Input Signals tap, Users need to set suitable value by themselves.

Figure 44 Mach Configuration – Output Signals tap

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Output Signals tap, Users need to set suitable value by themselves.

Figure 45 Mach Configuration – Spindle tap

Spindle tap, specify same value of 24000 rpm in item 0 and Max Spindle Motor to get full

analog range

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Appendix I MB2 Specifications

Dimensions 115 x 155 mm Supply voltage 12-24Vdc ±10%, 500mA (without load) Supply voltage ripple ≤ 5% Outputs NPN, 5-24Vdc Output current 100mA Max (total 7 outputs ≤ 500mA) Analog output range (0V + 200mV) ~ (Vin – 200mV) Inputs NPN, PNP, 5-24Vdc Ambient operating temperature 0-40°C

Appendix II MB2 Board Dimensions

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Appendix III Safety connection

Notice. Safety class in this manual is NOT related to any safety standard. And the connections given here is just a guideline for users to follow.

Safety Class 1

Safety class 1 is a simple safety connection with fewer component and wiring. Mostly, it relies on good functional of computer and electronics components to disengage drive power thru “servo on” signal or similar.

PAN

ASO

NIC

MIN

AS-A

Step command

Series of limits switches

0V

X115 (Limit signal)

PAN

ASO

NIC

MIN

AS-A

PAN

ASO

NIC

MIN

AS-A

MB

2 B

oard

Servo DrivePower circuit

Noise Filter

CircuitBreaker

To main power 1ph, 3ph

24Vdc Power supply0V

24V 24V

0V

Noise Filter

E-Stop

0V

X203 (E-Stop signal)

Servo OnY316

0V

24V24V

Fault (Drive2)0V

X209 (Fault input)

X210 (Fault input)Fault (Drive1)

Direction command

External Circuit

Note. 1.Make X203, X209, X210 as inputs of safety circuit by soldering thier bridges underneath of MB2 board. Then assign X202 as the E-Stop input.2.Assign X115 as Limit input3.Assign Y316 as Enable2.

Control share power with Main

Servo DriveControl circuit

Figure 46 Safety Class1 connection

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Safety Class 2

Safety class 2 is more concern about disengaging power from drives or hazard devices by unintelligent components, such as limit switches, Estop button and magnetic contactor.

In situation of motor runs away that caused by electromagnetic interference or even an error of human. A good design system should be able stop by limit switches themself or stop by hitting of Estop button.

However, in normal circumstance, MB2 with external circuit and computer should work well together. In some drive connections may need timer relays to handle an error of under voltage.

PAN

ASO

NIC

MIN

AS-A

M1

24V

NO2 (Y214)E-Stop.2

Step command

Series of limit switches0V

X115 (Limit signal)M1

PAN

ASO

NIC

MIN

AS-A

PAN

ASO

NIC

MIN

AS-A

MB

2 B

oard

Servo DrivePower Cicuit

Noise Filter

CircuitBreaker

Magnetic Contactor

To main power 1ph or 3ph

1 body, 2 contacts

On board relay

1N2004

Controlpower

Main power

24Vdc Power supply0V

24V 24V

0V

Noise Filter

OVR (safety override)

X110 (Reset signal)

E-Stop.1

0V

X203 (E-Stop signal)

Reset

M1 Servo On

Alarm clearY316

0V

24V24V

Fault (Drive2)0V

X209 (Fault input)

X210 (Fault input)Fault (Drive1)

Direction command

External Circuit

Note. 1.Make X203, X209, X210 as inputs of safety circuit by soldering thier bridges underneath of MB2 board. Then assign X202 as the E-Stop input.2.Assign X115 as Limit input3.Assign X110 as OEM Trigger, Then assign “Reset oem code” or 1021 to System hotkey > External button.4.Assign Y214,Y316 as Enable1, Enable2 respectively.

Limit override

Servo DriveControl circuit

Figure 47 Safety Class2 connection

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