RTK3 Logic Controller User Manual
Contents
1. Worklight Output 110 ACN Chassis Ground Rotary Clamp Output 110 ACN Chassis Ground Red Light Output 110 ACN Chassis Ground Green Light Output 110 ACN Chassis Ground Yellow Light Output Cpr 110 ACN L amp p Chassis Ground2. I 24 Ground eS 24 VDC EZ Chassis Ground Z KA nc TW m mangap 3 2 2 nr 1m mj A B B8 35307 2225232285970 2 823885328225 EE EE SERE BEEBEERESR gELEESEEREESE 22 EESE gt eel 85 afe 2222222222 fO 20g2PRARBPEII REC BARBARA SERES Digo Ea E ad oy 2 AN EE AS E 2T o9 NAL EE ENEE E aa ESEA ACERO FoR ia n 2 k amp A a MRR 6 24 08 9 03 AM svn software hardware RTK3 docs rtk3 man doc aa A 5 24 Ground Ep 24 VDC Chassis Ground Tool Unclamped Input Tool Clamped Input Door Interlock Input RTK30 Middle Board Connections E 24 ACI Input En oI 24 AC2 Input 5 Chassis Ground Chiller Output Common Chiller Output E Auxiliary 2 Output Common Pi p Auxiliary 2 Output Chassis Ground Range Change Common Range Change Output E Auxiliary 1 Common y Auxiliary 1 Output L Chassis Ground Chiller Configuration Jumpers JB1 Veas Pin 1 Lube Low Input rr 24 Ground Chassis Ground Lube Pump 220 ACI Auxiliary 2 Configuration Jumpers LA JB4 JB3 Pin 1 EL Lube Pump 220 AC2 Chassis Ground Spindle Fan 220 ACI EL spindle Fan 220 AC2 Chassis Grou
3. 43 z683 262 256 2xga s Eaad ERE pit p poa E LZZZZ LZUZZZZZ LZZZZ UULU LULZ Em Est ep Input Him 277 Estop Output amp Es Es S E 24 AC2 in pl 5 i 5 BG ig in 1 I 5 hj UU ALA ou a ul TT Ear y z 5 7 Analog Chassis Ground Z E Z Limit Input E 24 Ground E amp F Z Limit Input 24 Ground EL 24 VDC E Chassis Ground n f Limit Input PER oto ges BRE aca 3 El S Limit Input M ES Q E amp op EO aW o e E a Ning X Limit Input E 24 Ground E X Limit Input E 24 Ground E Y Limit Input E 24 Ground EL Y Limit Input mmm lt Chassis Ground N E Rangel Input lt Range Input e3 Input ler Input E 24 VDC 24 Ground E 24 Ground lt Chassis Ground Im E mmm IN L E Tool Release Switch Input E 24 Ground mmm Chassis Ground 7 7 24 Ground E5 24 VDC 4 Chassis Ground E Carousel Out Input E Carousel In Input Output Configuration 2 Jumpers Analog Offset Pot TAi a A Pi Analog Gain Pot A eese Jem lm aS Auxiliary 1 Input E Tool Counter Input ey 24 VDC EZ 24 Ground E 24 Ground Chassis Ground x Air Low Input
4. Error Check N A in Speed Bi in Speed Bi mem NA Internal Internal gt n o ElZ gt gt zZ Z gt zZ gt in Speed Bi zz gt Z gt zz in Speed Bi n A wW ry gt Z gt in Speed Bi gt in Speed Bi gt ES gt in Speed Bi in Speed Bit in Speed Bi gt Z gt nin arn n gt Z gt wpoj in Speed Bi Spin Speed Bit 10 Spin Speed Bit 11 Gear Change AUXI RANGE Rotary Clamp Solenoid ROT CLAMP Carousel Enable AROUSEL MOTOR Red Light ovac rop RED LIGHT Green Light RN LIGHT Yellow Light TOVAC fop YEL LIGHT Worklight ORKLIGHT Auxiliary AUX 1 RANGE Auxiliary 2 Configurable Middle AUX 2 CHILLER Auxiliary 3 AUX DRIVERS 1 Auxiliary 4 AUX DRIVERS 1 Fast 1 O Enable Auxiliary 5 AUX DRIVERS 1 Auxiliary 6 AUX DRIVERS 1 n gt Z gt gt N Aju wj u m gt j gt A JN EOS sl ae Uo o Auxiliary 7 pen Collector AUX DRIVERS 1 Auxiliary Open Collector Bottom AUX DRIVERS I Auxiliary Open Collector Bottom AUX DRIVERS i Auxiliary 10 Open Collector Bottom AUX DRIVERS Auxiliary TI UX DRIVERS 2 Auxiliary 12 Open Collector UX DRIVERS 2 NOT USED NOTUSED NOTUSED NOT USED NOTUSED A A A A A A A A A A o A A zz gt gt z gt NOT USED NOT USED NOTUSED NOTUSED NOTUSED Auxiliary 13 Open Col
5. the RTK3 Specifications table to ensure compatibility Two wire sensors should not be used with the RTK3 since they normally do not meet the Input On Voltage and Input Off Voltage specifications Care must be taken to wire each input correctly as the cable for each input has signals that are not used in all cases These include 24VDC and Input Ground for powering sensors and a shield connection that should normally be connected only to the RTK3 The 24VDC supply fuse is located on the bottom logic board The DIGITIZE PROBE connector has an additional fuse on its 24VDC supply pin which can also be found on the logic board These fuses are in series such that the digitizer fuse could fail without affecting other inputs However a short in any other 24VDC circuit will blow the main 24VDC fuse causing a loss of all input voltages Connectors are available on the RTK3 to plug in limit and fault inputs from a Centroid DC brushed servo drive The DRV FAULT and LIMITS TO DRIVE headers are intended only for allowing straight through cable connections to a drive Limit switch wiring should be done from the X X Y Y LIMITS and W W 5 5 LIMITS headers When using a Centroid DC brushed servo drive with an RTK3 the G and 5 power DIP switches on the drive should be turned on 4 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Output Wiring Several output types ar
6. RTK3 Logic Controller User Manual Revised 6 24 08 MRR 6 24 08 9 03 AM svn software hardware RTK3 docs rtk3_man doc 1 of 16 Overview The RTK3 is intended to simplify and expedite control wiring Centroid s PLCIO2 was the starting point for the RTK3 and modifications were aimed at increasing efficiency on standard system configurations To reduce the number of connections in the control cabinet input and most output voltages are standardized Logic and input power supplies are built in to the RTK3 to further simplify installation Positive locking connectors on pre assembled cables eliminate the need to individually connect each wire to the RTK3 Much remains common between the PLCIO2 and RTK3 The motion control card CPU10 or compatible connected to the RTK3 must be equipped with an IO2PIC chip see TB133 for upgrade procedure PLCCOMP or XPLCCOMP or both PLC compilers can be used with the RTK3 just like the PLCIO2 The RTK3 also retains the Fast I O feature which is now dedicated to a sourcing sensor input and relay output There are three layers in the RTK3 to minimize footprint and maximize cabinet efficiency Only rarely used connectors are located on the backside of the unit to allow mounting against the cabinet wall if necessary The bottom board has six mounting holes for direct attachment to standoffs See the RTK3 Mounting Dimensions section for mounting standoff configuration The bottom or logic board is home to
7. X 2 CHILLER connector The configurable output jumper settings must be verified before connecting these outputs to prevent damage to the RTK3 or associated hardware Internal Circuitry Configurable Relay Outputs OUTPUT 24 AC2 1 2 OUTPUT COMMON J2 or J4 24V AC Output Setting Relay Contact Output Setting Pin 1 Pin 1 J1 or J3 J1 or J3 J2 or J4 J2 or J4 6 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Spindle Outputs The RTK3 is equipped with an analog output and specialized relay outputs to simplify spindle drive wiring The analog output has a 12 bit resolution and can be configured for 0 to 5VDC or 0 to 10VDC output The analog ground should not be connected to other grounds on the RTK3 All input and output functions required for a standard inverter connection are located on the 15 pin INVERTER connector Internal Circuitry Spindle Drive Outputs SPINDLE DRIVE RESET OUT 15 SPINDLE OUTPUT COMMON SPINDLE DRIVE RESET COMMON Internal Circuitry SPINDLE ORIENT Analog Output SPINDLE ENABLE SPINDLE ANALOG OUTPUT SPINDLE DIRECTION COMMON ANALOG GROUND J4 SPINDLE FORW ARD s SPINDLE REVERSE ANALOG 12 VDC GROUND OUT 13 Jumper Setting for Direction Run Through Enable Jumper Setting for Direction Pulled to Common Pin 1 Pin 1 J4 J5 J4 J5 7 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Analog Output Adjustment Output voltag
8. a hard coded function that is enabled when output 40 is turned on in the PLC program The Fast I O immediately turns off output 31 when a falling edge is detected on input 26 This is done immediately before sending any data back to the control The function is self resetting after output 31 is turned off output 40 must be turned on again in order to reactivate the Fast I O Using the Fast I O prevents the carousel from moving too far due to communication delays When output 40 is off output 31 and input 26 work normally In the RTK3 implementation of the Fast I O input 26 is dedicated to a sourcing tool counter sensor and output 31 controls the carousel enable relay Output 40 is not a physical output since using this output for purposes other than Fast I O enable could cause confusion Timing Diagram Fast I O Enabled Timing Diagram Normal PLC Operation OUT40 m OUT40 f INP26 INP26 Ecl OUTI OUT31 6mS 30mS Status Indicator LEDs Six green indicator LEDs lights located on the bottom board display RTK3 status All six LEDs will be lit under normal operating conditions Five of the LEDs indicate the presence of required operating voltages The 110VAC input feeds the power supply to generate these voltages The PLC OK LED lights when the RTK3 and motion control card CPU10 have a working communication link This LED will not be lit as soon as power is applied After the control software CNC10 has initialized the motion co
9. e present on the RTK3 to reduce wiring time when interfacing with specific components These include 110VAC 220VAC and 3 phase outputs as well as a 24VAC and an analog output Open collector and relay contact outputs are also available for more general application See the Output Map section for more information Each power relay output is protected by a fuse The DOOR FAN and CONSOLE unswitched 110VAC outputs are also fuse protected Fuses are 5x20mm and should be rated equal to or less than the ratings printed on the RTK3 for safety Signal relays such as those on the inverter outputs are not fuse protected Internal Circuitry Internal Circuitry Internal Circuitry 110VAC Output 220VAC Output Relay Output 110 VAC H 220 VAC L1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 Output Common 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 AAA A A Internal Circuitry Internal Circuitry Flood Pump Output Open Collector Output 0 0 E FLOOD OUTPUT ee 5 VDC FLOOD COMMON Output 5 GROUND 5 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Internal Circuitry Carousel Outputs CAROUSEL DIRECTION 1 CAROUSEL DIRECTION 2 CAROUSEL COMMON OUT 31 24 ACI AA A A AAA A A A A Configurable Outputs Outputs 11 and 37 may be configured as 24VAC or relay contact outputs These outputs are routed to the AU
10. e range can be set to 0 to 5 VDC or 0 to 10VDC by setting jumpers J1 J2 and J3 according to the diagrams below Trimming the output can be accomplished with VR1 and VR2 potentiometers See the RTK3L Bottom Board Connections diagram for the location of adjustment hardware The analog levels are adjusted at the factory for the 0 to 10VDC range so only slight adjustments should be needed for each installation Only adjust the OFFSET potentiometer pot VR2 at the minimum possible spindle speed This adjustment is intended only to null the voltage level when 0 RPM is commanded The GAIN pot VR1 should be used at maximum speed to match actual RPM with commanded RPM Adjustments to the analog output should be very minor and cannot be used to compensate for incorrect inverter or control settings 0 to 10 VDC Jumper Settings 0 to 5 VDC Jumper Settings Pin 1 f Pin 1 f f J3 J2 J1 J3 J2 J1 Emergency Stop Connector The E stop connector has an input and output unlike most RTK3 connectors The input notifies the control of an external E stop press The output allows an E stop to be triggered by the PLC program Because the E stop connector sources 24V AC a 24V AC contactor coil must be used This reduces the number of connections at the cost of some versatility Internal Circuitry 24VAC E stop Output 8 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Fast I O Operation The Fast I O is
11. lector UX DRIVERS 2 Auxiliary 14 AUX DRIVERS 2 Auxiliary 15 AUX DRIVERS 2 Auxiliary 16 AUX DRIVERS 2 zz gt gt Z gt z gt 37 Fast I O Related A Often used to store the tool number svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM RTK3 Specifications Characteristic Min Typ Max Unit 5 Volt Supply Current 1 6 A 24 Volt Supply Current 0 6 A Input Pullup Voltage 24 NA Input On Voltage 22 V Input Off Voltage 1 25 V Power Relay Output Current 0 01 10 A 250VAC Power Relay Output Current 0 01 5 A 30VDC Power Relay Output Current 10 400 mA 100VDC Signal Relay Output Current 0 001 0 5 A 125VAC Signal Relay Output Current 0 001 1 A 24VDC Open Collector Output Current 500 mA Open Collector Output Voltage 5 V 3 Phase Output Load 0 50 HP E 250VAC 110 VAC Input Current 9 28 A 3 Phase Input Current Input Operating current 9 11 15 mA Analog Output Resolution 12 bits Analog Output Voltage 0 10 V Analog Output Current 0 1 20 mA Size 12 5 4 W D H RTK3 Troubleshooting Symptom Possible Cause Corrective Action All status LEDs out 1 10VAC not connected connect 110VAC supply to H7 on top board check voltage between 110ACN and 110ACH terminals Fibers faulty or incorrectly connected Check connections inspect or swap fibers INo analog output or n
12. nd E 220 ACI Input et 220 AC2 Input Chassis Ground r Flood Output r Flood Common JBS ad DAR 24 AC2 o Carousel Direction 1 7 Carousel Direction 2 JB6 Carousel Common 24 AC2 15 of 16 svn software hardware RTK3 docs rtk3 man doc MRR 60 24 08 9 03 AM Chassis Ground 110 ACN Console 110 ACH 16 of 16 RTK3T Top Board Connections Carousel Out Outpu 110 ACN 110 ACN 110 ACN E Chassis Ground s B 3 3 a O 3 S o Z Z 30 36 a mM lt aS 4e O XX ED DoorFan 110 ACE s Ep Chassis Ground pn Tool Clamp Output k amp Chassis Ground k G EC Chassis Ground E Chassis Ground M UU Pin 1 d 3 Pin 1 Pin 1 Pin 1 Pin 1 Pin 1 m SEERE Pin 1 TT Hm RU D Pin 1 j Pin 1 b 4 Pin 1 h 7 Pin 1 f 4 Pin 1 b 4 svn software hardware RTK3 docs rtk3_man doc MRR 6 24 08 9 03 AM 110 ACH 110 ACN Chassis Ground 110 Lube Output 110 ACN Chassis Ground i Mister Output 110 ACN Chassis Ground
13. ntrol card communication can be established with the RTK3 which lights the PLC OK LED 9 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM 10 of 16 Input Map Input Specification Numer Function Type Board Rowew Sid Pn iit Sewimg Bottom TV LIMITS 2 X Limit Sourcing Bottom X X Y Y LIMITS cme B 1 3 Xeimi pf Lit S soeg poom fee Zits fs A Wemi Sewing Boom We7W 5e78 LIMITS 17 Pf We Limit Seweng Boom WerW rsers LiMmrs EN 79 athe Limi Soureing Bottom WerW rsers LiMmTs 5 EmegewySup Sourcing Bowm festo fr PT Sourcing Boom AUX f i4 ex Source Bottom DIGmzEPROBE fr Probe Perea Sourcing Bonom DIGITIZE PROBE i or Check _Intemal NA NA 15 Dormero Sourcing Bowm JDOORSWITCH fi iq Tow Lae Sourcing Mie jowLUBE fr 1p Spindle Zero Speed Sewing Boom NVERTER 10 Fast I O Related svn software hardware RTK3 docs rtk3 man doc MRR 60 24 08 9 03 AM 11 of 16 Output Map Output Specification Connection Location Number Tipe Pi Emergency Stop 24VAC STOP 2 Lube Pump 220VAC Middle D20 LUBE 2 Lube Pump 110VAC T 110 LUBE T a in PHASE 123 HOVAC Internal NA HOVAC HOVAC A Aro Through novac Rp hIRBLOW A Carouset ta Sotenoid HOVAC CARIN 1 507 A SpmieEsie Relay Contact Bem INVERTER A
14. oints on the RTK3 reduce the quantity of external hardware required These advantages allow for quicker more organized more compact and more reliable panel wiring 3 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Power Connection Three power connections are necessary on a full RTK3 installation Five position plugs are used for the 220VAC and 24VAC power inputs Three wires are positioned uniquely in the housing to prevent operation with incorrect voltage connections Screw terminals on the top board are used for 100VAC connection The 220V AC input supplies the 220V AC lube and spindle cooling fan outputs The 110VAC input powers the on board power supply as well as 110VAC outputs The E stop output and configurable outputs may use the 24V AC input Input Wiring All inputs on the RTK3 are optically isolated and 24VDC powered Some inputs are sourcing and others are sinking see the Input Map section for details The two basic input configurations are shown below Internal Circuitry Internal Circuitry Sourcing Input Sinking Input i 424 VDC i 24 VDC INPUT POWER INPUT eh 24 GROUND 24 GROUND INPUT GROUND Either type of input may be used with a switch Sourcing inputs may be used with sinking sensors that are capable of sinking 15mA at 24VDC Sinking inputs may be used with sourcing sensors that provide 15mA at 24VDC Compare sensor and RTK3 input specifications using
15. on linear output Incorrect Parameter 31 setting Set P31 to 1 IEstop contactor or other 24VAC outputs D4VAC not connected plug 24VAC cable into 24VAC input on middle board check Inot working connections and voltage AUX2 or CHILLER outputs not working Jumpers J1 J4 on Output middle board not set Refer to page 6 in the manual correctly If 24VDC LED is lit digitizer fuse blown or poor Check digitizer fuse and fuseclips on bottom board onnection 12 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 6 24 08 9 03 AM 13 of 16 RTK3 Mounting Dimensions K 4 275 0 200 0 200 0 500 k 0 475 svn software hardware RTK3 docs rtk3_man doc MRR 6 24 08 9 03 AM 275 14 of 16 5 Ground 5 VDC Auxiliary Output Driver 9 Auxiliary Output Driver 8 Auxiliary Output Driver 7 Auxiliary Output Driver 6 Auxiliary Output Driver 5 Auxiliary Output Driver 4 Auxiliary Output Driver 3 5 Ground 5 VDC Auxiliary Output Driver 16 Auxiliary Output Driver 15 Auxiliary Output Driver 14 Auxiliary Output Driver 13 Auxiliary Output Driver 12 Auxiliary Output Driver 11 Auxiliary Output Driver 10 Programming Header Do Not Connect Inverter Output Configuration Jumpers RTK3L Bottom Board Connections Ss e x o 3 m E s 4 E FE oO a4 Ex M lu s E 5 ER 9885 E E eo 223 2 Y 3 Hon ERE Eo du B S E aoc 268 E O SEs 224 252249 2222 628 EFE g g S
16. the logic controller s processor input isolators analog output section output drivers and power supply section This is where the fiber optic and almost all input connections are made The middle board has 10 relays one logic input and two power inputs Various voltage and load levels are controlled by relays on the middle board The top board is equipped with 110VAC outputs and the 110VAC power input connector RTK3 System Constraints The lube pump output must be either 220VAC or 110VAC single phase In addition the E stop power loop must be 24VAC solenoids and lights must be 110VAC and sensors must be compatible with 24VDC inputs when using an RTK3 2 of 16 svn software hardware RTK3 docs rtk3_man doc MRR 60 24 08 9 03 AM Wiring Concept Visual Comparison Previous ATC Wiring Sample PC Transformer Inverter XY NN p Estop Contactor Intermediate Terminal Intermediate Terminal Strip Power Supply PLCIO2 C T Intermediate Terminal Strip Carousel Motor Contactor Flood Pump Contactor AL d RTK3 Wiring Sample Transformer PC Estop Contactor JUE Wi Note the simplified layout and wiring enabled by the RTK3 Fewer individual wires thin lines are used and intermediate terminal block connections are reduced Cables thick lines with quick connect ends replace many individual wires Integrated components and specialized connection p
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