Control Techniques AXIMA 2000 Installation Manual

© Control Techniques Drives, Inc. 1997, 2001, 2005 AXIMA 2000/4000 Multi-Axis Controller

accurate and reliable. However, no responsibility is assumed by Control Techniques for its use. Control Techniques reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. Control Techniques also assumes no responsibility for any errors that may appear in this document. Information in this document is subject to change without notice. P/N 400266-00 Revision: A8 Date: December 8, 2005 © Control Techniques Drives, Inc. 1997, 2001, 2005 AXIMA 2000/4000 Multi-Axis Controller Installation Manual

Part Number: 400266-00 Revision: A8 Date: December 2005 Printed in United States of America Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Control Techniques. The following are trademarks of Control Techniques and may not be reproduced in any fashion without written approval of Control Techniques: EMERSON Motion Control, EMERSON Motion Control PowerTools, AXIMA, “Motion Made Easy.” Control Techniques is a division of EMERSON Co. Control Techniques Drives, Inc. is not affiliated with Microsoft Corporation, owner of the Microsoft, Windows, and Windows NT trademarks. IBM is a registered trademark of International Business Machines Corporation. Modbus is a registered trademark of Gould, Inc. Data Highway Plus is a trademark of Allen-Bradley Littelfuse is a trademark of Littelfuse, Inc. This document has been prepared to conform to the current released version of the product. Because of our extensive development efforts and our desire to further improve and enhance the product, inconsistencies may exist between the product and documentation in some instances. Call your customer support representative if you encounter an inconsistency.

Eden Prairie, Minnesota 55344-3620 U.S.A. Telephone: (952) 995-8000 or (800) 893-2321 It is Control Techniques’ goal to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax or modem, you can access Control Techniques support information 24 hours a day, seven days a week. Our wide range of services include: FAX (952) 995-8099 You can FAX questions and comments to Control Techniques. Just send a FAX to the number listed above. Website and Email www.emersonct.com Website: www.emersonct.com Email: [email protected] If you have Internet capabilities, you also have access to technical support using our website. The website includes technical notes, frequently asked questions, release notes and other technical documentation. This direct technical support connection lets you request assistance and exchange software files electronically. Technical Support (952) 995-8033 or (800) 893-2321 Email: [email protected] Control Techniques’ “Motion Made Easy” products are backed by a team of professionals who will service your installation. Our technical support center in Eden Prairie, Minnesota is ready to help you solve those occasional problems over the telephone. Our technical support center is available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, if needed, are available through our customer service organization. When you call, please be at your computer, with your documentation easily available, and be prepared to provide the following information: • Product version number, found by choosing About from the Help menu • The type of controller or product you are using

• What you were doing when the problem occurred • How you tried to solve the problem Need on-site help? Control Techniques provides service, in most cases, the next day. Just call Control Techniques’ technical support center when on-site service or maintenance is required. Training Services (952) 995-8000 or (800) 893-2321 Email: [email protected] Control Techniques maintains a highly trained staff of instructors to familiarize customers with Control Techniques’ “Motion Made Easy” products and their applications. A number of courses are offered, many of which can be taught in your plant upon request. Application Engineering (952) 995-8000 or (800) 893-2321 Email: [email protected] An experienced staff of factory application engineers provides complete customer support for tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications. Customer Service (Sales) (952) 995-8000 or (800) 893-2321 Email: [email protected] Authorized Control Techniques distributors may place orders directly with our Customer Service department. Contact the Customer Service department at this number for the distributor nearest you. Document Conventions Manual conventions have been established to help you learn to use this manual quickly and easily. As much as possible, these conventions correspond to those found in other Microsoft® Windows® compatible software documentation. Menu names and options are printed in bold type: the File menu. Dialog box names begin with uppercase letters: the Axis Limits dialog box. Dialog box field names are in quotes: “Field Name.” Button names are in italic: OK button. Source code is printed in Courier font: Case ERMS.

Note For the purpose of this manual and product, “Note” indicates essential information about the product or the respective part of the manual. “Warning” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. “Caution” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. “Caution” used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage. Safety Instructions General Warning Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the product can cause severe electric shock and/or burns and could be lethal. Extreme care is necessary at all times when working with or adjacent to the product. The installation must comply with all relevant safety legislation in the country of use. This Represents bold Characters that you must type exactly as they appear. For example, if you are directed to type a:setup, you should type all the bold characters exactly as they are printed. italic Placeholders for information you must provide. For example, if you are directed to type filename, you should type the actual name for a file instead of the word shown in italic type. ALL CAPITALS Directory names, file names, key names, and acronyms. SMALL CAPS Non-printable ASCII control characters. KEY1+KEY2 example: (Alt+F) A plus sign (+) between key names means to press and hold down the first key while you press the second key. KEY1,KEY2 example: (Alt,F) A comma (,) between key names means to press and release the keys one after the other.

the installation, construction and operation of the equipment and the hazards involved. In addition, this individual has the following qualifications: • Is trained and authorized to energize, de-energize, clear and ground and tag circuits and equipment in accordance with established safety practices. • Is trained in the proper care and use of protective equipment in accordance with established safety practices. • Is trained in rendering first aid.

The AXIMA 2000/4000 Multi-axis Controllers are marked with the “Conformite Europeenne Mark” (CE mark) after passing a rigorous set of design and testing criteria. This label indicates that this product meets safety and noise immunity and emmisions (EMC) standards when installed according to the installation guidelines and used within the product specifications. AXIMA® 2000/4000 Multi-axis Controller Installation Manual

Declaration of Conformity Manufacturer’s Name: Control Techniques Manufacturer’s Address: 12005 Technology Drive Eden Prairie, MN 55344 USA Declares that the following products: Products Description: AXIMA 2000/4000 Multi-axis Controller Model Number: AXIMA 2000 and AXIMA 4000 System Options: This declaration covers the above products with the stepper axis, source mode expanded I/O, analog inputs, Modbus and Data Highway Plus. Conforms to the following product specification: Electomagnetic Compatibility (EMC): EN 55011/1991 Class A Group 1, CISPR 11/1990 Class A Group 1 EN 50082-2/1995: IEC 1000-4-2/1995; EN 61000-4-2, 4kV CD IEC 1000-4-3/1995; EN 61000-4-3, ENV 50140/1993, 80% AM, 10V/m @ 3 m IEC 1000-4-4/1995; EN 61000-4-4, 2 kV ALL LINES IEC 1000-4-8/1993; EN 61000-4-8, 30 A/m ENV 50141/1993, 80% AM, 10V, .15-80 MHz ENV 50204/1995, Pulse, 900 MHz, 50% DTY, 200 Hz Supplementary information: The products herewith comply with the requirements of the Low Voltage Directive (LVD) 73/23/EEC and EMC Directive 89/336/EEC This electronic drive product is intended to be used with an appropriate motor, electrical protection components and other equipment to form a complete end product or system. It must only be installed by a professional assembler who is familiar with requirements for safety and electromagnetic compatibility (“EMC”). The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used. Refer to the product manual for installation guidelines. February 24, 1999 Bradley Schwartz/ VP Engineering Date European Contact: Sobetra Automation Langeveldpark Lot 10 P. Dasterleusstraat 2 1600 St. Pieters Leeuw, Belgium

Installation 5 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Environmental Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Basic Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 System Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Connections and Cabling 17 Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 COM Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 COM Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Controller ID Number/Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Axis Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Encoder 1 or 3 Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Input/Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Diagnostics Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Analog Input Option 51 Axis Inputs Connector Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Expanded I/O Option 55 Sinking Versus Sourcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Direct Wiring Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Connectivity Options 69 Modbus Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Data Highway Plus Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Table of Contents AXIMA® 2000/4000 Multi-axis Controller Installation Manual

Stepper Option 75 Specifications 77 AXIMA® 2000/4000 Controller Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Cable Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Glossary 87 Index 91

a fully integrated solution for servo control motors. It also provides a simple operator interface, machine I/O and host communications in one unit. Housed in an industrial hardened chassis, AXIMA 2000/4000 controller combines digital servo control and 41 optically isolated I/O lines to create a powerful tool for solving motion control applications that require coordinated control of up to four axes. Figure 1: AXIMA 2000 and 4000 Multi-Axis Controllers The AXIMA 2000/4000 controller uses a 32-bit floating point Digital Signal Processor (DSP). The DSP gives the AXIMA 2000/4000 controller the processing power, flexibility and functionality to handle the wide range of multi-axis applications found in plant automation and industrial machinery. AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

With AXIMA 2000/4000 controller, as many as four Motion, eight PLC and eleven Auxiliary Programs can be operating simultaneously and control up to four separate coordinate systems, with one axis of motion each, one coordinate system with up to four axes of motion, or any combination of up to four coordinate systems and up to four axes of motion. The onboard executive program allows axis assignments to be made to create one or multiple coordinate systems. Each coordinate system operates from an independent program. This allows the programmer to concentrate on one coordinate system at time.

Figure 2: AXIMA 2000/4000 Controller Front Panel Connections

system. If installed incorrectly, it may present a safety hazard. The product uses high voltages and is used to control mechanical equipment which can cause injury. Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and the instruction manual carefully. It is your responsibility to comply with the safety requirements of your system. This includes installing the system with an appropriate master interlock switch for emergency shutdown that will remove AC power from the system any time the equipment is not running or the emergency stop is activated. This reduces the possibility of electrocution or unwanted motion. Enclosure The controller is intended to be mounted in an enclosure which prevents access except by trained and authorized personnel, and which prevents the ingress of contamination. The controller was designed for use in an environment classified as pollution degree 2 in accordance with IEC 664-1, meaning that only dry, non-conducting contamination is acceptable. Selecting an Enclosure The AXIMA 2000/4000 multi-axis controller is designed for most industrial environments. However, no sophisticated electronic system can tolerate atmospheric contaminants such as moisture, oils, conductive dust, chemical contaminants and metallic particles. If the AXIMA 2000/4000 controller is going to be subject to this type of environment, it must be mounted in a metal enclosure with a minimum rating of NEMA 12. The temperature inside the enclosure should not exceed 40° C (104° F). If the ambient temperature exceeds 40° C (104° F) active cooling must be installed. Setting Up, Commissioning and Maintenance It is essential that changes to the controller settings are given careful consideration. Depending on the application, a change could have an impact on safety. Appropriate precautions must be taken against inadvertent changes or tampering. AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

Restoring default parameters set in certain applications may cause unpredictable or hazardous operation. Safety of Machinery Within the European Union all machinery in which this product is used must comply with Directive 89/392/EEC, Safety of Machinery. The AXIMA 2000/4000 hardware and PowerTools software are designed and tested to a high standard, and failures are very unlikely. However the level of integrity offered by an AXIMA 2000/4000 control function – for example stop/start, forward/reverse and maximum speed – is not sufficient for use in safety-critical applications without additional independent channels of protection. All applications where malfunction could cause injury or loss of life must be subject to a risk assessment, and further protection provided where needed. Electromagnetic Compatibility (EMC) The AXIMA 2000/4000 controllers are designed to the high standards of EMC. Under extreme conditions an AXIMA 2000/4000 controller might cause or suffer from disturbances due to electromagnetic interaction with other equipment. It is the responsibility of the installer to ensure that the equipment or system into which the drive is incorporated complies with the relevant EMC legislation in the country of use. The following instructions provide you with installation guidance designed to help you meet the requirements of the EMC Directive 89/336/EEC. Although Control Techniques cannot guarantee your system will meet tested emission or immunity requirements, adhering to the following guidelines will greatly improve the electromagnetic compatibility of your system. • Choose an enclosure made of a conductive material, such as carbon steel, aluminum or stainless steel. • Devices mounted to the enclosure mounting plate, which depend on their mounting surfaces for grounding, must have the paint removed from their mounting surfaces and the mating area on the mounting plate to ensure a good ground. The AXIMA 2000/4000 controller does not require removal of paint. • If grounding is required for cable grommets, connectors and/or conduit fittings at locations where cables are mounted through the enclosure wall, paint must be removed from the enclosure surface at the contact points. • AC line filter input and output wires and cables should be shielded, and all shields must be grounded to the enclosure. Although final responsibility for EMC compliance rests with the machine builder, we are including the following installation suggestions. They describe the components that were used and how they were installed during the EMC compliance testing.

Immunity can be improved and emissions reduced by maintaining the components of the installation at the same ground potential. Establishing zero potential difference between components requires a low impedance connection between the components. This can be achieved by bringing the conductive surfaces of the components into direct contact. Over the short term this can be very effective. Over an extended period of time, degradation of the connection may occur due to corrosion. Corrosion can occur when a material reacts with the atmosphere or when two dissimilar materials react with each other. Therefore component materials should be conductive, compatible and exhibit good atmospheric corrosion resistance. Bringing components into direct contact cannot always be achieved. In these situations a conductor must be relied upon to provide a low impedance path between components. The impedance of the conductor is dependent on conductivity and frequency. Conductors that provide a low impedance path at low frequencies may not provide a low impedance path at higher frequencies. A good rule to follow when specifying conductors for high frequency applications is to use a metal strap with a length to width ratio that is less than 3:1. A low impedance connection should exist between the following components, but not limited to: • Enclosure and mounting plate • Servo amplifier chassis and mounting plate • EMI/RFI AC line filter chassis and mounting plate • Other interface equipment chassis and mounting plate • Other interface equipment chassis and electrical connectors • Enclosure and conduit fittings or electrical connectors • Enclosure mounting plate and earth ground • Motor chassis and conduit fittings or electrical connectors • Encoder chassis and electrical connector • Cable shields when and where they should be grounded Note It is critical that you keep the filter inputs routed away from any electrical noise sources to prevent noise from being induced into them and carried out of the enclosure.

Environmental Concerns If your AXIMA 2000/4000 controller will be subjected to atmospheric contaminants such as moisture, oils, conductive dust, chemical contaminants and metallic particles, you must mount it vertically in a metal NEMA type 12 enclosure. If the ambient temperature inside the enclosure will exceed 40° C (104° F), you must consider forced air cooling. The amount of cooling depends on the size of the enclosure, the thermal transfer of the enclosure to the ambient air and the amount of power being dissipated inside the enclosure. Basic Installation Notes You are required to follow all safety precautions during start-up, such as providing proper equipment grounding, correctly fused power and an effective Emergency Stop circuit which can immediately remove power in the case of a malfunction. • To avoid problems associated with Electromagnetic Interference (EMI), you should route high power lines (AC input power and motor power) away from low power lines (encoder feedback, serial communications, etc.). • You should consider future troubleshooting and repair when installing all wiring. All wiring should be either color coded and/or tagged with industrial wire tabs. • As a general rule, the minimum cable bend radius is ten times the cable outer diameter. • All wiring and cables, stationary and moving, must be protected from abrasion. • Ground wires should not be shared with other equipment. Also ensure that metal to metal contact is made between the enclosure ground lug and the metal enclosure. • All inductive coils must be suppressed with appropriate devices, such as diodes or resistor/capacitor (RC) networks. General Warning Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to it. The installation must comply with all relevant safety legislation in the country of use. AC supply Isolation device The AC supply must be removed from the controller using an approved isolation device or disconnect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. Grounding (Earthing, equipotential bonding) The controller must be grounded by a conductor sufficient to carry the prospective fault

adhered to. Fuses Fuses or over-current protection must be provided at the input in accordance with the instructions in the manual. Failure to observe the instructions closely may cause a fire hazard. Isolation of control circuits The control circuits are isolated from the power circuits in the controller by basic insulation only. The installer must ensure that the external control circuits are isolated from human contact by at least one layer of insulation rated for use at the applied AC supply voltage. Mounting Requirements The AXIMA 2000/4000 controller should be back mounted vertically in a metal NEMA enclosure. A minimum spacing of four inches must be maintained above and below the controller for ventilation. The following diagram shows the dimensions of the AXIMA 2000/ 4000 controller.

Figure 3: Mounting Dimensions System Grounding Requirements AXIMA 2000/4000 Controller Grounding The PE terminal of the AXIMA 2000/4000 controller is internally bonded to the chassis. The enclosure PE and the AXIMA 2000/4000 controller PE should have a common signal point that ultimately is a continuous path to earth ground. These ground wires of the AXIMA 2000/ 4000 controller should not be shared with other equipment in the enclosure. The TE terminal is connected to the internal digital ground of the AXIMA. The TE connection should be tied to the PE connection in the enclosure. Do not jumper the connection to the PE terminal on the AC input connector. 0.20 (5.08) typ. 4 places 11.70 (297.18) 11.19 (284.23) 3.68 (98.30) 5.5 (139.70) 0.9 (22.86) 3.0 (76.20) 7.1 (183.00) 0.25 (6.35) Dimensions in ( ) are in millimeters. 3.0 (76.20) 1.25 (31.75)

The AXIMA 2000/4000 controller PE terminal must be connected to the equipment grounding conductor of the AXIMA’s AC supply circuit and bonded to the enclosure. This should be accomplished with a short wire from the PE terminal to a grounding block in the enclosure. All other equipment in the enclosure must use its own connection to this grounding block.

AXIMA/E Series Drives Grounding Example Figure 5: E Series Drive and AXIMA System Grounding Diagram

Figure 6: MX Drive and AXIMA System Grounding Diagram Control Transformer Convenience Outlet Neutral Hot Output AC Power Supply 3 Phase Line Power DC I/O Supply Fuses Enclosure Single Point Ground (Bonded to Enclosure) PE Connection TE Connection AXIMA Multi-axis Controller MX Digital Servo Drive Pin 11 Jumper from AMP GND to "Y" Terminal + VDC Power

AXIMA/LX Drives Grounding Example Figure 7: LX Drive and AXIMA System Grounding Diagram Power Requirements Rated AC power input is 120 VAC at 1 A or 240 VAC at 0.5 A, single phase, 50 or 60 Hz. AC power must be between 96 and 204 VAC. The AC power connects to a removable connector on the top of the AXIMA 2000/4000 chassis. The AC power input must be between 96 and 264 VAC, single phase, and 50 to 60 Hertz. At 115 VAC, 1.0 Amps RMS is required, or at 230 VAC, 0.5 Amps RMS is required. However, at power-up the unit has an inrush current that is typically 20 Amps at 115 VAC

choosing AC power fusing. Note The AC Power removable connector terminals are to be torqued 6 to 7 inch pounds at installation of wiring. Figure 8: AC Power Connector External Fusing Requirement The AC power supply must be fused with a 2 amp fuse in each ungrounded line. A grounded line (neutral) must not be fused. Littelfuse®’s FLM-2 SLO-BLO type fuse, or an equivalent, can be used. AC Supply Voltage Current Inrush Current (2 ms) Fusing Frequency (Hz) AC Supply Limit 115 VAC 1 Amp 20 Amps FLM-2 or equivalent 50/60 96 to 264 VAC 230 VAC 0.5 Amp 40 Amps 2 Amp Slo-Blo

Grounded Supply Requirement A significant AC power problem occurs when the secondary of the AC distribution transformer is not electrically referenced to earth ground (i.e., left floating). In this case, the voltages that develop between the AC power lines and earth ground can continuously exceed the voltage limit of 264 VAC. When this happens the protection circuit in the AXIMA 2000/ 4000 controller will try to suppress this excess voltage. If the condition is prolonged, the AXIMA 2000/4000 controller protection circuits will fail. The voltage limit of 264 VAC applies from L1 to PE and L2 to PE as well as from L1 to L2. Use a ground referenced AC supply.

Serial Communications The AXIMA® 2000/4000 controller has two optically isolated serial ports (COM 1 and COM 2). COM 1 is a RS232 port. COM 2 can be configured for RS232, RS422 or RS485 using DIP switches located behind the removable access panel on the top front of the AXIMA 2000/ 4000 controller. Figure 9: AXIMA 2000/4000 Controller Communication Ports, Com 1 and Com 2 COM Port 1 The AXIMA 2000/4000 controller COM 1 connection is a RS232 serial communication port. The COM 1 port is activated and will automatically detect the baud rate by receiving one carriage return after power up. Both serial ports, COM 1 and COM 2, can be open simultaneously and attached to different programs. For example, one port could be used as a programming and diagnostics port while the second port is communicating with an operator interface panel such as the Control Techniques T-60 panel. Pin Number Description 1 Shield 2 Rx 3 Tx 4 Not connected AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

Note The COM 1 port is supplied through a DC-to-DC convertor which is isolated from the main board’s 5 VDC supply. All communications signals are isolated using optoisolators. Serial Port and Cable Specifications It is recommended that all communication lines be twisted pair shielded cable. Cables should be routed away from motor power and other high voltage or noisy wiring. The RS232 serial communication cables should be no longer than 50 feet to comply with RS232 specifications. However, longer cables may be used at slower baud rates (less than 9600). The wiring diagrams on the next page show the TIX and TIA serial cables which are available from Control Techniques in 10, 25 and 50 foot lengths. Non-standard lengths can be special ordered. 5 Common 6 Not connected 7 Not connected 8 Not connected 9 Not connected Serial Communication Setup Max baud rate 38.4 K Stop bit 1 Data bits 8 Parity none Pin Number Description

Figure 10: RS232C Serial Communication Cables Wiring Diagram COM Port 2 To communicate with more than one AXIMA 2000/4000 controller, and using the AXIMA Software or other host controller, you must use COM 2 configured as an RS485. The COM 2 serial communication port is shipped as a RS232 as default. DIP Switch Settings COM 2 can be configured for RS232, RS422 or RS485 using switches located behind the removable access panel on the top front of the AXIMA 2000/4000 controller. TIX-XXX CABLE 25 PIN "D" CONNECTOR FEMALE PIN NUMBER PIN NUMBER SHLD GND Rx Tx 9 PIN "D" CONNECTOR MALE 5 1 9 8 7 6 4 3 2 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 2 3 7 2 3 5 1 GND Tx Rx TIA-XXX CABLE 9 PIN "D" CONNECTOR FEMALE PIN NUMBER PIN NUMBER SHLD GND Rx Tx 9 PIN "D" CONNECTOR MALE 5 1 9 8 7 6 4 3 2 3 2 5 2 3 5 1 GND Tx Rx 5 1 9 8 7 6 4 3 2 COM 1 COM 1 COMPUTER COMPUTER

Figure 11: AXIMA 2000/4000 Controller DIP Switches Location DIP Switch Settings 1 2 3 4 RS232 DOWN RS422 UP DOWN DOWN DOWN RS485 (2 wire/SD) UP UP UP UP RS485 (4 wire/SD) UP DOWN UP UP RS485 (4 wire/RTS) UP DOWN DOWN UP

Mode Selection RS232C Mode (Default Mode) The AXIMA 2000/4000 controller is shipped with COM 2 in RS232 mode. Figure 12: COM 2, RS232 Configuration Note The COM 2 port is supplied through a DC-to-DC convertor which is isolated from the main board’s 5 VDC supply. All communications signals are isolated using optoisolators. RS422 Mode With COM 2 in RS422 mode, the transmitter is not put into a tri-state mode. The Tx (Transmit) lines of multiple AXIMA 2000/4000 controllers CAN NOT be wired together. The receive line of the last AXIMA should be terminated with a 100 ohm ½ watt resistor. See Figure 13. RS485 Mode RS422 and RS485 modes are similar because they both use differential drivers and receivers. RS485 mode adds the ability to enable and disable the receivers and transmitters as required for multidrop installations. See Figure 14 and 15. The enable and disable operations of the AXIMA 2000/4000 controller serial port can be selected to operate in two different transmission methods. These methods are selectable with a DIP switch behind the access panel on the top front of the controller. It is labeled, SD (Send Data) or RTS (Ready to Send). See Figure 11. SD (Send Data) Method: This is the simplest mode. Whenever the AXIMA 2000/4000 controller serial port senses that data is present the transmitter is enabled. The transmitter stays enabled long enough to assure the last bit has been sent then it disables or tri-states the transmission. It does this for baud 1 2 3 4 5 6 7 8 Shld Rx Tx Com Tx+ Tx- Rx+ Rx- 232 485 Com 2 Tx Rx GND RS232C DEVICE

rates down to 9600 baud. The transmitter is in tri-state mode or disabled when data is not being sent so it can receive data. RTS (Ready to Send) Method: This method enables the transmitter under two conditions. 1. When a particular AXIMA 2000/4000 controller has been chosen by the host to be online, the command, CTRL A - “Axis ID #” - Enter, is issued. The transmitter stays enabled until a “CTRL B” command is received. 2. When the AXIMA Software Application executes an Open Com Instruction, the transmitter is enabled. The transmitter goes back to tri-state mode when a Close Com Instruction is issued. See the AXIMA Software User’s Guide (P/N 400263-00) for more information. The Echo On/Off DIP switch controls the enable/disable function of the AXIMA receiver. With the switch “On”, the receiver is always enabled. This switch should be “On” for RS422 and RS485 four wire operation. With the switch “Off”, the receiver is disabled whenever the transmitter is enabled. This is needed for two wire mode. This is to prevent the AXIMA 2000/ 4000 controller from receiving the same characters it just transmitted. The figure below shows a wiring diagram for serial communications of a RS422 configuration.

Figure 13: RS422 Two Wire Muli-Drop Wiring Diagram Note A standard RS-422 host transmitter can drive up to 10 slaves. However, the AXIMA transmitter can drive up to 15 slaves in RS-422 mode. The figure below shows a wiring diagram for serial communications in an RS485 four wire multi-drop configuration. 15 E NC NC TYPICALLY UP TO 10 SLAVES SEE NOTE BELOW NC NC GND 100 Ω ½ WATT

Figure 14: RS485 Four Wire Multi-Drop Wiring Diagram The figure below shows a wiring diagram for serial communications of a RS485 two wire termination connection. 15 E UP TO 15 SLAVES GND

Figure 15: RS485 Two Wire Termination Connection Wiring Diagram RS485 termination Two 120 ohm, ½ watt resistors must be installed on an RS-485 network, one at the node (RS- 485 port) physically at the beginning of the cable and one on the node at the end. 15 E UP TO 15 SLAVES GND

Figure 16: COM 2, RS485 Configuration Serial Port Grounding The AXIMA 2000/4000 controller provides an isolated logic supply for its communication circuitry. COM is the circuit common for both COM port circuits. COM 1 and COM 2 devices, such as PC serial ports, typically have signal ground connected to earth ground internally in the PC. If your COM devices do not have signal grounds that are common with respect to each other (such as both connected to earth ground) then you must connect them together. Failure to connect device grounds together could cause damage to the device or the AXIMA 2000/4000 controller. 1 2 3 4 5 6 7 8 Shld Rx Tx Isolated Com * Tx+ Tx- Rx+ Rx- Com 2 Rx - Tx + Tx - RS485 or RS422 Device GND Rx + * Isolated from the rest of the AXIMA Controller through a DC-to-DC convertor.

Figure 17: Serial Communications Grounding Diagram Serial Port and Cable Specifications It is recommended that all communication lines be twisted pair shielded cable. Low capacitance shielded twisted pair cable will deliver optimum performance especially with long cable lengths and high baud rates. Cables should be routed away from motor power and other high voltage or noisy wiring. Note As baud rates increase or cable lengths get longer your susceptibility to noise increases. Therefore, if you are experiencing communication problems, it is recommended that you install a ½ watt terminating resistor, 100 ohm for RS422 and 120 ohm for RS485. Serial Communication Setup Max baud rate 38.4 K Stop bit 1 Data bits 8 Parity none 5 1 9 8 7 6 4 3 2 9 PIN "D" CONECTOR 1 2 3 4 5 6 7 8 Shld Rx Tx Com Tx+ Tx- Rx+ Rx- 232 485 COM 1 COM 2 COM 2 DEVICE (RS422 OR RS485) COM 1 DEVICE (RS232C) SIGNAL COMMON SIGNAL COMMON GROUND GROUND INTERNALLY CONNECTED

Controller ID Number/Address The following table shows how the Address DIP switch positions relate to the AXIMA 2000/ 4000 controller axis ID number. The DIP switches are located behind the top front access panel of the AXIMA 2000/4000 controller. Figure 18: AXIMA 2000/4000 Controller Address DIP Switch Location AXIMA ID Address DIP Switch Settings 1 2 3 4 0 OFF OFF OFF OFF 1 OFF OFF OFF ON 2 OFF OFF ON OFF

Note The following procedure is needed if a corrupted program is run on power-up or in making communications. The reserved address setting is used for bypassing the flash memory and ignoring the run on power-up command for programs in the Application. This is needed if the flash memory becomes corrupted. Corrupted flash can lock-up communications and load the corrupted program into RAM on power-up. This requires revision A7 or later firmware. The instructions for using this function are as follows: 1. Turn the AXIMA 2000/4000 controller power “Off”. 2. Set the DIP switches to the reserved positions. (All switches in the “On” position). 3. Turn the AXIMA 2000/4000 controller power “On”. 4. Set the DIP switches back to the address being used. 5. Download the AX-WIN Application. Multi-Drop Installations If your application uses more than one AXIMA 2000/4000 controller (up to 15 can be linked serially), each must have a different ID number. This allows each AXIMA 2000/4000 controller to be addressed individually over the same multi-drop serial cable in the RS422 and RS485 modes. 3 OFF OFF ON ON 4 OFF ON OFF OFF 5 OFF ON OFF ON 6 OFF ON ON OFF 7 OFF ON ON ON 8 ON OFF OFF OFF 9 ON OFF OFF ON A ON OFF ON OFF B ON OFF ON ON C ON ON OFF OFF D ON ON OFF ON E ON ON ON OFF Reserved ON ON ON ON AXIMA ID Address DIP Switch Settings

Axis Connections The front panel of the AXIMA 2000/4000 controller has four, 25 pin female “D-sub” connectors. The AXIMA 2000 has two axes and two auxiliary encoder connections, while the AXIMA 4000 has four axes connections. Figure 19: AXIMA 2000/4000 Controller Connectors (4 Axes)

These axis connectors are used to connect the AXIMA 2000/4000 controller to the individual amplifiers (E Series, MX, LX, etc.). The following table shows the pinout of the 25-pin female “D-sub” connectors. * Grayed-out Pin Numbers are NOT available in the AXIMA 2000’s Encoder Connection 3 and 4. Pin Number Signal Name Pair Number 13 A Encoder Input Signal 1 25 A/ Encoder Input Signal 12 B Encoder Input Signal 2 24 B/ Encoder Input Signal 11 Z Encoder Input Signal 3 23 Z/ Encoder Input Signal 10 +5 VDC for Encoder Feedback 4 22 VDC Common (0 VDC Common for Encoder Feedback - Pulse Output 5 5 Pulse/ Output 17 Direction Output 6 - Direction/ Output 8 Analog Command Output - 7 20 Analog Command Output + 9 Enable Contact 8 21 Enable Contact 14 Ø VDC I/O Supply Common 9 2 +24 VDC I/O Supply 3 Discrete Input (CCW Travel Limit) 10 16 Discrete Input (CW Travel Limit) 15 Discrete Input (Drive Status) 11 18 Low Current Mode Output 7 Analog Input 1 12 19 Analog Input 2 6 Analog Common 13 4 Overall Shield

Analog Inputs Note These are only active if the factory Analog Input option is installed. Encoder Inputs Encoder signals are low voltage, high frequency signals susceptible to noise if not properly shielded. For reliable operation it is important that encoder cables be shielded and routed away from motor power or other high voltage signals. Shields should be connected at the controller end. The encoder signals may come from an encoder or from the encoder simulation output of a brushless servo drive (see wiring diagrams below). Pin 7 Pin 19 Axis 1 Analog Input 1 Analog Input 2 Axis 2 Analog Input 3 Analog Input 4 Axis 3 Analog Input 5 Analog Input 6 Axis 4 Analog Input 7 Analog Input 8 Specifications Input Signal Quadrature square wave Maximum Rate 8 MHz Type Differential Receiver, DS26LS32 Voltage 5 VDC maximum, 2 VDC minimum Supply 5 VDC, 250 mA maximum per axis

Figure 20: Encoder Simulation Wiring Diagram Figure 21: AX4-ED Encoder Cable Wiring Diagram 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 25 PIN "D" CONNECTOR A/ B B/ Z Z/ A 25 12 24 11 23 13 PIN NUMBER 4 A A/ SHLD B B/ Z Z/ AXIS CONNECTION ENCODER SIMULATION FROM SERVO DRIVE AXIS 1 (FOR 4000) ENCODER 3 (FOR 2000) 25 PIN "D" CONNECTOR 9 PIN "D" CONNECTOR 5 1 9 8 7 6 4 3 2 ENCODER 1 OUTPUT (FOR 4000) ENCODER 3 OUTPUT (FOR 2000) 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD Z/ Z B/ B A/ A PIN NUMBER 25 12 24 11 23 13 4 PIN NUMBER 9 4 8 3 7 5 A Z/ Z B/ B A/ RED/WHT YEL/WHT BLU/WHT BLK/WHT YEL BLU EARTH GROUND LOGIC COMMON 6 EARTH GROUND LOGIC COMMON BLK RED N/C N/C N/C N/C

Shown below is the wiring diagram for the AX4-ENC-XXX cable which is available from Control Techniques in 15, 25 and 50 foot lengths for connection to Control Techniques’ SCSLD encoders. Figure 22: AX4-ENC Encoder Cable Wiring Diagram Encoder Power Supply The AXIMA 2000/4000 controller can be used to provide the 5 Volt power source for external encoders. Connections are provided on each axis I/O connector. The current on the 5 Volts must be limited to 250 milliAmps per axis and the maximum current for 4 encoders must be limited to 1 Amp. Each 5 volt Encoder Supply has a PTC switch in line thus excessive currents will open the switch. The switch will close if it is allowed to cool down. Removing the load for a few seconds will reset the fuse. Analog Outputs The AXIMA 2000/4000 controller’s analog command output to the servo amplifier is a precision 16 bit output. These signals are susceptible to noise if not properly shielded. For reliable operation it is important that command cables be shielded and routed away from motor power or other high voltage signals. Shields should be connected at the AXIMA 2000/ 4000 controller end. The input stage of the amplifier should be a differential circuit. The output voltage is ±10 VDC, output current is 5 milliAmps maximum. AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 10 PIN "MS" CONNECTOR ENCODER 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD ENC SUP +5V ENC COM 0V Z/ Z B/ B A/ A PIN NUMBER 22 10 25 12 24 11 23 13 4 F D H B I C J A A Z/ Z B/ B A/ RED/WHT YEL/WHT BLU/WHT BLK/WHT YEL BLU BLK RED EARTH GROUND LOGIC COMMON C D E F J I G H B A ØV 5V

Figure 23: Analog Command Output Drive Enable (Enable Contact) Each axis has an Enable Relay Contact. The contact has a rating of 30 VDC and is capable of switching 0.5 Amps for a resistive load. All Enable relays are interlocked with the Watchdog relay as well as the Enable Drives input. Each relay is also individually controlled by the pre- defined Drive Enable output. Figure 24: Drive Enable (Enable Contact) Circuit Note It is recommended that the Enable Contact be used. If these contacts are not used, physically connecting a drive (E Series, MX, LX or other) to the controller while that drive is enabled may cause unwanted motion. In the event the Enable Contact is not used, the following power sequence must be followed: 1. Apply power to the AXIMA 2000/4000 controller 2. Apply power to the drives 3. Enable the drives 4. Normal machine operation 5. Disable or power down the drives 6. Power down the AXIMA 2000/4000 controller 8 20 ENABLE CONTACT 9 21

Drive Status and Overtravel Drive Status or Overtravel inputs do not perform any pre-defined action in the controller. They are available as pre-defined bits and may be used in the AXIMA Software’s PLC, Motion or Auxiliary Programs to perform desired logic. Figure 25: Drive Status and Overtravel Input Circuit Example Axis Connections If desired, the AXIMA 2000/4000 controller can be used to generate a torque or current command instead of a speed command. When the drives are used in torque mode, the drive velocity loop gain adjustments no longer need to be considered. This can simplify the tuning procedure for some applications. E Series Drives All command and I/O signals are accessed using the 44 pin command connector located on the front of the E Series drive. The wiring diagram below shows the typical command connections between the AXIMA 2000/4000 controller and an E Series drive using the AX4-CEN-XXX cable. 1.2K + 5 0 VDC I/O Supply AXIMA INPUT LED INPUT 2.21K COM 2.21K

Figure 26: AX4-CEN Cable Note See Figure 5 , E Series Drive and AXIMA System Grounding Diagram. MX Drives To operate an MX drive in torque mode, set the command selector bit bØ6 in the MX drive, to 1. Refer to the MX Drives Setup and Programming Operator’s Manual (P/N 400268-00) for detailed information on setting and saving this bit status. AXIMA 2000/4000 Controller to MX Drive Connections (Torque Mode) The wiring diagram below shows the typical command connections between the AXIMA 2000/4000 controller and an MX amplifier. 44 PIN "D" CONNECTOR E SERIES DRIVE PIN NUMBER 31 14 15 16 9 23 24 37 38 8 34 17 18 19 43 44 A ANALOG OUT 2 ANALOG OUT 1 OUTPUT #1 OUTPUT #2 OUTPUT #3 I/O SUPPLY + DRV ENABLE IN ANALOG CMD IN + ANALOG CMD IN - I/O COM - Z/ Z B/ B A/ AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - Z/ Z B/ B A/ A PIN NUMBER 8 20 9 21 3 16 25 12 24 11 23 13 15 7 19 4 N/C PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT EARTH GROUND LOGIC COMMON LOGIC COMMON 6 13 12 11 10 1 2 3 4 5 6 7 8 9 15 14 28 27 26 25 16 17 18 19 20 21 22 23 24 30 29 42 41 40 39 31 32 33 34 35 36 37 38 44 43 33 29 ANALOG COM N/C 2 14 I/O SUPPLY + N/C I/O SUPPLY + I/O COM - YEL/BRN BRN/YEL PULSE/ CMD OUT 17 5 GRN/PRP PRP/GRN DIRECTION CMD OUT 20 OPEN COLLECTOR PULSE/ PE 10 Ω 36 OPEN COLLECTOR DIRECTION N/C

Figure 27: AXIMA 2000/4000 Controller to MX Amplifier Connections Using The AX4-MX cable (Torque Mode) Note Make sure AXIMA Logic Common is connected to the same point in the cabinet as the MX Logic Common. See Figure 5 , E Series Drive and AXIMA System Grounding Diagram. LX Drives AXIMA 2000/4000 Controller to LX Drive Connections (Torque Mode) To operate an LX drive in torque mode, connect the AXIMA 2000/4000 controller command wires to the Current CMD and Common inputs on the LX drive (terminal pins 2 and 3) as shown in the wiring diagram below. AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 9 PIN "D" CONNECTOR 5 1 9 8 7 6 4 3 2 MX AMPLIFIER 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - PIN NUMBER 8 20 9 21 3 16 15 7 19 4 PIN NUMBER 9 10 14 2 3 4 5 6 1 13 4 5 15 17 16 N/C N/C N/C N/C A ANALOG OUT TACH OUT DR OK PROG INPUT (CW) PROG INPUT (CCW) +10V ENABLE CMD + CMD - Z/ Z B/ B A/ PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT EARTH GROUND LOGIC COMMON LOGIC COMMON 6 RESERVED "B" CONNECTOR STRIP 11 TO PANEL GROUND BLU/RED RED/BLU Z/ Z B/ B A/ A 25 12 24 11 23 13 ENC COM ØV 22 N/C N/C RESERVED

Figure 28: AXIMA 2000/4000 Controller to LX Amplifier Connections Using The AX4- GP Cable (Torque Mode) Note Make sure AXIMA Logic Common is connected to the same point in the cabinet as the LX Logic Common. See Figure 5 , E Series Drive and AXIMA System Grounding Diagram. The current command input of the LX amplifier is a single ended input not a differential input. Refer to the LX Drives Setup and Programming Operator’s Manual (P/N 400272-00) for more detailed information. LX AMPLIFIER AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - Z/ Z B/ B A/ A 8 20 9 21 3 16 25 12 24 11 23 13 15 7 19 N/C PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT LOGIC COMMON 6 ENC SUP +5V ENC COM ØV 10 BLU/RED RED/BLU SHIELD PIN NUMBER 4 EARTH GROUND LOGIC COMMON PULSE/ CMD OUT I/O SUPPLY + I/O COM - 17 14 2 5 N/C GRY/PRP PRP/GRY BRN/YEL YEL/BRN GRN/PRP PRP/GRN DIRECTION CMD OUT N/C 22 18 (STEPPER) LOW CURR MODE 4 5 10 37 40 39 42 41 38 9 2 3 Z/ Z B/ B A/ A +10V ENABLE CUR CMD COMMON DRIVE OK DRIVE OK 12 HIGH IRMS

If the CMD output of the AXIMA 2000/4000 controller is mistakenly connected to the common input of the LX drive, this could damage the AXIMA 2000/4000 controller analog output signal. Because the input is single ended, it will be more susceptible to noise. Be sure the LX common pin number 11 is connected to a single point ground as shown in the system grounding illustration. When the LX amplifier is used in current mode, the LX I2t (high RMS) circuitry is bypassed and does not fold back the current to the motor. To prevent damage to the amplifier or motor, the high RMS output of the LX must be connected to an AXIMA 2000/4000 controller input. This input would then be programmed to limit the AXIMA 2000/4000 controller command voltage using the command limit instruction to decrease or shut off the analog command. This input could also be used to turn off the drive enable output. When using the LX drive in current mode the LX limit switch inputs are inactive. AXIMA 2000/4000 Controller to LX Drive Connections (Velocity Mode) The wiring diagram below shows the typical command connections between the AXIMA 2000/4000 controller and an LX amplifier operating in velocity mode.

Figure 29: AXIMA 2000/4000 Controller to LX Amplifier Connections using the AX4- GP Cable (Velocity Mode) Note Make sure AXIMA Logic Common is connected to the same point in the cabinet as the LX Logic Common. See Figure 5 , E Series Drive and AXIMA System Grounding Diagram. Encoder 1 or 3 Output Connection An encoder output port is provided to allow easy cable connections between multiple AXIMA 2000/4000 controllers for line shafting type applications using the AX4-ED-XXX cable. LX AMPLIFIER AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - Z/ Z B/ B A/ A 8 20 9 21 3 16 25 12 24 11 23 13 15 7 19 N/C PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT LOGIC COMMON 6 ENC SUP +5V ENC COM ØV 10 BLU/RED RED/BLU SHIELD PIN NUMBER 4 EARTH GROUND LOGIC COMMON PULSE/ CMD OUT I/O SUPPLY + I/O COM - 17 14 2 5 N/C GRY/PRP PRP/GRY BRN/YEL YEL/BRN GRN/PRP PRP/GRN DIRECTION CMD OUT N/C 18 (STEPPER) LOW CURR MODE 4 5 43 45 10 37 40 39 42 41 38 9 7 8 Z/ Z B/ B A/ A +10V ENABLE SPEED CMD + SPEED CMD - DRIVE OK DRIVE OK CW LIMIT CCW LIMIT 22

Figure 30: Internal Encoder Connections for AXIMA 2000/4000 Controller Figure 31: Front Panels of AXIMA 2000/4000 Controllers AXIS 1 (for 4000) OR ENCODER 3 (for 2000) ENCODER 1 OUTPUT (for 4000) OR ENCODER 3 OUTPUT (for 2000) 13 25 12 24 11 23 25 PIN "D" CONNECTOR PIN NUMBER 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 A A/ B B/ Z Z/ 5 1 9 8 7 6 4 3 2 9 PIN "D" CONNECTOR PIN NUMBER A A/ B B/ Z Z/ 5 9 4 8 3 7 AXIMA INTERNAL CONNECTIONS ENCODER 1 OUTPUT TO AXIS 1 CONNECTION ENCODER 3 OUTPUT TO ENCODER 3 CONNECTION AXIMA 2000 AXIMA 4000 AXIS 1 ENCODER 3 ENCODER 1 OUTPUT ENCODER 3 OUTPUT

Input/Output Connections Dedicated I/O Figure 32: Enable Drives and Watchdog Output Locations on the Front Panel of the AXIMA 2000/4000 Controller Enable Drives Input The Enable Drives input provides the +24 VDC supply to one side of all the drive enable relays. The + Enable Drives input is connected to the +24 V terminal. Watchdog Output This relay contact is closed and the LED is ON under normal conditions. The contact is rated for +30 VDC and .5 Amps maximum.

Figure 33: Watchdog, Drive Enable Circuit Customer Contact or PLC Output 24 V LED - - + Enable Drives Enable Drives LED + 5 V + 5 V EN + 24 Common Watchdog Output WD WD Watchdog Output Relay Pre-defined AXIMA Output (See Software Manual) Controller Watchdog Output Typical Drive Enable CKT 2 for AXIMA 2000 4 for AXIMA 4000 Drive Enable Relay Enable Contacts on Axis Connector + 24 V FUSE F103 (Located Under the Access Panel) Littlefuse 451002 EMERSON P/N 212132-02 2 A WD Diagnostic Status LED Decimal Point + 24 VDC 0 VDC I/O Supply + Watchdog LED Enable Drive LED 24 V SUPPLY Pin 2 Pin 14 Predefined AXIMA Input

User Defined I/O Inputs Figure 34: Inputs Location on the Front Panel of the AXIMA 2000/4000 Controller The inputs can be wired for either sink or source mode in groups of eight. The inputs are rated at 24VDC and the input voltage operating limit is +10 to 30 VDC. Each input line requires a minimum of 5 milliAmps at 10 VDC to be recognized as a valid input. Figure 35: Sinking Mode Input Diagram 2K 1.33K 2K 1.33K 2K 1.33K 2K 1.33K + 5 V + 5 V + 5 V + 5 V 0 VDC I/O SUPPLY + 24 VDC

Figure 36: Sourcing Mode Input Diagram Special Purpose Inputs Inputs 13 through 16 can be assigned to trigger the high speed hardware encoder position capture function. These inputs and the Z encoder channels have direct connection to the encoder DSP gate arrays. If your application requires accurate positioning or measurements based on inputs from sensors or switches, inputs 13 through 16 should be used. See position capture input table below. See the Encoder Capture Instruction Registration Move in the AXIMA Software Reference Manual (P/N 400262-00) for more information. Since these inputs go through filtering and optoisolation, there is up to10 microsecond delay from the time the input is turned on until the position is captured. The capture can be programmed to trigger on rising or falling edge of the input. Due to the switching characteristics of the opto-isolators, faster triggering speeds can be obtained by using the rising edge rather than the falling edge. The encoder Z channel time delay is significantly less at 0.1 microsecond. Encoder Input Number Position Capture Input # 1 13 or 14 2 13 or 14 3 15 or 16 4 15 or 16 2K 1.33K 2K 1.33K 2K 1.33K 2K 1.33K + 5 V + 5 V + 5 V + 5 V 0 VDC I/O SUPPLY + 24 VDC

Outputs Figure 37: Outputs Location on the Front Panel of the AXIMA 2000/4000 Controller Outputs can be operated in source mode only. Maximum allowable output voltage is 18 to 30 VDC, maximum current is 150 milliAmps per output continuously. Note It is your responsibility to limit the current to 150 milliAmps or less. Figure 38: Output Circuit Diagram + 5 V + 24 1 - 12 0 VDC I/O SUPPLY TO ALL OUTPUT CIRCUITS CONTROLLER OUTPUT SIGNAL OUTPUT LED DIODE REQUIRED FOR ALL INDUCTIVE LOADS AXIMA MACHINE

I/O Power Supply The AXIMA requires a customer supplied I/O power supply, usually +24 VDC. This power supply must be connected to the 24V ± terminals. The +24 VDC are protected against reverse polarity. If the polarity is reversed the +24 VDC fuse blows. The fuse is located under the front access panel. This supply is the "machine side" of the inputs and outputs and also provides power for the Enable Drive relay coils. The system is designed to operate from a 24 VDC power supply but will function between 18 and 30 VDC. Figure 39: I/O Power Supply Location on the Front Panel of the AXIMA 2000/4000 Controller Note For situations where all 16 inputs, 12 outputs at full load and 4 relays are being used simultaneously, your power supply must supply at least 2.5 Amps @ 24 Volts. Each input requires 12 mA @ 24 VDC (5 mA @ 10 VDC). Each output can source up to 150 mA to drive a load. Your power supply must be capable of supplying enough current for the dedicated load requirements. (Enable Drive, Drive Status, Overtravel L.S.) as well as the input and output load requirements. Each Input: (# of inputs) * (12 mA) Each Output: (# of outputs) * (Load Current) Dedicated Circuits: Inputs: CW Limits SW 5 mA

CCW Limit SW 5 mA Status 5 mA Output: Enable Drives 8 mA For example, suppose you had four axes of dedicated I/O, four inputs (# 1 through 4), and four outputs (# 1 through 4) with a 150 mA load, and your power supply was 24 VDC, in the worst case scenario (all inputs and outputs are being used simultaneously) the current load on the power supply would be 0.74 Amps. This value was found using the following formula: (12 mA * 4 IN) + (150 mA * 4 OT) + (8 mA * 4 R) + 4 axis (5 mA * 3 D) = 0.74 Amps Where: IN = inputs OT = outputs R = relays for Enable Drives D = dedicated inputs Diagnostics Status Display The Diagnostic Status display on the top front of the AXIMA 2000/4000 controller is controlled by the programmer and can be used to display machine status or fault codes. During the download of an AXIMA Software Application an asterisk (*) is displayed. The decimal point is lit when the controller Watchdog is “On”. Note The very first time power is applied to the AXIMA controller the diagnostic status will display a random character.

An Analog Input feature is available as a factory option only. It allows the AXIMA® 2000/ 4000 controller to accept single-ended and differential inputs with 12 bit resolution. You can configure these inputs with up to eight single-ended inputs, four differential inputs or combinations of single and differential inputs. Note If you wish to add the Analog Input option to an existing AXIMA 2000/4000 controller, it must be returned to the factory. The source of each analog input can be selected to be either from the analog input connector on the left side of the unit or the axis connector on the front of the unit. This is done by setting a DIP switch located behind the left side panel, of the AXIMA 2000/4000 controller. This selection is provided to allow easy interface to the analog signals from an E Series drive. Figure 40: Analog DIP Switch Location Behind the Left-Side Panel of the AXIMA 2000/4000 Controller Quantity 8 Resolution 12 bits Configuration Single-ended or differential Input Voltage Range ±10 VDC AXIS INPUTS (Up Position) EXTERNAL INPUTS NOTE: DIP SWITCHES ARE MOUNTED BEHIND THE LEFT PANEL OF THE AXIMA CONTROLLER 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 S3 S4 AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

The AXIMA 2000/4000 controller takes raw voltage (±10 Volts) from the analog input terminal and, with the AXIMA Software, converts it to user units. Each analog input channel can be assigned to a Pre-defined Variable, within the AXIMA Software, which can be used in a Motion or an Auxiliary Program. Figure 41: AXIMA and Cable Dimensions and Clearances Switch Analog Input S3-1 Analog Input 1 S3-2 Analog Input 2 S3-3 Analog Input 3 S3-4 Analog Input 4 S4-1 Analog Input 5 S4-2 Analog Input 6 S4-3 Analog Input 7 S4-4 Analog Input 8 0.20 (5.08) typ. 4 places 11.70 (297.18) 11.19 (284.23) 3.68 (98.30) 5.5 (139.70) 0.9 (22.86) 3.0 (76.20) 7.1 (183.00) 0.25 (6.35) Dimensions in ( ) are in millimeters. 3.0 (76.20) 1.25 (31.75)

Axis Inputs Connector Wiring Using the AXIMA Software, any software channel can be attached to any hardware channel or pair of hardware channels. This gives you the flexibility to determine how the channel attachments are configured. Figure 42: Location of Analog Inputs The following diagrams show single-ended and differential configurations. Single-ended wiring configurations are with respect to the common “C” terminal. For example, voltages between input terminals 1 and C, input terminals 2 and C, etc. Differential wiring means that the resultant analog value is the difference in voltage measured between a pair of input terminals. For example, voltage between input terminals 1 and 2, 3 and 4. Note All signals, single-ended or differential, must be referenced to Pin “C”. The maximum voltage between any input terminal and "C" is ±10 VDC. Voltage in excess of this maximum could cause damage to the controller. 3 ANALOG INPUTS 1 2 4 5 6 7 8 C 1 2 3 4 5 6 7 8 C ANALOG INPUTS AXIMA Left Side Pin #6 Analog Common Pin #7 Analog Input #1 Pin #19 Analog Input #2 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 AXIMA Front Axis Connection

Figure 43: Single Ended Versus Differential Wiring Figure 44: Analog Input Circuit Diagram When using a differential configuration, the AXIMA 2000/4000 A/D converter measures the difference between two hardware channels and directs the value to a software channel. The AXIMA 2000/4000 controller does not allow you to assign terminal number 1 as the negative input. To measure differential values between terminal 1 and another terminal, the polarity must be reversed by connecting the positive input to terminal 1, and connecting the negative input to the desired terminal.

Two options are available for wiring the expanded I/O; by using direct wiring or external components. The direct wiring option is exactly that. All connections are directly wired from the AXIMA® 2000/4000 controller. The external components option uses the XIOR-32 mounting rack and digital input and output modules to control the I/O connections. Sinking Versus Sourcing A sourcing input configuration allows the current to flow from the external source to the input terminal. The input terminal voltage is high. In a sinking input configuration the current flows from the input terminal to the external circuit. The input terminal voltage is low. A sinking output configuration allows the current to flow from the external circuit into the output terminal. The output terminal voltage is low. In a sourcing output configuration the current can flow from the terminal to the external circuit. The output terminal voltage is high. Figure 45: Sinking Inputs and Outputs OPTICAL ISOLATION INPUT TERMINAL 24V COMMON +24 VDC 1.5K OPTICAL ISOLATION OUTPUT TERMINAL 24V COMMON +24 VDC +24 VDC LOAD NOTE: DIODE REQUIRED FOR ALL INDUCTIVE LOADS AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

Figure 46: Sourcing Inputs and Outputs Figure 47: AXIMA and Cable Dimensions and Clearances OPTICAL ISOLATION INPUT TERMINAL 24V COMMON +24 VDC 1.5K OPTICAL ISOLATION OUTPUT TERMINAL 24V COMMON +24 VDC LOAD 24V COMMON NOTE: DIODE REQUIRED FOR ALL INDUCTIVE LOADS. 0.20 (5.08) typ. 4 places 11.70 (297.18) 11.19 (284.23) 3.68 (98.30) 5.5 (139.70) 0.9 (22.86) 3.0 (76.20) 7.1 (183.00) 0.25 (6.35) Dimensions in ( ) are in millimeters. 3.0 (76.20) 1.25 (31.75)

Direct Wiring Option These components must be assembled and wired by the user. Components include STI-32s or STI-50s and connectorized ribbon cables, all of which are available from Control Techniques. Figure 48: AXIMA 2000/4000 Controller Direct Wiring Option Using STI-32’s Figure 49: AXIMA 2000/4000 Controller Direct Wiring Option Using STI-50’s INPUTS BANK 0 OUTPUTS BANK 0 INPUTS STI-32 AXIMA 2000/4000 CONTROLLER OUTPUTS STI-32 CABLE AX4-XIOC-XXX CABLE AX4-XIOC-XXX ± 24 VDC INPUTS STI-50 AXIMA 2000/4000 CONTROLLER OUTPUTS STI-50 INPUTS BANK 0 OUTPUTS BANK 0 CABLE AX4-XIOC-XXX CABLE AX4-XIOC-XXX ± 24 VDC

Components of the Direct Wiring Option Quantities of the components required for the direct wiring option depend on the number of I/O used. For example: For the full use of 32 expanded inputs and 32 expanded outputs, the required quantities are: (1) AXIMA 2000/4000 controller with X-IO option (2) STI-32 or STI-50 for digital I/O (2) Connectorized ribbon cables (50 pin) (P/N AX4-XIOC-XXX) Dimensions of STI-50 and STI-32 Components Figure 50: STI-50 and STI-32 Components (DIN Rail Mountable) I/O Setup and Wiring Using the direct wiring option, the inputs and outputs can be wired directly to the STI-32 (sourcing only) or STI-50 (sinking or sourcing) using ribbon cables. Sourcing mode is recommended for the direct wiring option. To use the direct wiring option, you must meet the following criteria: For Inputs: Electrical specifications of 24 VDC and a minimum of 11 mA of current. Expanded I/O Current Draws Minimum Maximum Input Value 18 VDC 27 VDC Current Draw 5.5 mA 7.5 mA STI-50 STI-32 5.28 (134.11) 3.00 (76.2) 7.423 (188.54) 3.53 (89.76) Dimensions in () are millimeters

For Outputs: Electrical specifications of +24 VDC X-I/O Supply and less than 50 mA of current. All 32 outputs can supply 50 mA continuously or 12 outputs supply 125 mA continuously if distributed across the four output drives as follows: Specifications for Direct Wiring Option The equivalent circuits of the I/O, electrical specifications and the pin assignments are shown on the next page. You are responsible for determining if your 24 VDC supply can handle the additional current load. up to 3 outputs between #1 through #8 up to 3 outputs between #9 through #16 up to 3 outputs between #17 through #24 up to 3 outputs between #25 through #32

Figure 51: Outputs and Inputs Equivalent Circuit (Sourcing) INPUT TERMINAL AXIMA 2000/4000 1.5K +24 VDC RIBBON CABLE STI-32 AXIMA 2000/4000 +24 VDC 0 VDC X-I/O Supply OUTPUT TERMINAL RIBBON CABLE STI-32 OPTICAL ISOLATION OPTICAL ISOLATION LED LED 0 VDC X-I/O Supply 0 VDC X-I/O Supply 0 VDC X-I/O Supply 0 VDC X-I/O Supply AX4-XIOC-XXX AX4-XIOC-XXX

Use the table below to determine the pin assignments of the STI-50 inputs and outputs. Inputs Pin Assignments Outputs Pin Assignments Input Number Pin Number Output Number Pin Number 0 37 0 37 1 39 1 39 2 38 2 38 3 40 3 40 4 35 4 35 5 42 5 42 6 36 6 36 7 41 7 41 8 47 8 47 9 50 9 50 10 44 10 44 11 48 11 48 12 49 12 49 13 43 13 43 14 46 14 46 15 45 15 45 16 14 16 14 17 12 17 12 18 13 18 13 19 11 19 11 20 16 20 16 21 9 21 9 22 15 22 15 23 10 23 10 24 4 24 4 25 1 25 1 26 7 26 7 27 3 27 3 28 2 28 2 29 8 29 8 30 5 30 5 31 6 31 6 24V Common 17, 19, 21, 22, 23, 25, 26, 28, 30, 31, 32, 34 24V Common 17, 19, 21, 22, 23, 25, 26, 28, 30, 31, 32, 34

External Components Option Note When using the External Components option, the AXIMA must be equipped with the sinking option for the expanded I/O. If your I/O devices do not meet the criteria established for the direct wiring option, then external components are required. These components must be assembled and wired by the user. External components include; I/O mounting rack(s), digital input modules, digital output modules and connectorized ribbon cables, all of which are available from Control Techniques. With the external components option your electrical specifications are determined by the module you select. These modules allow you to wire the I/O for sinking or sourcing. Some time delay is inherent in these devices that should be accounted for in time critical applications. Figure 52: AXIMA 2000/4000 Controller External Components Option DIGITAL INPUTS DIGITAL OUTPUTS AXIMA 2000/4000 CONTROLLER XIOR-32 WITH IDC-24-G4's XIOR-32 WITH ODC-24-G4's INPUTS BANK 0 OUTPUTS BANK 0 ± 24 VDC CABLE AX4-XIOC-XXX CABLE AX4-XIOC-XXX

Components of the External Components Option Quantities of the external components required depend on the number of expanded I/O used. For example: For the full use of 32 expanded inputs and 32 expanded outputs, the required quantities are: (1) AXIMA 2000/4000 controller with X-I/O option (2) XIOR-32 I/O mounting racks (32) Digital input modules (P/N IDC-24-G4 or IAC-24-G4) (32) Digital output modules (P/N ODC-24-G4 or OAC-24-G4) (2) Connectorized ribbon cables (50 pin) (P/N AX4-XIOC-XXX) Dimensions of the XIOR-32 Component Figure 53: XIOR-32 Component I/O Setup and Wiring You need to supply +24 VDC to the XIOR-32 for the digital I/O modules. 10.00 [254.0] 9.500 [241.30] 0.25 [6.4] 6.00 [152.4] 6.50 [165.1] 2.32 [58.9] .62 [15.7]

Specifications for Digital Modules From these specifications you can choose the type of module needed for your particular application. Additional Digital I/O modules are also available from Opto-22 Corporation in a variety of specifications. 24 VDC Power Supply Loading You are responsible for determining if your +24 VDC supply can handle the additional current load. When using +24 VDC modules: Inputs (on): 64 mA per input. Outputs (on): (Load current + 21 mA) per output.* Outputs (off): 3 mA per output. When using 120 VAC modules: Inputs (on): 39 mA per input. Digital Input and Output Module Specifications IDC-24-G4 IAC-24-G4 Digital DC input module Digital AC input module Input voltage range 10-32 VDC 90-140 VAC Input voltage nominal 24 VDC 120 VAC Input current @ nominal 16 mA 9 mA rms Logic voltage nominal 24 VDC 24 VDC Logic current @ 24 VDC 18 mA 18 mA Turn on time 5 msec 20 msec Turn off time 5 msec 20 msec ODC-24-G4 OAC-24-G4 Digital DC output module Digital AC output module Output voltage range 5-60 VDC 12-140 VAC Output voltage maximum 60 VDC 120 VAC Output current @ max voltage 3 Amps 3 Amps RMS Off state leakage @ max voltage 1 mA 5 mA RMS Logic voltage nominal 24 VDC 24 VDC Logic current @ 24 VDC 18 mA 18 mA Logic pickup voltage 19.5 VDC 19.5 VDC Logic dropout voltage 1 VDC 1 VDC Turn on time 50 usec 8.3 msec Turn off time 50 usec 8.3 msec

Outputs (on): 21 mA per output. Outputs (off): 2.4 mA per output. *The load current for the output modules must be limited to no more than 3 Amps. Figure 54: Power Wiring for External I/O Mounting Racks Control Techniques recommends that you use twisted pairs for the +24 VDC power wiring. Connection Diagrams for Mounting Rack Input Connections Figure 55: +24 VDC Digital Input Module Connection Diagram For Sinking Inputs Switch on the +24 VDC common as shown in the diagram above and wire +24 VDC to the other terminal. SINGLE POINT GROUND INPUT MOUNTING RACK OUTPUT MOUNTING RACK POWER SUPPLY AXIMA + 24 VDC X-I/O SUPPLY 0 VDC X-I/O SUPPLY GND + -

For Sourcing Inputs Switch +24 VDC as shown in the diagram above, and wire +24 VDC common to the other terminal. When wiring inputs, you can wire the switch to either the Odd or Even Terminal. Figure 56: 120 VAC Digital Input Module Connection Diagram For Sinking Inputs Switch on the neutral as shown in the diagram above and wire 120 VAC to the other terminal. For Sourcing Inputs Switch 120 VAC as shown in the diagram above, and wire neutral to the other terminal. When wiring inputs, you can wire the switch to either the Odd or Even Terminal.

Output Connections Figure 57: 24 VDC Digital Output Module Connection Diagram For Sinking Outputs Wire the load to the Odd # Terminal on the mounting rack. Tie the other side of the load to +24 VDC. The 24 volt common should be wired to the Even # Terminal. For Sourcing Outputs Wire 24 VDC to the Odd # Terminal on the mounting rack. Wire the load to the Even # Terminal. Tie the other side of the load to +24 volt common. If your load is inductive, it is recommended to use a commutating diode across the load to clamp any voltage transients during switching. Figure 58: 120 VAC Digital Output Module Connection Diagram

For Sinking Outputs Wire the load to the Odd # Terminal on the mounting rack. Tie the other side of the load to 120 VAC. Neutral should be wired to the Even # Terminal. For Sourcing Outputs Wire 120 VAC to the Odd # Terminal on the mounting rack. Wire the load to the Even # Terminal. Tie the other side of the load to Neutral.

4000 controller to communicate with the Modicon Modbus serial communication protocol or Allen Bradley’s Data Highway Plus. Note AXIMA 2000/4000 controllers can be equipped with either Modbus or DH+. They cannot be used simultaneously. AXIMA 2000/4000 controllers equipped with the Modbus option have two serial connectors on the left-side of the front panel. The 9-pin DB connector is a RS-232C and RS-485 connector. The six-pin connector is used for multi-drop systems and is configured for RS- 485. AXIMA 2000/4000 controllers equipped with the DH+ option are equipped with one serial connector on the left-side of the AXIMA 2000/4000 controller. The six-pin connector is configured for DH+ is RS-485. AXIMA® 2000/4000 Multi-Axis Controller Installation Manual

Figure 59: Left-side of AXIMA 2000/4000 Controller The previous figure shows the Modbus configuration with the connectors. When equipped with the DH+ option, only the six-pin connector would be available. PIN 1 PIN 1 RS-232C CONNECTOR RS-485 CONNECTOR COM 3 COM 4 MODBUS RS-232/485 MODBUS MULTIDROP 1 2 3 4 5 6 RS-485

0.20 (5.08) typ. 4 places 11.70 (297.18) 11.19 (284.23) 3.68 (98.30) 5.5 (139.70) 0.9 (22.86) 3.0 (76.20) 7.1 (183.00) 0.25 (6.35) Dimensions in ( ) are in millimeters. 3.0 (76.20) 1.25 (31.75)

Modbus Connection The RS-232C/485 serial port (9-pin DB connector) pin-out is shown below. The RS-485 serial port (6-pin connector) pin-out is shown below. Pin 1 is internally connected to 4, pin 2 is connected to pin 5, and pin 3 is connected to pin 6. These are also connected to the 9-pin connector’s 485 terminals. Pin Signal 1 Shield 2 RX (Receive) 3 TX (Transmit) 4 485 Data (+) 5 Signal Ground 6 NC (No Connect) 7 RTS (Request to Send) 8 CTS (Clear to Send) 9 485 Data (-) Pin Signal 1 485 Data (+) 2 Signal Ground 3 485 Data (-) 4 485 Data (+) 5 Signal Ground 6 485 Data (-) RS-232/485 MODBUS DATA HIGHWAY PLUS 2 SH 1 2 SH 1

The DH+ network connections are available using the six-pin Phoenix connector (Com 4). The connector pin-out is shown below. Note The nodes at the two physical ends of the network should have terminating resistors. All other nodes should not. Every network should have exactly two terminators. The AXIMA controller does not have an internal terminator. If you require a terminator, it consists of a resistor between the blue and clear wires. The Data Highway Plus specifications recommend a 150 ohm resistor at 57.6 and 115.2 kbaud and an 82 ohm resistor at 230.4 kbaud. Note If your DH+ network does not use blue on pin 1 and clear on pin 2, connect the clear on pin 1 and blue on pin 2. Pin Signal "Blue Hose" wires 1 Line 1 (485 Data +) Blue SH Shield (bare) 2 Line 2 (485 Data -) Clear MODBUS MULTIDROP 1 2 3 4 5 6 RS-485

of Ø to 4 MHz, with a varying pulse width based on frequency (< 6kHz = 167 µs, > 6kHz = 50% duty cycle). No pull-up resistor is internal to the AXIMA 2000/4000 controller. For reliable operation it is important that command cables be shielded and routed away from motor power or other high voltage signals. Shields should be connected at the AXIMA 2000/ 4000 controller end. Figure 61: Stepper Command Output Connected to Differential Amplifier PULSES OUT AMPLIFIER 17 5 DIR IN THIS OUTPUT DRIVER IS A SN7406 22 POWER SUPPLY +5 VDC 5-30 VDC MAX SINK CURRENT MAX OUTPUT VOLTAGE RATING OUTPUT VOLTAGE (LOW) OUTPUT LEAKAGE 40 mA 30 V @16 mA = .4 V @40 mA = .7V 40 µA 10 MAXIMUM SINK CURRENT OF 40mA PULSE INPUT - PULSE INPUT + DIR INPUT + DIR INPUT - + AXIMA® 2000/4000 Multi-axis Controller Installation Manual

Figure 62: Stepper Command Output Connected to a Single Ended Amplifier PULSES OUT AMPLIFIER RESISTOR SIZE IS BASED ON CABLE CAPACITANCE (1K Ohm recommended) 17 10 5 DIR OUT THIS OUTPUT DRIVER IS A SN7406 22 POWER SUPPLY +5 VDC 5-30 VDC IMPORTANT: DO NOT TWIST THESE WIRES TOGETHER MAX SINK CURRENT MAX OUTPUT VOLTAGE RATING OUTPUT VOLTAGE (LOW) OUTPUT LEAKAGE 40 mA 30 V @16 mA = .4 V @40 mA = .7V 40 µA 120 Ohm +

AXIMA® 2000/4000 Multi-axis Controller Installation Manual

AXIMA 2000 will only use the first two coordinate systems and the AXIMA 4000 will only use the first four coordinate systems. Feature AXIMA 2000 AXIMA 4000 Maximum Axis 2 4 Maximum Coordinate Systems 8 * 8 * Maximum Motion Programs 8 8 Maximum Auxiliary Programs (minus the number of Motion Programs) 15 15 Maximum PLC Programs 8 8 Analog Inputs Eight analog inputs, ±10V, 12 bit, single ended or 4 differential mode Yes Yes Encoder Inputs Each Axis plus 2 Each Axis Standard Inputs 16 16 Pre-defined Outputs 7 13 Standard Outputs 12 12 Pre-defined Inputs Axis enable - (1) per axis, dry contact (1) Watchdog timer, dry contact Expanded I/O Banks (Optional) (32 Inputs/32 Outputs) 2 2 Data Highway Plus® (Optional) Yes Yes Modbus® (Optional) Yes Yes Stepper Axis (Optional) 2 4 Power Requirements 96 to 264 VAC, 50/60 Hz single phase, 2 Amps max. DSP Speed 50 MHz 50 MHz Communications (1) 9-pin, D-sub, RS-232C serial port. (1) RS-232C/422/485 terminal block 38.4k max baud rate Yes Yes Yes Yes Yes Yes Memory 128K, 128k Flash 128K, 128k Flash Noise Immunity Designed to meet IEC801.2 standard Environmental Operating Temperature Relative Humidity 32° to 133° F (0 to 40° ambient) 0 to 90%, non-condensing Weight 5 lbs 5 lbs

Heat Dissipation Note It using double expanded I/O and DH+ the total maximum encoder supply must not exceed 800mA. Dimensions and Clearances Base Unit 27W 1 X-I/O 16 2 X-I/O 32 Modbus 1 DH+ 2 0.20 (5.08) typ. 4 places 11.70 (297.18) 11.19 (284.23) 3.68 (98.30) 5.5 (139.70) 0.9 (22.86) 3.0 (76.20) 7.1 (183.00) 0.25 (6.35) Dimensions in ( ) are in millimeters. 3.0 (76.20) 1.25 (31.75)

PIN NUMBER 31 14 15 16 9 23 24 37 38 8 34 17 18 19 43 44 A ANALOG OUT 2 ANALOG OUT 1 OUTPUT #1 OUTPUT #2 OUTPUT #3 I/O SUPPLY + DRV ENABLE IN ANALOG CMD IN + ANALOG CMD IN - I/O COM - Z/ Z B/ B A/ AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - Z/ Z B/ B A/ A PIN NUMBER 8 20 9 21 3 16 25 12 24 11 23 13 15 7 19 4 N/C PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT EARTH GROUND LOGIC COMMON LOGIC COMMON 6 13 12 11 10 1 2 3 4 5 6 7 8 9 15 14 28 27 26 25 16 17 18 19 20 21 22 23 24 30 29 42 41 40 39 31 32 33 34 35 36 37 38 44 43 33 29 ANALOG COM N/C 2 14 I/O SUPPLY + N/C I/O SUPPLY + I/O COM - YEL/BRN BRN/YEL PULSE/ CMD OUT 17 5 GRN/PRP PRP/GRN DIRECTION CMD OUT 20 OPEN COLLECTOR PULSE/ PE 10 Ω 36 OPEN COLLECTOR DIRECTION N/C

AX4-ED AXIS 1 (FOR 4000) ENCODER 3 (FOR 2000) 25 PIN "D" CONNECTOR 9 PIN "D" CONNECTOR 5 1 9 8 7 6 4 3 2 ENCODER 1 OUTPUT (FOR 4000) ENCODER 3 OUTPUT (FOR 2000) 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD Z/ Z B/ B A/ A PIN NUMBER 25 12 24 11 23 13 4 PIN NUMBER 9 4 8 3 7 5 A Z/ Z B/ B A/ RED/WHT YEL/WHT BLU/WHT BLK/WHT YEL BLU EARTH GROUND LOGIC COMMON 6 EARTH GROUND LOGIC COMMON BLK RED N/C N/C N/C N/C

ENC COM 0V Z/ Z B/ B A/ A PIN NUMBER 22 10 25 12 24 11 23 13 4 F D H B I C J A A Z/ Z B/ B A/ RED/WHT YEL/WHT BLU/WHT BLK/WHT YEL BLU BLK RED EARTH GROUND LOGIC COMMON C D E F J I G H B A ØV 5V

AX4-GP LX AMPLIFIER AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - Z/ Z B/ B A/ A 8 20 9 21 3 16 25 12 24 11 23 13 15 7 19 N/C PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT LOGIC COMMON 6 ENC SUP +5V ENC COM ØV 10 BLU/RED RED/BLU SHIELD PIN NUMBER 4 EARTH GROUND LOGIC COMMON PULSE/ CMD OUT I/O SUPPLY + I/O COM - 17 14 2 5 N/C GRY/PRP PRP/GRY BRN/YEL YEL/BRN GRN/PRP PRP/GRN DIRECTION CMD OUT N/C 18 (STEPPER) LOW CURR MODE 4 5 43 45 10 37 40 39 42 41 38 9 7 8 Z/ Z B/ B A/ A +10V ENABLE SPEED CMD + SPEED CMD - DRIVE OK DRIVE OK CW LIMIT CCW LIMIT 22

85 Specifications TIX-XXX TIA-XXX 25 PIN "D" CONNECTOR FEMALE PIN NUMBER PIN NUMBER SHLD GND Rx Tx 9 PIN "D" CONNECTOR MALE 5 1 9 8 7 6 4 3 2 13 25 24 23 12 11 10 22 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 2 3 7 2 3 5 1 GND Tx Rx COM 1 COMPUTER 9 PIN "D" CONNECTOR FEMALE PIN NUMBER PIN NUMBER SHLD GND Rx Tx 9 PIN "D" CONNECTOR MALE 5 1 9 8 7 6 4 3 2 3 2 5 2 3 5 1 GND Tx Rx 5 1 9 8 7 6 4 3 2 COM 1 COMPUTER

AX4-MX AXIMA 2000/4000 CONTROLLER 25 PIN "D" CONNECTOR 9 PIN "D" CONNECTOR 5 1 9 8 7 6 4 3 2 MX AMPLIFIER 13 25 24 23 12 11 1022 21 20 19 18 17 16 15 14 1 2 3 4 5 6 7 8 9 SHIELD ANALOG COM ANALOG IN 2 ANALOG IN 1 DRIVE STATUS CW LIMIT CCW LIMIT DRV ENABLE ANALOG CMD OUT + ANALOG CMD OUT - PIN NUMBER 8 20 9 21 3 16 15 7 19 4 PIN NUMBER 9 10 14 2 3 4 5 6 1 13 4 5 15 17 16 N/C N/C N/C N/C A ANALOG OUT TACH OUT DR OK PROG INPUT (CW) PROG INPUT (CCW) +10V ENABLE CMD + CMD - Z/ Z B/ B A/ PRP/BLU BLU/PRP PRP/ORG ORG/PRP PRP/BRN BRN/PRP WHT/BLU BLU/WHT BLK/GRN GRN/BLK BRN/BLK BLK/BRN YEL/GRY GRY/YEL WHT/GRN GRN/WHT WHT/RED RED/WHT EARTH GROUND LOGIC COMMON LOGIC COMMON 6 RESERVED "B" CONNECTOR STRIP 11 TO PANEL GROUND BLU/RED RED/BLU Z/ Z B/ B A/ A 25 12 24 11 23 13 ENC COM ØV 22 N/C N/C RESERVED

Baud Rate The number of binary bits transmitted per second on a serial communications link such as RS- 232. (1 character is usually 10 bits.) CRC Cyclical Redundancy Check. DIN Rail Deutsche Industrie Norm Rail EEPROM An EEPROM chip is an Electrically Erasable Programmable Read-Only Memory; that is, its contents can be both recorded and erased by electrical signals, but they do not go blank when power is removed. EMC Electromagnetic Compatibility EMI - Electro-Magnetic Interference EMI is noise which, when coupled into sensitive electronic circuits, may cause problems. Firmware The term firmware refers to software (i.e., computer programs) that are stored in some fixed form, such as read-only memory (ROM). AXIMA® 2000/4000 Multi-axis Controller Installation Manual

Hysteresis For a system with an analog input, the output tends to maintain it’s current value until the input level changes past the point that set the current output value. The difference in response of a system to an increasing input signal versus a decreasing input signal. I/O Input/Output. The reception and transmission of information between control devices. In modern control systems, I/O has two distinct forms: switches, relays, etc., which are in either an on or off state, or analog signals that are continuous in nature generally depicting values for speed, temperature, flow, etc. Inertia The property of an object to resist changes in rotary velocity unless acted upon by an outside force. Higher inertia objects require larger torque to accelerate and decelerate. Inertia is dependent upon the mass and shape of the object. Input Function A function (i.e., Stop, Preset) that may be attached to an input line. Input Line The actual electrical input, a screw terminal. Least Significant Bit The bit in a binary number that is the least important or having the least weight. LED Light Emitting Diode. mA Milliamp. MB Mega-byte. Most Significant Bit The bit in a binary number that is the most important or that has the most weight. ms Millisecond.