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Controller Reference ManualMultiCam Systemsv1.05 March 5, 2014Table of ContentsControllers.6DCN Mapping.7list dcn Cross Reference.21Port 10 - Outputs.21Port 11 - Outputs.22Port 20 - Inputs.22Port 21 - Inputs.23Port 101 - Outputs.24Port 103 – Estop Contactor.25Port 104 - Outputs.25Port 106 - Outputs.26Port 107 – Drive Enables.27Port 109 – Inputs / Pause Mask.27Port 110 - Inputs.28Port 111 - Inputs.29Port 114 - Inputs.29Port 116.30Port 117.30Port 119 – Drive Faults.31Port 120 – 24v web.32Port 121 - Outputs.32Port 122 - Outputs.33Port 124 - Outputs.33Port 125 - Outputs.33Port 130 – RPI Outputs.34Port 141 – RPI Inputs (plasma unit outputs).34Controller Reference ManualPage 1

Port 142 – RPI Inputs (plasma unit outputs).35M2521 / M2621 / RPD-21 Controller.36Internal I/O Connector.36External I/O Connector.37User Interface Plug.39Tool Headers I/O.39Motor Drive Connectors.41M2545 & M3545 Controller.42HF1 Aux I/O (DB15 Female).42HF2 – PP Drives (DB25 Female).43HF3 – Primary I/O (DB37 Female).44HM1 – RS232 (DB9 Male).47HM2 – Aux Com (DB15 Male).47HM3 – SR Drives (DB25 Male).48M2545 & M3545 Notes.49HP4 & HP5 Controller.51L2 24 Pin CPC (internal Connector).51L1 37 Pin CPC (External Connector).52Drive 5-6 DB15 Connectors.55SB5 Controller.57L1 37 Pin CPC (External I/O Connector).57L2 24 Pin CPC (Internal I/O Connector).60L4 4 Pin CPC (Cycle Start and ESTOP Connector).63LPI (Integrated Plasma Interface).63Drive 5-6 DB15 Connectors.64RPD-24 Controller.66HMB1 (Modbus and Analog Input).66H1 (Spindle Analog Outputs).67H2 (Opto-22 Outputs).67H3 (Opto-22 Outputs).68H4 (Opto-22 Outputs).68H7 (Inputs).69H8 (Inputs).70H9 (Inputs).70H10 (Step / Direction Interface).71Controller Reference ManualPage 2

H11 (Step / Direction Interface).72HPRO (External Step / Direction Interface).73ATCB .74HIG1 Right angle connector.74HIG2 Vertical Connector.74PWR Power/Modbus.76HSOL Ribbon Connector.76RIO.78HOUT2 (Right Angle Connector).78HOUT3 (Vertical Connector).78H1 (Inputs).79H-Ang (Inputs and DAC Outputs).79QPI / DPI / SPI.80RPI.81LPI.83Modules.86AntiZ DustCollector.uc (INI ANTIZ meters.86DCN .86Menus.87atcb misctool.uc (INI ATCB s.88DCN .88Menus.88atcb multivision.uc (INI ATCB ters.89DCN .89Menus.90bevel cut.uc (INI BEVEL CUT).90Controller Reference ManualPage 3

Description.90Requirements.90Parameters.90DCN .92Menus.92Bevel Cut WJ.uc (INI BEVEL CUT WJ) *** WATER-JET 4DCN .96Conveyor.uc (INI s.96DCN .98Menus.99M2621 Drill.uc (INI M2621 100DCN .100Menus.100mh atcb tc.uc (INI MH ATCB TC).101Description.101Requirements.101Useful Commands.101Parameters.101DCN .102Menus.106mh rio linear tc.uc (INI MH RIO LINEAR 06DCN .107Menus.111Controller Reference ManualPage 4

TappingSpindle.uc (INI Useful Commands.112Parameters.112DCN .113Menus.113Teknic.uc (INI TEKNIC).114Description.114Requirements.114Useful Commands.114Data Files.114Parameters.114DCN .115Menus (under the Service menu).115Tool Number Assignments.115Standard File Locations.119Messages.121Error Messages.177Controller Reference ManualPage 5

ControllersThe processor board can be identified by looking at the serial number of the controller. This serial number is the number shown in the ( ) of theconnection.Processor BoardStarting Serial tsNotesM2521 Rev 1&2 M1LProcessor on motherboard.M2521 Rev 3&4 M3L (does not support KDM20g)M4L (KDM20g support)Processor on motherboard.M2521 Rev 5M5L (rev 5)Processor on motherboard.M2621M6LRPC-520 processor. Compatible replacement for M2521.RPD-21M3521RPC-353 processorThe silk screen on the board will indicate an RPD-21. The controller isan M3521. Compatible replacement for M2521 & M2621.M2545R1WRPC-520 processorM3545M3545RPC-353 processor. Compatible replacement for M2545.HP4H0LProcessor on motherboard.HP5M3564LRPC-353 processor. Compatible replacement for HP4.SB5M3564LRPC-353 processor.RPD-24R1W (RPC-520 processor)RPC-520 -or- RPC-353 processorThe silk screen on the board will indicate an RPD-24. The controller isan M2524 -or- M3524. Compatible replacement for M24.M3521 (RPC-353 processor)RPD-23Controller Reference ManualRPC353 processor. Compatible replacement for M23Page 6

DCN MappingDCNDescriptionKnife OnlyPlasma OnlyLaser OnlyWaterjet OnlyExtraTech Only2Tool Changer #1Chuck Open?Tool Changer #1Tool Loaded?3Tool Changer #1Chuck Closed?45671uCito CommandTypeParamNoteschuck open sensor?In145Param 145 value 1 ignore this signal.tool loaded?In145Param 145 value 2 ignore this signalParam 145 value 4 ignore this signalchuck closed?In145Air Pressure Low?Tool Changer #1 Limit Input?Dust Collector Middle?airlow?InInIn124This is also checked once a second in v8.25 of mh atcb module and v8.08of mh rio linear tc unless Param 145 value 8 is set to ignore the once asecond check.Air Pressure is always checked for ATC machines. If STD machine andparameter 124 indicates a QuickChange chuck, then the air pressure willalso be checked.Dust Collector is Open?Spindle Over Temperaturedust collector open?In201Used in Dustcollector 3pos.uc moduleIf 1, dust collector open signal ignored.Set to 2 to ignore signal on 2nd DustC.If param 618 1 then Spindle Overtemp is checked (v8.06.14 and later).8Dust Collector Closed?9Tool Changer #1 Extended?tool changer extended?In10Tool Changer #1 Retracted?Special Aggregate Tool SliderExtended?tool changer retracted?In11Controller Reference ManualInInAlso used in Dustcollector 3pos.uc module to check to see if dustcollector is closed.Used if parameter 127 1If parameter 176 bit 5 (value 16) is set, then this DCN will be deleted (see127DCN 164)Used if parameter 127 1If parameter 176 bit 6 (value 32) is set, then this DCN will be deleted (see127DCN 159)Used if any Special Tools are on slider. Requires v8.17 mh atcb tc module990-999 to be mapped.618Page 7

DCN1213DescriptionSpecial Aggregate Tool SliderRetracted?Tool Changer #1Open Chuck On/OffuCito Command16Spindle #1 Spindle Cooling17Spindle #1 Mister18Spindle #1 Air BlastTool Changer #1 Extend/Retract ToolChangerretract tool changerDust Collector Open(special 3 pos dustcollector)Tool Changer #1 Close ChuckOn/Offclose chuck onMisc Output on ATCB#1Misc Output on ATCB#1Misc Output on ATCB#1Heart BeatHeart Beat Devices(out port 10)Heart Beat Devices(out port 11)21222324252627282930313233Spindle #1 Cooling TimeSpindle #1 Chuck Closed MonitorATCB#1 MotorTool Changer Limit Input High MaskTool Changer Limit Input Low MaskKnife #1 Limit?3435Tap Control OutputSaw On/OffController Reference ManualNotesUsed if any Special Tools are on slider. Requires v8.17 mh atcb tc module990-999 to be mapped.Outpurge air on /purge air offSpindle #1 Purge AirSpindle #1 Dust Collector20ParamIn141519Typecooling on /cooling offmister pon /mister poffair blast on /air blast offOutOut650-699 Dust collector can be disabled by menu item.Starting in mh atcb tc.uc module v8.22 this DCN is not mapped to ATCBoutput 4 if spindle type 2000 (MAX40). DCN 152 is mapped instead to300ATCB output 4 if spindle type 2000OutOut1110OutMister can be disabled by menu or CNC command G98 P136108108 is the time in msec to have air on.127, 990- Used if parameter 127 1.999Also used for Aggregate slider extend/retract if parameter 990-999 are set.OutOutUsed in Dustcollector 3pos.ucOutOutOutOutHW valueHW valueHW valueHW valueMacroOutHW valueHW valueIn600OutOutPage 8Set to the number of seconds after turning off output 4 that it actually turnsoff. Uses as a timer to leave output 4 on for a duration of time after jobends.See DCN #215 for Knife 2 Limit.The output to switch the inverter to Motor #2 parameter for tapping.Typically wired to Multi-Function S5 input on inverter.Used in atcb saw.uc module with K5 inits.

960616263646566676869DescriptionuCito CommandSaw Up/DownSaw Up?Water Flow?Water PumpAll Limits (debug)Tool Changer #2Chuck Open?Tool Changer #2 Tool Loaded?Tool Changer #2 Chuck Closed?Tool Changer #2 Air Pressure Low?Tool Changer #2 Limit Input?Misc Input on ATCB#2Spindle #2 Dust Collector is Open?Misc Input on ATCB#2Tool Changer #2 Extended?Tool Changer #2 Retracted?WJ Bevel Theta Homing InputWJ Bevel Phi Homing InputTool Changer #2 Open ChuckOn/OffSpindle #2 Purge AirSpindle #2 Dust CollectorSpindle #2 CoolingSpindle #2 MisterSpindle #2 Air Blastair blast on2Tool Changer #2 Extend/Retract ToolChangerMisc Output on ATCB#2Tool Changer Close Chuck On/OffHeart BeatHeart Beat Devices(out port 10)Heart Beat Devices(out port 11)Spindle #2 Cooling TimeController Reference nNotesUsed in atcb saw.uc module with K5 inits.Used in Saw 90Deg.uc moduleUsed in atcb saw.uc module with K5 inits.Not Used. It was reserved for the water cooled spindles.Not Used. It was reserved for the water cooled spindles.145, 210145, 210145, 210Not Used. The Air Pressure is only checked on TC #1.OutOutOutOutOutOutOutOutOutOutOutOutHW valueHW valueHW valueHW valuePage 9

DCN707172DescriptionuCito CommandATCB#2 MotorTool Changer Limit Input High MaskTool Changer Limit Input Low MaskTypeOutHW valueHW valueParamNotesIf ZTrack Drag module is loaded, then this will get mapped to SSR2 onM2545/M3545 if the controller is a M2545/M3545 controller.73Z Solenoid UP/DOWNOut55747576Z Solenoid Up?Z Solenoid Down?Plasma Pierce CompleteInInOut55, 22151, 557778798099Start of Job/End of JobWaterjet Intensifier #2Waterjet Abrasive #2Waterjet JetValve #2Spindle 3 StoppedReserved for Spindle and Tool81-112 Changer #3113 Drill # 1 (Fire)114 Drill # 1 up?115 Drill # 1 (enable)116 Drill # 2 (Fire)117 Drill # 2 up?118 Drill # 2 (enable)119 Tapper Foot #1 Down120 Tapper Foot # 2 Down139 Spindle 4 StoppedReserved for Spindle and Tool121-152 Changer #4149 Open Chuck Foot Switch150Spindle Drive Axis ParkingController Reference For WaterJet machines, this is only used if parameter 55 indicates a Zsolenoid option.If this is used with the ZTrack Drag.uc module, then parameter 221 has tobe set to 256 because the CE Safety input is used for the Z Solenoid upsensor.For WaterJet machines, this is only used if parameter 55 indicates a Zsolenoid option.If parameter 51 0, then this input is ignored.Used with mh autocheckhome.uc module. Turn output on at start of job.Turns off at end of job.See DCN 217 for Waterjet #1176175175175175175175176InInBig Drill (uc40) machineBig Drill (uc40) machineWhen changing tools, turn on output to disable the checking of encodersso spindle drive does not fault if turned.OutPage 10

DCNDescription152153154Y Axis BrakeGrounding Clip InputChuck Foot Switch1553D Digitizer Up/Down156157158uCito CommandTypeParamOutInIn300279Out1653D Digitizer UP?In1653D surface sensorPause IndicatorInOut165grounding clip on?159160161162163Cycle Start # 2Oiler (Lube)H/W Estop Active?H/W Pause Active?Surface Block164165166Cycle Start #1 inputServo EnableServo Resethw cycle?servo enable167168Spindle EnableDrill Enablespindle enableController Reference Manualhw estop?hw pause?surface block?InOutInInIn176295InOutOutOut -orMacroOut176NotesY Axis Brake. Used in Tapping Spindle module (v3.34) to lock the Y axisduring a tapping cycle. Used with the MAX 40 spindle (spindletype 2000).In mh atcb tc.uc module v8.22 this DCN is mapped to output 4 and DCN16 is not mapped if spindle type 2000.Removed from Tapping Spindle module v3.41. Added to router module(v8.66) G98 P184 for manual control (500 msec hard-coded delay whenturning off brake)Big Drill (uc40) mac

Controllers The processor board can be identified by looking at the serial number of the controller. This serial number is the number shown in the ( ) of the