S500 Installation Manual - 2009

S500 – CNC
Hardware Manual (HW)

Manufacturer's Documentation
Valid for
Products: S 500.R0001, S 500.R0011, S

500.R0021
From version S 500.R00XX
Edition: December 2009

Code: 00009.HW.0.GB
Esa/Gv s.r.l.
1/Bis via Grieco
41011 Campogalliano Modena Italy
tel. +39 059 851414 - fax +39 059 851313
http://www.esagv.it - E-mail: info@esagv.it
S500 CNC Installation Manual
Restrictions Duplication, transmission and use of this document or its contents shall be considered
prohibited unless prior authorization has been received from Esa/Gv. All rights are
reserved.
Even when authorized, modification of this document (either by computer or on paper)
voids the guarantees specified below.
Guarantees The product may offer performances that are not described in these manuals. Esa/Gv
shall neither be obliged to maintain these functions in new versions of the product nor
to guarantee the relative assistance.
Checks have been carried out in order to ensure that the contents of these manuals
correspond to the documented product. Despite this fact, there may be discrepancies.
Esa/Gv therefore offers no guarantees as to the full compliance and completeness of the
texts.
The information in this document is periodically revised and new editions are issued
when necessary.
This manual has been compiled in partial compliance with ANSI/IEEE std 1063-1987
“IEEE Standard for software User Documentation”.
Editions This document is liable to be modified without prior notice. These modifications may
involve further editions or revisions of the document.
Further editions imply complete substitution of the document.
Revision involves replacement/addition/elimination of pages of the document.
Each page is identified by the code of the document at the bottom.
Notes
MS-DOS® Trademark registered by Microsoft Corporation.
2 Esa/Gv
The chronological list of editions of this document is given in the following table:
Evolution of the document

Edition Document Code Release Type of edition
18/12/2009 00009.HW.0.GB 0 Original
Modifications
Release Chapters - Pages Description
Esa/Gv 3
1 Notes for the reader......................................................................................................6
2 General Info ................................................................................................................10

2.1 Product description ...................................................................................................................10
2.2 CNCs Front view .....................................................................................................................15
2.3 CNC Rright side view.................................................................................................................22
2.4 Top view....................................................................................................................................26
2.5 CNC Bbottom view....................................................................................................................28
2.6 CNC front view with expansion modules installedretro..............................................................31
2.7 Etichette di identificazione.........................................................................................................45
2.8 CNC identification label.............................................................................................................45
2.9 Accessories...............................................................................................................................46
2.10 images\etienc.wmf .................................................................................................................46
3 Installation ..................................................................................................................47
3.1 CNC mounting .........................................................................................................................47
3.1.1 Dimensions ..................................................................................................................47
3.1.2 Fixing............................................................................................................................49
3.1.3 CNC placement............................................................................................................50
3.2 Environmental Conditions .........................................................................................................51
3.2.1 Climatic Working Conditions ........................................................................................51
3.2.2 Transportation and Storing Conditions ........................................................................52
3.2.3 Product end of life.........................................................................................................52
3.2.4 Electromagnetic Compatibility......................................................................................53
3.2.5 Protection against external contaminants ....................................................................54
3.3 Electrical Prescriptions ............................................................................................................55
3.3.1 Power Supply ..............................................................................................................55
3.4 Device Setup ............................................................................................................................56
3.4.1 Main Module configuration............................................................................................56
3.4.2 BRD.021.461 – 4 axes expansion module dip-switches set -up................................65
3.4.3 BRD.007.461 64 I/O Expansion module set-up dip-switches.....................................68
3.4.4 Mechatrolink BRD.021.421 and BRD.021.422 boards configuration .......................69
3.4.5 Sercos BRD.019.498 Digital Interface configuration ...................................................71
3.4.6 EsaLink BRD.019.436 Interface board configuration ..................................................72
3.4.7 BRD.021.461 – 4 axes expansion module - analog output offset adjustment...........73
3.5 Connections ..............................................................................................................................74
4 Esa/Gv
3.5.1 Indications and rules to be respected on building cables............................................74

3.5.2 Earth Connection .........................................................................................................75
3.5.3 Power Supply ..............................................................................................................77
3.5.4 12 bit resolution Analogue Input ..................................................................................79
3.5.5 Analogue Output...........................................................................................................81
3.5.6 Remoted I/O Interface (I/O Link) ................................................................................84
3.5.7 PS2 Keyboard / Mouse Interface ................................................................................88
3.5.8 PS2 Mouse Interface ...................................................................................................89
3.5.9 Ethernet Interface ........................................................................................................90
3.5.10 VGA Video Interface .................................................................................................91
3.5.11 USB Interface............................................................................................................92
3.5.12 BRD.007.461 32 Dig. Input + 32 Dig. Output Expansion module (Option)................94
3.5.13 Digital Inputs...............................................................................................................95
3.5.14 Digital Outputs..........................................................................................................100
3.5.15 Fast Input..................................................................................................................104
3.5.16 Encoder Input ( available only on BRD.021.461 expansion module)......................108
3.5.17 Homing and Touch probe inputs (available on BRD.021.461 exp. module)...........114
3.5.18 Analogue Output (available only on BRD.021.461 Four Axes Exp. Module)........116
3.5.19 BRD.019.436 - ESA LINK Interface .....................................................................121
3.5.20 BRD.019.421 MECHATROLINK I ........................................................................125
3.5.21 BRD.019.422 MECHATROLINK II Interface.........................................................128
3.5.22 CAN Interface ..........................................................................................................131
3.5.23 BRD.019.498 - SERCOS Interface ..........................................................................134
3.5.24 Serial Lines ............................................................................................................136
4 Diagnostic..................................................................................................................143
4.1 LEDs........................................................................................................................................143
4.1.1 Power Supply LEDs ...................................................................................................144
4.1.2 RUN LED...................................................................................................................144
4.1.3 System Monitor Display..............................................................................................144
4.1.4 Link I/O LED...............................................................................................................146
4.1.5 NETWORK activities LEDs........................................................................................147
4.2 Serial Lines..............................................................................................................................147
4.3 Device Debug .........................................................................................................................147
Esa/Gv 5
1 Notes for the reader
General information The information in this manual only applies to the software versions indicated on the
frontispiece.
Not all the available functions may be described in this manual. In these cases, Esa/Gv
shall be obliged to neither guarantee these functions nor include them in future versions.
Purpose This document contains information allowing technicians to correctly service the
product described on the frontispiece.
Users This document contains information for:

Specialized installer technicians/specialized test technicians with a good working
knowledge of the numeric control and machine. Basic knowledge of electro-
mechanics and industrial apparatus.
Use of the document The document is divided into chapters that describe a well defined characteristic of the
product.
Notification of Please contact Esa/Gv if any difficulties should arise when this manual is used.
difficulties
6 Esa/Gv
Explanation of the symbols

Graphic symbols may appear beside the text. These are used to emphasize information
of particular importance.
Attention
This symbol is used when failure to take the appropriate precautions could cause slight
damage to persons and property.
Danger
This symbol appears when failure to take the appropriate precautions or
accomplishment of incorrect operations could cause serious damage to persons
and/or property.
Important
This symbol appears in the manual to indicate information of particular importance. It
is essential to read these sections in order to fully understand the manual.
Option
This symbol indicates sections of the manual that describe optional functions or parts.
Use of optional performances must be established with the machine manufacturer.
Manufacturer
This symbol indicates those sections of the manual reserved to the machine
manufacturer.
Password
This symbol indicates sections of the manual that describe functions access to which is
safeguarded by software passwords.
CNC
This symbol indicates sections of the manual that describe functions only available in
CNC and not in the PC.
PC
This symbol indicates sections of the manual that describe functions only available in
the PC and not in CNC.
Esa/Gv 7
Printer’s conventions
Particular printer’s conventions are used to make it easier to identify the information in
this manual. These conventions are illustrated below.
Keyboard and video The following conventions are used.

• The names of the screen-printed keys are indicated in boldface and are
enclosed within square brackets. If the name of the key is preceded by
“button”, reference is being made to a key on the push button panel.
• [ENTER]. Identifies the key that bears the word ENTER.
• [+] indicates the + key of the keyboard, while button [+] indicates the + key of
the push button panel.
• The names of the function keys are indicated in boldface italics and are
enclosed within square brackets.
• [Plc Menu]. Identifies the function key that bears the words Plc Menu.
• References to fields and/or messages on the video are written in boldface
italics.
• The specific text to be digitized by the user is underlined.
• If the manual indicates “digitize ok, the user must digitize exactly “ok”.
• DIRECTION or DIRECTIONAL keys is the collective name used to indicate
the UP, DOWN, LEFT and RIGHT keys.
• Pressure, in sequence, on a series of keys is written by separating the identifiers
of the required keys with the “>“ character.
• [Manual] > [START]. Describes pressure, in sequence, on the [Manual] and
[START] keys.
• Pressure on several keys at the same time is indicated by separating the
identifiers of the keys themselves with the “+” character.
• [SHIFT] + [] Describes contemporaneous pressure on the [SHIFT] and []
keys.
Text The following conventions are used.

• Italics are used to identify specialist terms.
• Boldface is used to emphasize words of particular importance.
8 Esa/Gv
Glossary
CNC This is an abbreviation of Computerized Numerical Control and indicates the instrument
that governs the machine, i.e. the electronic device through which the machining cycles
are programmed, the axes moved, etc..
It corresponds to one of the devices whose operation is described in this manual.
NC Represents the Normally Closed status of an input or an output.
NO Represents the Normally Open status of an input or an output.
Esa/Gv 9
2 General Info
2.1 Product description

The S 500 is a compact high performances CNC based on a standard HW PC platform.
It can be interfaced to a Personal Computer (trough serial line or network),or to an operator panel or simply a VGA
display + keyboard. It integrates digital and analog input/output, interfaces to manage both in analog or in digital
way Axes drives , serial lines, interface to connect ( through fiber optic) remote I/O modules.
Under SW point of view it integrates PLC module and ISO language interpreter.
This manual contains only all necessary information for NC HW installation.
10 Esa/Gv
The NC version S 500 R0001 main specifications are:
Microprocessor AMD 5x86 133MHz.,

32 Mbytes of DRAM (used by the NC SW)
1 Mbytes of SRAM memory, back upped , to store the
machine parameters .
32 Mbytes of FLASH memory.
LEDs 1 green LED to indicate the status of the internally generated
+5VDC.
1 green LED to indicate the status of the external 24 VDC.
1 green LED to indicate the RUN status of the NC.
1 green LED to indicate the status of the remote I/O LINK.
1 seven segments display used as System Monitor.
Digital Input 4 fast input ( internally managed as CPU interrupts).
Analog Input 4 analog input 0 - 5V, 0 - 10V with 12 bit resolution.
Analog Output 1 analog output 0 - 10V with 12 bit resolution .
Communication Lines COM1 serial line , standard RS232C.
COM2 serial line , configurable as RS232C/RS422/RS485.
1 USB 1.1 interface.
2 CAN interfaces
Fiber optic interface versus remote I/O.
Battery 3,6V lithium battery type CR2032 used to back up SRAM
memory data an supply the internal Clock Calendar with
NC off
Other functions RESET, PWF, and WATCHDOG TIMER circuitries
Internal Expansion Mechatrolink ® (Yaskawa) interface
Sercos ®
EsaLink® Esa/Gv proprietary digital interface
External Expansion Till a maximum of 4 Four analog axes expansion boards
(inclusive of 4 encoder input and 4 analog output).
Till a maximum of 2 32 digital input + 32 digital output
expansion boards.
Expansion board to drive
2 proportional valves + 2 open loop valves.
Esa/Gv 11
The CNC versions S 500 R0011 and S 500 R0021 main specifications are:
Microprocessor Celeron M 600MHz (S 500 R0011) , Pentium M 1,8 GHz

(S 500 R0021)
256M ÷1Gbyte of DRAM (used by the CNC SW)
1 Mbytes of SRAM memory, back upped , to store the
machine parameters .
32 Mbytes of IDE FLASH disk.
LEDs 1 green LED to indicate the status of the internally generated
+5VDC.
1 green LED to indicate the status of the external 24 VDC.
1 green LED to indicate the RUN status of the NC.
1 green LED to indicate the status of the remote I/O LINK.
1 red seven segments display used as System Monitor.
Digital Input 4 fast input (internally managed as CPU interrupt)
Analog Input 4 analog input 0 - 5V, 0 - 10V with 12 bit resolution.
Analog Output 1 analog output 0 - 10V with 12 bit resolution .
Communication Lines COM1 serial line, RS232C standard.
COM2 serial line, configurable as RS232C/RS422/RS485.
10/100 MB Ethernet interface.
2 USB 2.0.
1 PS2 keyboard input.
1 PS2 mouse input.
2 CAN interfaces.
Fiber optic interface versus remote I/O.
Battery 3,6V lithium battery type CR2032 used to back up SRAM
memory data
Other functions RESET, PWF, and WATCHDOG TIMER circuitries
VGA video Interface.
Internal Expansion Mechatrolink ® (Yaskawa) interface
Sercos ®
EsaLink® Esa/Gv proprietary digital interface
External Expansion Till a maximum of 4 Four analog axes expansion boards
(inclusive of 4 encoder input and 4 analog output).
Till a maximum of 2 32 digital input + 32 digital output
expansion boards.
Expansion board to drive 2 proportional valves + 2 open
loop valves.
12 Esa/Gv
2.2 CNC Front view
Figure 2.1 - S 500 R0011/ R0021 Front view
Esa/Gv 13
1) Fixing slots
2) CAN 1 interface channel
3) 24 VDC supply voltage status
4) 24 VDC terminal input
5) Earth connection screw
6) Mouse PS2 connector
7) Keyboard PS2 connector
8) USB 1&2 Interfaces (2.0 version)
9) Ethernet connector
10)VGA monitor interface
11)COM1 serial interface
12)COM2 serial interface
13)+5 VDC presence LED
14)Removable cover to access to the internal bus for digital axes interface boards
installation
15)Fast Input connector
16)12 bit resolution 0 - 10V analog output
17)Dip switches to set analog input operative range
18)12 bit resolution analog input
19)Link I/O status LED
20)Link I/O Rx connector
21)Link I/O Tx connector
22)CNC setup and test Dip switches
23)CNC Run/Stop LED
24)System monitor display
25)CAN 2 interface channel
14 Esa/Gv
Figure 2.2 - S 500 R0001 front view
Esa/Gv 15
1) Fixing slot
2) CAN1 interface channel
3) 24 VDC supply voltage status LED
4) 24 VDC terminal input
5) Earth connection screw
6) USB interface (1.1 version)
7) COM 1 serial interface
8) COM 2 serial interface
9) + 5 VDC status LED
10)Removable cover to access to the internal bus for digital axes interface boards
installation
11)Fast Input connector
12)12 bit resolution 0 - 10V analog output
13)Dip switches to set analog input operative range
14)12 bit resolution analog input
15)Link I/O Status LED
16)Link I/O Rx connector
17)Link I/O Tx connector
18)CNC setup and test Dip switches
19)Led Run/Stop
20)System monitor display
21)CAN 2 interface channel
16 Esa/Gv
2.3 CNC right side view
PC104 Expansion Module Connector
Figure 2.3– CNC right side view
Esa/Gv 17
2.4 Top view
Figure 2.4 – CNC top view
1) Cooling slots
2) Dipswitches to adapt (with a 120 ohms resistor) CAN1 and CAN2 bus
18 Esa/Gv
2.5 CNC bottom view
Figure 2.5 – CNC bottom view
1) Cooling slots
2) Dip-switches to configure COM2 serial interface
3) Dip-switches to configure COM2 serial interface
Esa/Gv 19
2.6 CNC front view with two expansion modules installed
Figure 2.6 – CNC with 2 expansion modules installed – Front view
20 Esa/Gv
2.7 CNC identification label
Is here described the label attached on the CNC right side and all the info reported on it .
These info are necessary for a correct product identification in case of service request.
Figure 2.7 – Product identification label
1) Model (Example: S 500 Rack)

2) Code (Example: S 500.R0011)
3) Serial number (Example: 20083114)
4) Power consumption (Example: 60W)
5) Temperature range (Example 5÷55°C)
6) Supply (Example . 24VDC)
7) Production data (Example: 07/08)
8) CE mark
Esa/Gv 21
2.8 Accessories
2.9
The following list contains all the accessories supplied with the CNCs necessary for its
correct installation.
CODE QUANTITY DESCRIPTION

CNN.020.002 2 D-Sub 9 pins Male connector
CNN.020.027 2 Metallic case for D-Sub 9 pins connector
MRS.007.022 1 3 pins 5.08 mm pitch Female terminal strip
MRS.008.025 1 7 pins 3,81 mm pitch Female terminal strip
Note:
An additional kit of the above connectors can be ordered with the code
ASS.S 500.R0001
100 m of optical fiber for remote I/O module connection can be ordered with the code
OPF.005.001
22 Esa/Gv
3 Installation
3.1 CNC mounting
3.1.1 Dimensions
CNC module
Specification Value
Height 342 mm
Width (only CNC without expansion modules) 55,5 mm
Depth (maximum dimension) 234,5 mm
Weight 1,5 Kg
Esa/Gv 23
Figure 3.1 –CNC base unit dimensions
24 Esa/Gv
Fixing
The module must be fixed using 4 x M5 Allen screws. Use the under showed template to correctly execute the
necessary holes.
Figure 3.2 – Template to be respected to fix the CNC
Esa/Gv 25
CNC placement
The CNC position, into the electrical cabinet, must be chosen in order to guarantee a physical separation of the
device from power contactor / cables , drivers, inverter, transformer etc. of at least 50cm.
If such distance cannot be respected is strongly suggested to separate the CNC from the power components trough
metallic shields.
Power components too near to the CNC can in fact generate noise problems and consequently functional errors.
26 Esa/Gv
3.2 Environmental Conditions

The CNC has been designed to work at the environmental conditions under described.
For a correct working it is however necessary:
• To respect the environmental condition also during transportation and storing.
• Install the CNC properly following the instructions reported in this manual.
Additional Info and For questions , or info not reported in this manual you can contact the Esa/Gv
Help Applications & Technical Support Department .
Climatic Working Conditions

The CNC has been designed to doesn’t require any forced cooling . So it doesn’t
integrate any kind of fun. It requires however a vertical mounting to allow the air to
flow across its cooling slots.
It is also suggested to leave at least 100 mm of free room around it inside the electrical
cabinet
If necessary, to maintain inside the electrical cabinet the maximum accepted working
temperature , a heating exchanger or a conditioner have to been foreseen .
Specifications Limit Values

Working Temperature:
Minimum 5°C
Maximum 55°C
Average on 24h 50°C
Relative Humidity:
Minimum 50%
Maximum 95%
Condensation Not allowed
Maximum Working Altitude 2000m
Note.
To guarantee the CNC cooling and the above declared specifications, is

mandatory to install it vertically.
Esa/Gv 27
Transportation and Storing Conditions

The following data are applicable only to the CNC in its original packaging .
Specifications Limit Values

Storing Temperature :
Minimum -25°C
Maximum 70°C
Relative Humidity:
Minimum 5%
Maximum 95%
Condensation Not allowed
Atmospheric Pressure (Bigger or Equal) 70Kpa (3000m)
Product end of life

When the CNC will be removed by the Machine Tool for scraping or retro-fit it hasn’t
to be considered as a normal waste. .
It is mandatory to consign it to an authorized centre specialized on recycling and

disposal of electrical and electronic devices.
28 Esa/Gv
Electromagnetic Compatibility
Emission EN50081-2 – Generic standard for industrial environment .

Is used the basic rule EN55011.
Test Limit
Conducted interference on supply cable Class A
Radiated interference Class A
Immunity EN50082-2 – Generic standard for industrial environment

Are used the following basic rules
Test Limit
Conducted Radiofrequency Electro- Test voltage: 10 V rms
magnetic Field ( EN61000-4-6 )
Frequency: 0.15÷80 MHz
AM (80% of modulation) 1 KHz
Radiated Radiofrequency Electro-magnetic Field Intensity : 10 V/m
Field (EN61000-4-3)
Frequency : 80-1000 MHz
AM (80% of modulation) 1KHz
Impulsive Radiated Radiofrequency Field Intensity: 10V/m
Electro-magnetic Field (EN61000-4-3)
Frequency: 26÷1000 MHz
Frequency : 1400÷2000 MHz
Pulses (100% of modulation) 200 Hz
Fast transients - burst ( EN61000-4-4) Test Voltage : 2 KV
Electrostatic Discharges (EN61000-4-2) Contact Voltage test : 4 KV
Radiated Voltage test : 8 KV
Number of discharge x test : 10
Repetition : 1 discharge/s
To reduce radiofrequency interference is very important to study carefully the cable’s

path into the electrical Cabinet and properly filter all inductive loads. For ore info on
this matter see the generic Esa/Gv manual “EMC and LVD directives- Installation
Guide ” .
Esa/Gv 29
3.2.5 Protection against external contaminants

The presence of powder and dust , specially if conductive, can compromise the
correct working of the CNC. To avoid these kind of problems into cabinet that require a
consistent flow of air , it is mandatory to use filter and provide to clean or change or
clean them when necessary .
Degrees of Protection
SPECIFICATION Limite
S 500. R00xx IP 20 (Note)
Note:
Protection against solid parts with diameter bigger than 12mm, no protection against
liquids.
30 Esa/Gv
3.3 Electrical Prescriptions
Power Supply
Electrical The CNC supply has to respect the following characteristics:

Specifications
Specifications Limit Value

Typical Input Voltage 24 VDC
Maximum Input Voltage 28.8 VDC
Minimum Input Voltage 20.4 VDC
Maximum Input Current 3A
Maximum Absorbed Power 60 W
Insulating Voltage (DC / GROUND) It is necessary to
supply the CNC
with a DC Power
Supply insulated
and stabilized.
Over-Voltage protection Yes with varistor
Hold up Time >10 mSec
The power of the power supply must be equal or bigger of the CNC consumption. If
the input voltage goes down the nominal values the CNC will be powered Off. Il the
Input voltage isn’t enough stable it is suggested to use a UPS unit..
Esa/Gv 31
3.4 Device Setup
A wrong set up of the customization dip-switches can damages the CNC or the
eventually linked sensors. So this operation must be done only by specialized
technicians equipped with antistatic wrist collar.
3.4.1 Main Module configuration

To customize the CNC should be necessary to set-up some HW dip-switches. Into next
paragraphs all available switches will be detailed described .
Note: All the set up dip-switches are externally accessible. So it is not necessary to open
the CNC case to access to them.
32 Esa/Gv
3.4.1.1 SW1 - System Dip-switches
Figure 3.3 – System SW1 location
• SW1.1: Reserved use

• SW1.2: Enable AUTOSETUP procedure from USB
• SW1.3: SERVICE mode
• SW1.4: FLASH BIOS Disable
Esa/Gv 33
SW1.2 Through this switch is possible to enable the AUTOSETUP procedure from an USB
memory pen
SW1.2
AUTOSETUP enabled by DISABLED ENABLED

USB (default)
SW1.2 SERVICE mode Through this switch can be enabled the SERVICE mode.
SW1.2
SERVICE Mode DISABLED ENABLED

(default)
SW1.4 BIOS Disable Through this switch is possible to disable the loading of the BIOS from the FLASH
enabling the loading from the Silicon Disk (if available).
SW1.4
BIOS Loading From FLASH From Silicon Disk

(default)
Note.
During normal working of the device all dip-switches must be placed in OFF (Up)
position .
34 Esa/Gv
3.4.1.2 Analogue Input Setup Dip-switches
Figure 3.4 SW2 Analogue Input set-up dip-switches location
• SW2.1: Analogue Input 1 set-up

Esa/Gv 35
SW2.1 Analogue Through this switch it is possible to select the voltage range of the analogue Input 1
Input1 Set-up
SW2.1
0 - 10V 0 - 5V
(default)
Input2 Set-up
SW2.2
0 - 10V 0 - 5V
(default)
Input3 Set-up
SW2.3
0 - 10V 0 - 5V
(default)
Input4 Set-up
SW2.4
0 - 10V 0 - 5V
(default)
36 Esa/Gv
3.4.1.3 SW3 – CANOPEN Bus termination dip-switches
Figure 3.5 - CANOPEN bus termination dip-switches
• SW3.1 CANOPEN1 line termination

• SW3.2 CANOPEN2 line termination
Esa/Gv 37
SW3.1 CANOPEN 1 Through this switch is possible to insert a 120 ohm termination resistor on
termination CANOPEN1 line.
SW3.1
Termination No 120 ohm

(default)
SW3.2 CANOPEN 2 Through this switch is possible to insert a 120 ohm termination resistor on
termination CANOPEN2 line.
SW3.2
Termination No 120 ohm

(default)
38 Esa/Gv
3.4.1.4 COM 2 serial line dip-switches set-up
Figure 3.6 SW4 and SW5 Dip switches location
• SW4 COM2 Serial Line Set-up

• SW5 COM2 Serial Line Set-up
Esa/Gv 39
SW4, SW5 COM2 Through these 16 switches can be selected the working modality of COM2 serial
Serial Line set-up interface.
SW4/SW5 SW4 SW5
RS232
Default
RS422
RS485
without
termination
RS485
with
termination
40 Esa/Gv
3.4.2 BRD.021.461 – 4 axes expansion module dip-switches set -up

The dip-switches here described are directly accessible on the expansion module. So it isn’t necessary to open it.
Figure 3.7 - BRD.021.461 4 axes expansion module dip-switches location
• SW1: Encoder 1-2 set-up

• SW2: Encoder 3-4 set-up
• SW3: Expansion module address set-up
Esa/Gv 41
SW1.1 SW1.2 SW1.3 Through these 3 switches it is possible to insert a termination resistor of 120 ohm on
Encoder 1 set-up the 3 differential input of encoder 1
SW1.1, SW1.2, SW1.3
Encoder 1 Lines not adapted Lines adapted

(default)
SW1.4, SW1.5, SW1.6

(default)
SW2.1, SW2.2, SW2.3

(default)
42 Esa/Gv
SW2.4, SW2.5, SW2.6

(default)
SW3 4 Axes Through these switches it I s possible to select the number (address) of the 4 axes
expansion module expansion module. The address is also reported on the module identification label .
address
Module Nr. SW3
Expansion
Module N. 1
(Default)
Expansion
Module N. 2
Expansion
Module N. 3
Expansion
Module N. 4
Note: For a CNC correct working cannot coexist 4 axes expansion modules with
the same address.
Esa/Gv 43
3.4.3 BRD.007.461 64 I/O Expansion module set-up dip-switches
The dip-switches here described are directly accessible on the 64 I/O expansion module. So it isn’t necessary to
open it.
Figure 3.8 - BRD.007.461 64I/O Expansion Module dip-switches location
SW1 64 Digital I/O Through these switches it I s possible to select the number (address) of the 4 axes
expansion module expansion module. The address is also reported on the module identification label .
address
Module Nr. SW1
I/O Expansion
module N. 1
(Default)
I/O Expansion
module N. 2
Note: For a CNC correct working cannot coexist two 64 I/O expansion modules
with the same address.
44 Esa/Gv
3.4.4 Mechatrolink BRD.021.421 and BRD.021.422 boards configuration
SW2
SW3
SW1
Figure 3.9 – Mechatrolink BRD.019.421 board jumpers location
Note. The jumpers set-up must be done by Esa/Gv technicians or qualified

personnel. However normally the board is supplied already properly configured
so no change have to be done.
Esa/Gv 45
Figure 3.10 Mechatrolink II BRD.019.422 configuration jumpers location

46 Esa/Gv
3.4.5 Sercos BRD.019.498 Digital Interface configuration 2-16 Mbit/s Single ring application
Figure 3.11 - BRD.019.498 Sercos ® Interface – Jumper Set-u location

Esa/Gv 47
3.4.6 EsaLink BRD.019.436 Interface board Single ring application

configuration
Figure 3.12 – BRD.019.436 EsaLink interface board- Jumper set-up location

48 Esa/Gv
3.4.7 BRD.021.461 – 4 axes expansion module - analog output offset

adjustment
On this module is also possible, through a trimmer, to adjust the offset of the analogue output present on
the board. The adjustment is normally done in Esa/Gv. So it can be used only when a finest tuning is
necessary. The trimmer works contemporary on all four output . Is so possible to verify small differences
among the four outputs. Normally the unbalancing error is however inside the range of 1 mV.
Note. This tuning must be done only by specialized personnel.
T1: Analogue Output Offset Trimmer
Figure 3.13 - BRD.021.461 – Analogue output offset tuning trimmer location
Esa/Gv 49
3.5 Connections
3.5.1 Indications and rules to be respected on building cables

To guarantee absence of electro-magnetic interference during the device working the positioning of the cables into
the electrical cabinet must be carefully done.
Signals cables :
• Serial Lines,
• +24V DC ON/OFF Digital Input / Output,
• Encoder input,,
• Analogue Input ,
• Analogue Output.
Power cables :
• Supply voltage cables (380 VAC, 230 VAC).
• Cables to connect Drives and Motors.
• Cables used to connect inductive loads supplied with voltages equal or bigger
that 100 VAC.
Installation Rules To guarantee the maximum noise immunity must be respected the following rules:
• To position signals cables far as possible from power cables.
• Don’t place signal cable near high intensity magnetic fields produced , for
example, by motors or transformers.
• Place the signal cables far from neon lamps that usually are big generators of
interferences.
• Cables with impulsive signals ( characterized by very fast variations in
voltage or current must be maintained separated from all the other . If this
cannot be possible use shielded cable or metallic shield to electro-magnetic
insulate them.
• To install the CNC it self far from high intensity electromagnetic fields as, for
example, neon lamps or power cables.
Doesn’t respect the above rules can generate problems while the CNC is working.
Filter for noise To eliminate electro-magnetic noise generated by coils , electro valves, Hydraulic
suppression valves contactors, motors and other inductive loads can be used noise suppress filters
that must be placed nearest more as possible to the inductive loads. To avoid mechanical
damages to the filters is suggested to fix them strongly to the load.. For more details on
filters and theirs use please consult the Esa/Gv manual “LMC & LVD prescriptions
- Installation Guide ”
50 Esa/Gv
3.5.2 Earth Connection

To guarantee a safe use of the CNC and contemporary increase its noise immunity it is necessary ground it
correctly.
The CNC must be connected through its earth screw to the main ground of the
electrical cabinet (PE) . The earth screw, located on the front pane of the CNC is
identifiable by the standard Earth Label.
A wrong earth connection of the CNC can compromise the operator safety and
the correct working of the system (reducing its noise immunity).
Esa/Gv 51
3.5.2.1 Earth example of connection
Figure 3.14 – CNC Ground Linking
52 Esa/Gv
3.5.3 Power Supply
The ground pin of the supply socket of the CNC must be linked with the main
ground of the electrical cabinet (PE).
Type of connector 3 pins Male terminal Phoenix MSTBV 2,5/3-GF-5,08 Cod.. 1777086
Flying part : Phoenix FRONT-MSTB 2,5/3-STF-5,08 Cod. 1777811
Figure 3.15 – Power supply socket
Pin Signal Name Type

1 DC- TERMINAL VI
2 GND VI
3 DC+ TERMINAL VI
Signal Name:
DC +/- TERMINAL Supply Voltage
GND Ground reference
Signal Type:
VI Input Voltage
Esa/Gv 53
3.5.3.1 Example of correct 24 VDC supply connection
Figure 3.16 – 24 VDC supply
Also the negative terminal of the power supply must be connected to the main Earth of the
electrical cabinet (PE).
54 Esa/Gv
3.5.4 12 bit resolution Analogue Input
• The connection of a potentiometer must be done using a shielded cable. The

shield must be connected only at CNC side.
• In case an intermediate connector has to been used to separate the cable never
mix on ,the same connector , analogue signal and power connection . In this case
provide to connect the shield at both side of the flying connection in order to
avoid its interruption.
Electrical
Specifications
Static Characteristics Value
Input Number 4
Input Impedance 1 M Ohm
Voltage input range
(configurable independently on every input) 0÷+5V
0÷+10V
Digital resolution 12 bit

Value of the Less significant bit 1,25mV
Maximum admitted permanent input (without damages) -12V
+12V
Output digital value with maximum input applied = Full scale
Type of input Single ended
Potentiometer supply :
• Supply voltage + 5V DC.
• Maximum supply current 40 mA
Protection against short circuit condition Yes (not permanent)
Dynamic Characteristics Value

Conversion time 1 mS
Sampling time Programmable
Input filter characteristics :
 Order First
 Transition frequency (-3 dB) 1 kHz
Esa/Gv 55
General Characteristics Value

Type of protection RC
Insulation voltage in normal working conditions :
- between channel and channel +12V / -12V
Type of connector Terminal strip 7 pins Male: Phoenix MC 1,5/7-G-3,81 1803329

Flying part: Phoenix MC 1,5/7-ST-3,81 Cod. 1803620
Figure 3.17 – Analogue Input – Terminal strip

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 VAL VO
6 GND VO
7 GND EARTH REF
Signal Name:
GND 0V supply
GND EARTH EARTH reference
INPUT 1÷4 Signal Input
VAL + 5V supply
Signal Type:
I Input Signal
VO Voltage Output
56 Esa/Gv
Connection Example
Figure 3.18 – Example of connection of potentiometers
3.5.5 Analogue Output
• The connection of a potentiometer must be done using a shielded cable. The

shield must be connected only at CNC side.
• In case an intermediate connector has to be used to section the cable, never mix
analogue signals with power conductors. Also verify that the shield is connected
at both side of the two flying connectors in order to avoid its interruption.
.
Esa/Gv 57
Electrical Specifications

Output number 1
Output voltage range 0 - 10 V
Maximum output current 5 mA
Maximum Output Ripple 20 mV
Digital resolution 12 bit
Value of the Least Significant Bit 2,44 mV

Conversion time 1 uS

Type of protection NO
Insulation voltage in normal working conditions :
(between channel and supply) 0V c.c.
Type of permitted load Insulated .Connected
to Ground
Note: In case of wrong connection the related circuitry can be permanently
damaged
Type of connector 2 pins Male Terminal strip : Phoenix MC 1,5/2-G-3,81 1803277

Flying part : Phoenix MC 1,5/2-ST-3,81 Cod. 1803578
58 Esa/Gv
Figure 3.19 – Analogue Output Terminal Strip
Pin Name Type

1 OUTPUT 1 O
2 GND REF
Signal Name:
OUTPUT 1 Signal Output
GND Ground
Type of Signal :
O Signal Output
REF Signal reference
Figure 3.20 – Analogue Output connection example
Esa/Gv 59
3.5.6 Remoted I/O Interface (I/O Link)
Figure 3.21 I/O Link Interface
Fibre Optic Specifications
Specification Value
Type Plastic
Diameter 2.2 mm
Diameter Tolerance ± 0,05mm
Maximum attenuation 0.27 dB/m
Maximum applicable force 1N
Bending maximum radius 35 mm
Max length on TX output 20 m
Maximum transmission baud rate 2 Mb/s
Storing temperature range -55÷85°C
Installation and working temperature range -20÷85°C
Fibre Optic linking For a correct fibre optical connection to a TX and RX connectors is necessary to
respect the following rules:
• Cut the fibre using a cutter.
• Insert the optical fibre into the RX and TX module till the base of the connector is reached.
• To extract the optical fibre from a connector is necessary to press the external ring end
contemporary pull the fibre as described in the next Figure..
60 Esa/Gv
Anello Esterno
Premere
Tirare
Premere
Fibra ottica
Figure 3.22 – As to remove the optical fibre from its connector
Don’t remove the optical fibre from the RX and TX connectors without press the
external ring because this can broken the fibre inside the connector.
For a correct use of the optical fibre it is necessary:

• Avoid that powder or dust enters inside the TX or RX connectors.
• Doesn’t use acids or alkaline solvent to clan the RX and TX connectors
• Doesn’t exceed minimum bending radius or max force extension values to
avoid damages to the optical fibre.
Make attention on choosing the optical fibre path to avoid it mechanical damages . For
more details on connection of the available remote I/O modules please refer to the
specific Esa/Gv manual .
Esa/Gv 61
Example of one Remote I/O module connection
Figure 3.23 – Connection CNC  Remote I/O (1 module)
62 Esa/Gv
Example of two Remote I/O modules connection
Figure 3.24 – Connection CNC  Remote I/O (2 modules)
Esa/Gv 63
3.5.7 PS2 Keyboard / Mouse Interface
Type of Connector 6 pins Female PS2 Mini Din .
Figure 3.25 – Keyboard / Mouse Connector

1 KBD DATA IO
2 MS DATA IO
3 GND VO
4 VCC VO
5 KBD CLK O
6 MS CLK O
Signal Name :
KBD DATA Data
MS DATA
GND Ground
VCC +5 VDC Supply
KBD CLK Clock
MS CLK
Signal Type:
I Input Signal
O Output Signal
VO Output Voltage
Note Through this connector it is possible, using a specific adapter cable, to connect
contemporary a keyboard and a mouse.
64 Esa/Gv
3.5.8 PS2 Mouse Interface
Type of Connector 6 pins Female PS2 Mini Din
Figure 3.26 Mouse connector

1 MOUSE DATA I
2 Not Connected NC
3 GND VO
4 VCC VO
5 MOUSE CLK O
6 Not Connected NC
Signal Name :
MOUSE DATA Data
GND Ground
VCC +5 VDC Supply
MOUSE CLK Clock
Signal Type:
I Input Signal
O Output Signal
VO Output Voltage
NC Not Connected
Esa/Gv 65
3.5.9 Ethernet Interface
The Ethernet network adapter supports the 10 and 100Mbit/s baud rate on an RJ45 connector .
Type of connector RJ45.
Figure 3.27 – Ethernet Connector

1 TX+ O
2 TX- O
3 RX+ I
4 Not Connected NC
5 Not Connected NC
6 RX- I
7 Not Connected NC
8 Not Connected NC
Signal Name :
TX+ Positive Differential Transmission Signal
TX- Negative Differential Transmission Signal
RX+ Positive Differential Reception Signal
RX- Negative Differential Reception Signal
NC Not Connected
Signal Type:
O Output Signal
I Input Signal
NC Not Connected
66 Esa/Gv
3.5.10 VGA Video Interface
The CNC Model S 500.R0011 /R0021 integrate a VGA video interface To the
associated connector can be so to be connected an analogue VGA monitor or multi-
frequency.
For a monitor connection it is necessary to use the cable supplied with the monitor or
an however homologated VGA cable.
Don’t respect the above prescription can cause a wrong working of the peripheral.
VGA Interface Specification Value

Reference Standard VGA IBM
Monitor resolution 1024x768 (16 M/colours )
Memory 1 MB shared with the system memory
Type of managed monitors SVGA - XGA
Type of connector 15 pins Female D-Sub 15
Figure 3.28 – VGA Video Interface Connector
Esa/Gv 67

1 RED O
2 GREEN O
3 BLUE O
4 Not Connected NC
5 GND REF
6 GND (Red) REF
7 GND (Green) REF
8 GND (Blue) REF
9 Not Connected NC
10 GND (Synchronism ) REF
11 Reserved NC
12 DDDA NC
13 H SYNC O
14 V SYNC O
15 DDCK NC
3.5.11 USB Interface
The CNC models S 500.R0011 / R0021 integrates two USB respecting 2.0 Version.
The CNC model S 500.R0001 integrates instead only one USB connector respecting
1.1 version.
To connect the CNC to the USB peripheral it is necessary to use the cables supplied
with the peripheral devices or an homologated USB cable.
Don’t respect the above prescription can cause a wrong working of the peripheral.
USB Specification Value

S 500 R0011 / R0021 Number of Channels: 2 : Version 2.0
S 500.R0001 Number of Channels 1: Version 1.1
68 Esa/Gv
Type of Connector Type A Female
Figure 3.29 – USB Interface Connector

1 VCC VO
2 - USB IO
3 + USB IO
4 GND VO
Connector case SHIELD SCH
Signal Name:
VCC +5 VDC Supply
- USB Negative Differential Universal Serial Bus Signal
+ USB Positive Differential Universal Serial Bus Signal
GND Ground
SHIELD Shield – Must be connected to the metallic case of the connector
Signal Type:
IO Input / Output Signal (BUS)
VO Output Voltage
SCH Shield
Esa/Gv 69
3.5.12 BRD.007.461 32 Dig. Input + 32 Dig. Output Expansion module (Option)
Figure 3.30 - BRD.007.461 Digital Input/ Output Expansion Module
70 Esa/Gv
3.5.13 Digital Inputs
General Info The input voltage can be obtained through a three-phases transformer with a rectifier
diodes bridge + a capacitor. However is important that the ripple) respect the requested
values ( see Specifications)..
A relay or an over-travel contact connected to a Input terminal strip must be only

connected to a 24 VDC supply. Is in fact strongly suggested never use double contact
Over-travel switch with the second contact linked to 110 VAC or higher voltage.
Humidity can in fact cause a discharge between the two sections. Doesn’t respect this
prescription can damage the input circuitry of the CNC.
Parallel Input In case it is necessary to connect the same contact to another input ( for example to a
PLC input) is necessary to decouple it using a diode as specified in Figure 2.35.
Contact Choosing a relay take care of the voltage and of the minimal commutation value of its
Characteristics contacts . The first is 24VDC, the second around 12 mA.
Cable’s Section The section of the connection cable must take care of the mechanical traction due to
the cable weight. A section of 0,5 mm² is a good choice. Bigger section can instead
generate problems on crimping it to the connector. The maximum section for the input
terminal strip is in fact 1 mm².
Input Common It is necessary to link at least one common Reference (GND REF)
(GND REF)
Esa/Gv 71
Electrical
Specifications
Specification Value
Number of Input 32
Typical Input Voltage +24V DC
Maximum Input Voltage +30V DC
Minimum Input Voltage +10V DC
Typical Input Current 4,5 mA
Maximum Input Current 6 mA
Digital Input Filter Yes
Maximum commutation Frequency 3 kHz
Delay on activation
Delay on de-activation
Protection against polarity inversion Yes
Protection against over-voltage No
Opto-insulation of the Input respect to the internal bus Yes
Type of connector 17 pins Male terminal strip Phoenix MC 1,5/17-G-3,5 1844362

Figure 3.31 – Input Terminal Strip
72 Esa/Gv

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 INPUT 5 I
6 INPUT 6 I
7 INPUT 7 I
8 INPUT 8 I
9 INPUT 9 I
10 INPUT 10 I
11 INPUT 11 I
12 INPUT 12 I
13 INPUT 13 I
14 INPUT 14 I
15 INPUT 15 I
16 INPUT 16 I
17 GND REF REF
Signal Name:
INPUT 1÷16 Input Signal
GND REF Common Input Reference
Type of Signal:
I Input Signal
REF Reference
Esa/Gv 73
Example of connection of an over-travel switch or a relay contact
Figure 3.32 – Example of connection of a relay contact or over-travel switch
Example of connection of a PNP open collector sensor
Figure 3.33 – Example of connection of a PNP open collector sensor
74 Esa/Gv
Example of connection of a Push-Pull sensor
Figure 3.34 – Example of connection of a Push-pull sensor
Example of connection in parallel of two inputs
Figure 3.35 – Example of connection in parallel of two input
Esa/Gv 75
3.5.14 Digital Outputs
Cable’s section The section of the connection cable must take care not only of the max output current
(0,6A) but also of the mechanical traction due to the cable weight. A section of 1 mm²
satisfy both requirements. Bigger section can instead generate problems on crimping it
to the connector. The maximum section for the output terminal strip is in fact 1 mm².
Output Common Link to GND as shown in the Figure

connection
Electrical
Specifications
Specification Value
Number of Output 32
Typical Output voltage +24 VDC
Maximum Output voltage +28 VDC
Minimal Output voltage +20 VDC
Output insulated respect the BUS No
Max continuous output current 0,6 A (Note )
Typical output current 10 mA÷600 mA
Maximum continuous current with two output in parallel. 1A
Maximum continuous current with four output in parallel 2A
Maximum current on every common pin 2,5 A
Maximum commutation frequency with 0.7 A current 3 KHz
Short circuit Protection Yes
Overload protection Yes
Over voltage protection Max. +47V
Maximum dissipated energy with an inductive load 60 mJ
Minimum Output voltage with a load current of 0.6 A cand a 23.8 V
supply voltage of +24VDC
Maximum voltage output in OFF condition and with a power 0.1 V
supply of +24V DC
Note: It is the maximum possible value before the overload protection becomes active.
Type of connector 6 pins Male Terminal Strip: Phoenix MC 1,5/16-G-3,5 Cod. 1844359
76 Esa/Gv
Figure 3.36 – Digital Output Terminal Strip

1 OUTPUT 1 O
2 OUTPUT 2 O
3 OUTPUT 3 O
4 OUTPUT 4 O
5 OUTPUT 5 O
6 OUTPUT 6 O
7 OUTPUT 7 O
8 OUTPUT 8 O
9 OUTPUT 9 O
10 OUTPUT 10 O
11 OUTPUT 11 O
12 OUTPUT 12 O
13 OUTPUT 13 O
14 OUTPUT 14 O
15 OUTPUT 15 O
16 OUTPUT 16 O
Signal Name:
USCITA Output Signal
1÷16
Signal Type:
O Output Signal
Type of Connector 7 pin Male Terminal Strip: Phoenix MC 1,5/7-G-3,5 Cod. 1844265
Flying Part : Phoenix MC 1,5/7-ST-3,5 Cod. 1840418
Esa/Gv 77
Figure 3.37 - 24V Output Common Terminal Strip

1 + 24V OUTPUT 1-16 VI
4 + 24V OUTPUT 17-32 VI
5 + 24V OUTPUT 17-32 VI
6 + 24V OUTPUT 17-32 VI
7 GND VI
Signal Name:
+ 24V OUTPUT 1-16 Common Output from 1 to 16
+ 24V OUTPUT 17-32 Common Output form 17 to 32
GND Reference output supply
Signal Type:
VI Input Voltage
78 Esa/Gv
Example of +24VDC electro valve connection
Figure 3.38 – Example of 24 VDC electro-valve connection
Example of 24 VDC relay connection
Figure 3.39 –Example of 24VDC Relay connection
The protection diode identified by the asterisk * is necessary to reduce the

electromagnetic noise issue by the load during tits commutation .
Note
Esa/Gv 79
Example of external PLC connection
Figure 3.40 – Example of external PLC connection
3.5.15 Fast Input
• The connection must be done with shielded cable. The shield must be connected
only at CNC side.
• In case an intermediate connector has to be used to
section the cable, never mix fast input signal with power conductors . Also
verify that the shield is connected at both side of the two flying connectors in
order to avoid its interruption.
General Info The input voltage can be obtained through a three-phases transformer with a rectifier
diodes bridge + a capacitor. However is important that the ripple) respect the requested
values ( see Specifications)..
A relay or an over-travel contact connected to a Fast Input terminal strip must be only
connected to a 24 VDC supply. Is in fact strongly suggested never use double contact
Over-travel switch with the second contact linked to 110 VAC or higher voltage.
Humidity can in fact cause a discharge between the two sections. Doesn’t respect this
prescription can damage the input circuitry of the CNC.
Parallel Input In case is necessary to connect the same contact to an another input ( for example to a
PLC input) is necessary to insert is series a decoupling diode as specified in Figure
3.35.
Contact Choosing a relay take care of the voltage and of the minimal commutation value of its
Characteristics contacts . The first is 24VDC, the second around 12 mA.
80 Esa/Gv
Cable ‘s Section The section of the connection cable must take care of the mechanical traction due to
the cable weight. A section of 0,5 mm² is normally OK. Bigger section can instead
generate problems on crimping it to the connector. The maximum section for the fast
input terminal strip is in fact 1 mm².
Specification Value
Number of Fast Input 4
Typical Input Voltage +24 VDC
Maximum Output Voltage +27.5 VDC
Minimal Input Voltage +19 VDC
Typical Input Current 12 mA
HW Filter No
Maximum Commutation Frequency 20 KHz
Inversion Polarity Protection Yes
Over-voltage Protection No
Input Opto-insulated respect the BUS Yes
Esa/Gv 81
Type of connector 6 pin Male Terminal Strip: MC 1,5/6-G-3,81 Cod. 1803345

Figure 3.41 – Fast Input Terminal Strip

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 GND VI
6 GND VI
Signal Name:
INPUT 1÷4 Input Signal
GND Common Input reference
Signal Type:
I Input Signal
VI Input Voltage
82 Esa/Gv
Connect the cable’s

Stringere la calzashields to the
nel capicorda,
GND avvitarlo
CNC screw nell'inserto presente
a fianco del connettore.
Figure 3.42 – Example of fast input connection
Esa/Gv 83
3.5.16 Encoder Input ( available only on BRD.021.461 expansion module)
Figure 3.43 - BRD.021.461 Four analogue axes expansion modules
84 Esa/Gv
• The encoder’s cable must be mandatory a shielded type, If the case of the
encoder is separately referred to ground the shield must be linked only at CNC
side. If instead the encoder is insulated from ground the shield must be connected
also at the encoder side. To guarantee the connection , at the CNC side, it is
enough to connect it to the metallic case of the DIN connector.
•In case an intermediate connector has to be used to section the cable, never mix
encoder signals with power conductors . Also verify that the shield of the cable
is connected at both side of the two flying connectors in order to avoid its
interruption.
Encoder Input in To connect the encoder input in parallel see the specific “Example of connection”
parallel taking care to the shield connection and the fan out of the encoder outputs. Connect the
encoder supply only at one side ( the nearest). A wrong connection of the encoder
supply can broken the CNC internal power supply.
Connector’s For the encoder connection use the connector an relative metallic case supplied by
characteristics Esa/Gv. If has to be used other connector verify it respects the following
specifications:
• Contact resistance <= 10 mOhm.
• Insulation Resistance >= 5.000 MOhm.
• Working temperature range -55 a +125 °C.
• Golden plated contacts.
•Perf. level 2 (DIN41652) guaranteed for at least 200 inser. / extractions.
•Metallic case to guarantee a correct shielding.
Cable’s section The section of the cables cannot be smaller than 0.2 mm². Is better to choose it
considering boot encoder consumption and cable’s length. Normally are used cables
with a section of 0.22 mm². The maximum distance reported into the specifications
table can be however doubled choosing a cable with a section of 0,5 mm
Doesn’t respect the above prescription can damage the Encoder input circuitries or not
guarantee a correct functioning of the system.
Esa/Gv 85
Specification Value
Encoder Inputs 4
Encoder Maximum Voltage +7 VDC
Minimum Input Voltage -0.3 VDC
Typical Input current 2.3 mA @ 5V
Maximum Input Current 5.0 mA @ 5V
Input Impedance ( in case of single-ended connection) 2.2 Kohm
Input Impedance (in case of differential – 5V Line driver 1 Kohm
connection)
Resistance to adapt the line in case of differential connection 120 ohm
HW filter 50 nS
Maximum commutation frequency 500 KHz
Protected against polarity inversion No
Protected against over- voltage No
Input insulated respect the I/O BUS No
Type of cable to be used Double shielded
cable with 0,22
mm² section
Maximum cable length ( with 0,22 mm2 section) 20m
Type of connector D-Sub 9 pins Female .

Flying connector : D Sub 9 pins Male
Figure 3.44 – Encoder input connector
86 Esa/Gv

1 ERROR I
2 +VE VO
3 GND VO
4 PHASE /A I
5 PHASE A I
6 PHASE /B I
7 MARKER /0 I
8 MARKER 0 I
9 PHASE B I
Case SHIELD SCH
Signal Name:
+VE Encoder Supply ( selectable as +5VDC or +12VDC)
GND GND - Supply
PHASE /A A inverted phase
PHASE A A phase
PHASE /B B inverted phase
PHASE B B phase
MARKER /0 Marker inverted
MARKER 0 Marker
ERROR Encoder Error (only if managed by the encoder)
SHIELD Shield to be connected to the D-shell metallic case.
Signal Type:
VO Output Voltage
I Input Signal
SCH Shield
Esa/Gv 87
3.5.16.1 Example of Encoder connection ( single ended )
Figure 3.45 – Single Ended Encoder connection.
3.5.16.2 Example of Encoder connection ( differential)
Schiacciare la calza fra le

calotte metallizzate del
connettore.
Figure 3.46 – Differential Encoder connection
88 Esa/Gv
3.5.16.3 Example of one Encoder connected in parallel at two different inputs
Figure 3.47 – Connection of one Encoder in parallel at two different input.
3.5.16.4 Example of shield connection
Press the shield against the

connector caselo schermo in
Schiacciare
mezzo al pressacavo e fra
le due calotte metallizzate
Figure 3.48 – Shield connection.
Esa/Gv 89
3.5.17 Homing and Touch probe inputs (available on BRD.021.461 exp. module)
Electrical
Specifications
Specification Value
Number of Inputs 8
Typical Input Voltage +24 VDC
Maximum Input Voltage +30 VDC
Minimal Input Voltage +10 VDC
Typical Input Current 4,5 mA
HW Filter (RC) No
Maximum Commutation Frequency 3 kHz
Protection against polarity inversion Yes
Protection against over – voltage No
Inputs insulated respect the I/O BUS Yes
Type of connector 9 pins Male Terminal strip: Phoenix MC 1,5/9-G-3,81 Cod. 1803345
Figure 3.49 – Axes Inputs terminal Strip
90 Esa/Gv

1 Homing Switch Axis 1 I
5 Touch Probe Axis 1 I
9 GND REF
Signal Name:
Homing Switch Axis 1÷4 Input Signal
Touch Probe Axis 1÷4
GND Input Common Reference
Signal Type:
I Input Signal
REF Reference
Esa/Gv 91
3.5.18 Analogue Output (available only on BRD.021.461 Four Axes Exp. Module)
• The connection must be executed with shielded cable. The shield must be
absolutely connected at CNC side. Generally is better to link it also at Drive side
also if some time , due to significant potential difference between the two
ground references, this connection cannot be directly done. .In case of doubt
please contact the Application & Service Esa/Gv department .
• In case an intermediate connector has to be used to section the cable, never mix
analogue output signals with power conductors . Also verify that the shield of
the cable is connected at both side of the two flying connectors in order to avoid
its interruption.
Connector For the encoder connection use the connector an relative metallic case supplied by
Characteristics Esa/Gv. If has to be used other connector verify it respects the following
specifications:
• Contact resistance <= 10 mOhm.
• Insulation Resistance >= 5.000 MOhm.
• Working temperature range -55 a +125 °C.
• Golden plated contacts.
•Perfor. level 2 (DIN41652) guaranteed for at least 200 insert. / extract.
• Metallic case to guarantee a correct shielding.
Don’t respect the above prescription can compromise the correct working of the
system.
92 Esa/Gv
3.5.18.1 Electrical Specifications

Number of analogue output 4
Range output voltage -10 -:- +10 V
Maximum output current 5 mA
Output Impedance 68 Ohm
Output Ripple 610 uV
Analogue Output Error
Max Error at 25°C +/- 0.03% F.S.
Temperature Coefficient +/- 0.001% F.S./°C
Maximum error on all temperature field +/- 0.1% F.S.
Digital Resolution 16 bit
Value of Least Significant Bit 305 uV

Total conversion time 10 uS
Maximum momentary deviation to electromagnetic noise
ENV50140 (Radiated Electro- +/- 0.03% F.S
magnetic fields)
+/- 0.03% F.S
ENV50141 (Conducted +/- 0.003% F.S
Electro-magnetic fields)
EN61004-8 (Magnetic field at
main frequency)
EN61004-2 (Electrostatic
discharges)
EN61004-4 (Burst)

Type of protection No
Insulation potential in normal working condition :
• Between Channel and supply 0V c.c.
Points common among channels GND
Type of allowed load Insulated, connected
to GROUND
Effect of a wrong connection Breaking
Esa/Gv 93
Type of Connector D-Sub 15 pins Female.

Flying connector D- Sub 15 pins Male
Figure 3.50 – Analogue Axes Output D-sub connector

1 OUTPUT 1 O
2 Not Connected NC
3 OUTPUT 2 O
4 Not Connected NC
5 Not Connected NC
6 OUTPUT 3 O
7 Not Connected NC
8 OUTPUT 4 O
9 GND REF
10 Not Connected NC
11 GND REF
12 Not Connected NC
13 GND REF
14 Not Connected NC
15 GND REF
Connector Case SHIELD SCH
Signal Name:
OUTPUT 1÷4 Output Signal
GND Ground
SHIELD Shield must be linked to the connector metallic case.
94 Esa/Gv
3.5.18.2 Connection Example
D
or
Invert
Drive or
Inverter
Figure 3.51 – Example of Analogue Output  Drive connection
Esa/Gv 95
Shield connection
Press the shield against

Schiacciare the connector
lo schermo in
case
mezzo al pressacavo e fra
Figure 3.52 – Shield Connection
96 Esa/Gv
3.5.19 BRD.019.436 - ESA LINK Interface

Is a specific board installed inside the CNC base module. Allows to manage digitally till 8 Esa/Gv ASP drives.
• The connection cable must be a crossover Ethernet type RJ45 CAT 5E SSTP or
however guarantee the specification under reported.
• The cable cannot be sectioned.
Cable’s Is suggested to use the cable supplied by Esa/Gv with his drivers. In any case the cable
Characteristics has to respect the following specifications:
Number of wires = 4 pairs twisted
Impedance = 100 Ohm.
Category 5E or superior .
SSTP Double shielding
Don’t respect the above prescription can compromise the correct functioning of the
system .
Electrical
Specifications
Specification Value
Number of Channel 1
Maximum number of drives / nodes 8
Scansion time Config. (2 ms typ.)
Maximum cable’s length 10m
Maximum baud rate 6.25 Mbps
Esa/Gv 97
Type of Connector RJ 45 8 pins
Figure 3.53 ESA LINK RJ45 RX Connector

1 RX+ I
2 RX- I
3 Not Connected NC
4 Not Connected NC
5 Not Connected NC
6 Not Connected NC
7 Not Connected NC
8 Not Connected NC
Signal Name:
RX+ Received Data
RX- Inverted Received Data
SHIELD Cable’s Shield
Signal Type:
I Input Signal
SCH Shield
NC Not Connected
98 Esa/Gv
Type of Connector RJ 45 8 pins
Figure 3.54 - ESA LINK RJ45 TX connector

1 Not Connected NC
2 Not Connected NC
3 TX+ O
4 Not Connected NC
5 Not Connected NC
6 TX- O
7 Not Connected NC
8 Not Connected NC
Signal Name:
TX+ Transmitted Data
TX- Inverted Transmitted Data
Type of Signal:
O Output Signal
SCH Shield
NC Not Connected
Esa/Gv 99
3.5.19.1 Example of ESA LINK connection
Figure 3.55 – ESALINK CNC  Drives Connection
100 Esa/Gv
3.5.20 BRD.019.421 MECHATROLINK I
Is a specific board installed inside the CNC base Module. Allows to manage digitally Yaskawa drives equipped
with this interface ( MECHATROLINK I) .
• The connection cable must absolutely be USB type with the characteristic after
reported.
• Isn’t allowed to section the cable .
Cable’s It is suggested to use cables directly supplied with the drives by Yaskawa . The cable
characteristics must however to respect the following specifications:
External diameter = 11 mm.
Number of conductors = 2 pairs.
Maximum signal attenuation <= 14dB/Km
Don’t respect the above prescription can be cause of a not correct working of the
system..
Electrical
Specifications
Specification Value
Number of communication channels 1
Maximum number of Drives / Nodes 15
Cycle Time 2ms
BUS Impedance 120 Ohm
Maximum cable’s length 50m max. (total)
Maximum transmission frequency 4Mbps
Esa/Gv 101
Type of Connector USB Type A 4 pins Female
Figure 3.56 – Mechatrolink Interface

1 Not Connected NC
2 /S IO
3 S IO
4 Not Connected NC
Signal Name:
/S Inverted BUS Signal
S BUS Signal
Signal Type:
SCH Shield
NC Not Connected
102 Esa/Gv
3.5.20.1 MECHATROLINK I Example of connection
Figure 3.57 – Mechatrolink I - CNC  Drives connection
Esa/Gv 103
Note:
The Mechatrolink I BUS requires terminator resistors at both end side of the
BUS. Considering that a 120 ohms resistor is already installed on the BRD.019.421
board, it is necessary only to verify that another resistor is inserted on the last
drive connected on the BUS.
3.5.21 BRD.019.422 MECHATROLINK II Interface

Is a specific board installed inside the CNC base Module. Allows to manage digitally Yaskawa drives equipped
with this interface ( MECHATROLINK II) .
• The connection cable must absolutely be USB type with the characteristics after
reported..
Cable’s It is suggested to use cables directly supplied with the drives by Yaskawa . The cable
characteristics must however to respect the following specifications:
External diameter = 11 mm.
Number of conductors = 2 pairs.
Maximum signal attenuation <= 14dB/Km
system.
Electrical Specifications Value

Maximum number of Drives / Nodes 30
Sampling Time 2ms
Max Cable’s Length 50m max. (14 nodes )
104 Esa/Gv
Type of Connector USB type A 4 pins Female
Figure 3.58 – MECHATROLINK II Interface Connector

1 Not Connected NC
2 /S IO
3 S IO
4 Not Connected NC
Signal Name:
/S Inverted BUS Signal
S BUS Signal
SHIELD Cable’s shield . Must be connected to the connector metallic case
Signal Type :
IO Input / Output signals (BUS)
SCH Shield
NC Not Connected
Esa/Gv 105
3.5.21.1 MECHATROLINK II Example of connection
Figure 3.59 – Mechatrolink II CNC  Drives Connection
106 Esa/Gv
Note:
The Mechatrolink II BUS requires terminator resistors at both end side of the
BUS. Considering that a 120 ohms resistor is already installed on the BRD.019.422
board, it is necessary only to verify that another resistor is inserted on the last
drive connected on the BUS.
3.5.22 CAN Interface
It allows to connect both I/O and drives (Axes) .
• The connection cable must respect the specification CiA/DS-102.

• The cable cannot be sectioned.
Cable’s Number of wires = pair, shielded.

characteristics
Resistance and Capacity = depend by the length and transmission baud rate.
Don’t respect the above specification can compromise the correct working of the
system.
Specification Value
Number of available CAN channels 2
Maximum number of nodes x Channel 60
Maximum Cable’s Length 25 m (1Mbps)
1 km (50Kbps)
Esa/Gv 107
Type of connector 9 pins Female - Sub-D
Figure 3.60 - CAN Interface connector

1 Not Connected NC
2 CAN-Low IO
3 CAN GND
4 Not Connected NC
5 Not Connected NC
6 CAN GND
7 CAN-High IO
8 Not Connected NC
9 Not Connected NC
Signal Name:
CAN-High Positive BUS Signal
CAN-Low Negative BUS Signal
SCHERMO Shield to be pressed against the two parts of the metallic connector
case.
Signal Type:
SCH Shield
108 Esa/Gv
3.5.22.1 CAN BUS Example of Connection
Figure 3.61 – CAN Bus CNC  Drives & I/O Connection
Esa/Gv 109
Note:
The CAN BUS requires a termination resistor of 120 ohms at both side s of the
BUS. The CNC is factory shipped with the resistor already inserted on both
channels. This set-up can be however changed through two specific switches It is
however important to remember to insert a termination resistor also on the last
device connected on the BUS.
3.5.23 BRD.019.498 - SERCOS Interface

Is a specific board installed inside the CNC base Module. Allows to manage digitally Third Parts drives equipped
with this interface ( SERCOS®) .
• The connection cable must absolutely on optical fibre

• It is necessary to use only the optical fibre supplied by

Optical Fibre the drives maker. This because is already provided with the specific flying
characteristics connector.
system..
Electrical
Specifications
Specifications Value
Maximum number of drives 8
Cycle Time 2ms
Fibre optic diameter 1mm
Max fibre optic length ( between two contiguous nodes) 45m
Type of Connector Fibre -SMA Connector ( As prescribed by IEC-874-2 rule) .
110 Esa/Gv
3.5.23.1 SERCOS® Interface - Example of connection
Figure 3.62 – Sercos ® Interface - CNC  Drives connection
Esa/Gv 111
3.5.24 Serial Lines
• The connection between CNC and the peripheral must be done with both devices
powered off. To don’t respect this prescription can cause the breaking of the line
drivers / receivers components.
• The connection must be done using a shielded cable that must be absolutely connected
at both sides.
• In case an intermediate connector has to been used to separate the cable never mix
on ,the same connector , serial line signals and power connection . In this case provide
to connect the shield at both side of the flying connection in order to avoid its
interruption.
Don’t respect the above prescription can cause damages to the device and however not
guarantee their correct functioning.
3.5.24.1 Electrical Specifications
RS232C Specifications Value

Number of channels 2
Minimum Input Voltage ±3V
Maximum Input Voltage ±30V
Minimal Input Resistance 30K
Minimum Output Voltage ±9 V
Typical Output Voltage ±10.5V
Maximum Cable Length 10m
Maximum Transmission Frequency 115 000 Baud
112 Esa/Gv
RS422 Specifications Value

Number of Channel 1
Minimum differentia Input Voltage ±200 mV
Maximum differential Input Voltage ±6V
Maximum Common Mode Input Voltage ±7V
Line termination Resistance 100 Ω
Minimum Differential Output Voltage ±2V
Typical Output Voltage ±3,5V
Maximum Cable’s Length 1200m
Maximum Transmission Frequency 115000 Baud
Type of Connectors D-Sub 9 pins Male.
Figure 3.63 – Serial Lines Connector
3.5.24.2 RS232C Standard

1 DCD I
2 RX I
3 TX O
4 DTR O
5 GND REF
6 DSR I
7 RTS O
8 CTS I
9 RI I
Case SHIELD SCH
Esa/Gv 113
Signal Name :
DCD Data Carrier Detect
RX Receive
TX Transmit
DTR Data Terminal Ready
GND Ground
DSR Data Set Ready
RTS Request To Send
CTS Clear To Send
RI Ring Indicator
SHIELD The shield must be linked to the metallic case of the D-sub connector.
Signal Type:
I Input Signal
O Output Signal
REF Signal Reference
SCH Shield
Note – The RI (Ring Indicator) signal is normally not managed by the CNC. IF it is
instead necessary please contact Esa/Gv.
3.5.24.3 RS232C example of connection

calotte metallizzate
del connettore
Figure 3.64 – RS 232C CNC, → PC DTE, with 25 pins connector
114 Esa/Gv

calotte metallizzate
del connettore
Figure 3.65 – RS232C CNC, → PC DCE with 9 pins connector
3.5.24.4 Standard RS422
Pin Name Type

1 TX- O
2 TX+ O
3 RX+ I
4 RX- I
5 GND REF
6
7
8
9 +5VDC VO
Case SHIELD SCH
Signal Name:
TX- Transmit -
TX+ Transmit +
RX+ Receive +
RX- Receive -
GND Ground
+5VDC Vcc Supply
SHIELD Cable’s Shield - must be pressed against the metallic case of the
D-Sub connector
Esa/Gv 115
Type of Signal :
I Input Signal
O Output Signal
REF Signal’s Reference
SCH Shield
3.5.24.5 RS422 Example of connection
RS-422 Peripheral
Figure 3.66 – CNC → Generic RS422 Peripheral Example of connection
3.5.24.6 RS485 Standard

1 DATA BUS - IO
2 DATA BUS + IO
3 Not Connected NC
4 Not Connected NC
5 GND REF
6 Not Connected NC
7 Not Connected NC
8 Not Connected NC
9 Not Connected NC
116 Esa/Gv
Signal Name:
DATA BUS + Positive Differential Receiver7Transmitter Signal
DATA BUS - Negative Differential Receiver/Transmitter Signal
GND Ground
SHIELD Shield – Must be pressed against the metallic case of the connectors.
Signal Type:
IO Input/Output Signal (BUS)
REF Signal Reference
NC Not Connected
SCH Shield
3.5.24.7 RS485 Example of connection
Figure 3.67 – CNC → Generic RS485 Peripheral- Example of connection
Esa/Gv 117
3.5.24.8 Example of Shield connection
Press the shield against the

two parts of lothe
Schiacciare metallic
schermo in
mezzo al case
connector pressacavo e fra
Figure 3.68 –Cable’s Shield connection.
118 Esa/Gv
4 Diagnostic
4.1 LEDs
Figure 4.1 –Diagnostic devices
1) + 24VDC LED (green). When ON indicates presence of the external supply.

2) Network LEDS (green and yellow). Used to signal the status and the activity on
the network.
3) + 5VDC LED (green). When ON indicates presence of the internal supply.
4) Link I/O LED (green).
5) Run LED (red/green). When green the CNC is running.
6) Seven segments (red) System Monitor Display.
Esa/Gv 119
4.1.1 Power Supply LEDs
• LED (green) +24VDC: used to signal the presence of the external + 24VDC .
• LED (green) + 5VDCV: used to signal the presence of the internal supply .
The 2 LEDs give an indication on the status of the voltages externally supplied to the device and internally
generated by the unit. Can happen the following situations:
• Both LEDs are ON: the CNC is correctly working.
• Both LEDs are OFF: the CNC isn’t correctly powered. Possible causes can be:
− The external 24VDC supply isn’t present;
− The CNC is in failure. Please contact the Esa/Gv maintenance service.
• The +5VDC LED is OFF but the +24VDC LED is ON.
• The +24VDC LED is OFF but the +5VDC LED is ON.
− In both cases the CNC is in failure. Please contact the Esa/Gv maintenance
service.
4.1.2 RUN LED
When the CNC is properly supplied this LED indicates its working status. Can happens the following conditions:
• The RUN LED is ON (green light) the CNC is correctly working.
• The RUN LED is ON (red light) the CNC is not correctly working. In this
condition is suggested to substitute the device.
4.1.3 System Monitor Display
Also this 7 segments LEDs display indicates the CNC Status. Can happens the following conditions:
• The display is OFF. In this case the possible cause are:
− Is only the display that is not correctly working ( the CNC is however OK);
− The CNC is in fault. Please contact the Esa/Gv maintenance service.
On the seven segments display is reported a code. Are here reported a list of code and the related meanings:
• 0 – OK Status . The CNC is correctly working.
• 1 – Reserved .
• 2 - Reserved.
120 Esa/Gv
• 3 – CNC Installation .
− The display indicates this code during the ISO , Axes SW (SLAVE) and
PLC execution. So if the CNC hangs with 3 on the display should be that
the PLC wasn’t able to start. Some can be the reasons: PLC not loaded,
wrong I/O definition or IOREDIR configuration file. In all cases it is
necessary to restore correctly running the Autosetup procedure.
• 4 - CNC Application.
− After the execution of the STARTCN procedure, if into the H: disk of the
CNC is present the KVARA.GZ file, the display will report the number
“4” .
• 5 – CNC LOADER.
− During the power ON the display will indicate “5” if into the CNC ‘s
FLASH memory are both present the BIOSEXT and the LOADER and
the CNC is executing the STARTCN procedure.
• 6 – CNC BIOSEXT.
− During the power ON the display will indicate “6” if into the CNC ’s
FLASH memory is present only the BIOSEXT. In this case it is necessary
to restore the LOADER executing the Autosetup procedure .
• 7 - Power Fail.
− The input power supply goes down for a short time (not enough long to
generate e HW Reset). This mean that the supply isn’t stable. It is necessary
to power OFF the CNC and verify, before power ON it again, the external
supply and the related cable.
• 8 - Power ON.
− It will be showed immediately after the CNC power ON. In parallel to the
CNC Startup the number will change till reach the 0.
• 9 - User interface DLL not present.
− The GUIAPP.DLL file isn’t present . It must be restored
• A - Diagnostic menu.
− After the execution of the STARTCN procedure on the display will appear
“A” if, into the H: disk of the CNC , isn’t present the file KVARA.GZ file
or if the key “PERMISSION” of the PC KVARA.INI file is set =
LOADER. In both cases it is necessary to execute the Autosetup procedure.
Other situations where “A” will appear on the display are:
− Autosetup is running .
− Recovery is under execution.
− The LOADER has found problems on decompressing the KVARA.GZ
file or verifying memory or loading the applications.
• B - CPU CN battery failure.
− The Battery used for the CMOS SETUP is low. It is necessary to change it.
• C - Shut Down.
Esa/Gv 121
− It is possible to power OFF the CNC without any risk to loose machine
parameters data.
• D – Reserved for Debug.
• E – Reserved ( at the moment not used).
• F - Reset problems.
− The CNC has been reset. A reset command has been sent to the CNC. It is
necessary to wait that the Reset procedure end.
− LOADER with problems on opening the File System.
System Monitor Resuming, in absence of errors, on the Display System Monitor, after the 24VDC is
Display sequence applied to the CNC, will appear in sequence the following numbers:
during Power ON
8  5  4  3  0.
4.1.4 Link I/O LED
This LED is used to give information on the status of the LINK I/O remote bus.
Can happens the following situations:

• LED ON: The serial fiber optic connection with the transmitter node is
present. The interface is correctly working.
• LED OFF: The serial fiber optic connection with the transmitter node is not
present. The CNC will show an error message. The problem cause can be one
of the following :
− The receiving node isn’t addressed by the transmitter node of the CNC .
− The address stetted by a dipswitch on the receiver node is wrong.
− The optical fiber (at the RX and/or at the TX side) has not been linked,
broken or wrongly cut.
− The receiving note is broken.
− The transmitter node is broken.
• LED Blinking: sometime the communication with the transmitter node goes
into error. The CNC will show an error message. The problem cause can be
one of the following:
− Noises directly coupled on the receiver or transmitter circuitries.
− Optical fiber with a bad contacts inside the TX and/or RX connectors.
− Broken optical fiber or badly cut at its extremities.
− Receiver circuitry broken.
− Transmitter circuitry broken.
122 Esa/Gv
The LINK I/O LED OFF forces the status 0 on all the output of all the linked I/O
modules. The time between a RESET command is issue and the remote output are
forced low ( stop of the serial communication and LINK I/O LED forced OFF) is 50
ms.
4.1.5 NETWORK activities LEDs
The Network activities are monitored through two LEDs:
Link LED (green) It gives information on the Network status .
Activity LED (yellow) It indicates if the are data exchanged on the Network.
Can happen the following conditions:

• Both LEDs OFF. The causes can be:
− It isn’t present any network connection.
− Has been used a not adequate or wrong cable.
• The Link LED is ON while the Activity LED is OFF. The connection is OK
but there isn’t any exchange of data .
• The Link LED in ON while the activity LED is blinking. The connection and
the data exchange are OK.
4.2 Serial Lines

In case of errors during serial data transmission the only corrective action that can be done is to check the
cables and verify if on the cable path are present high energy electromagnetic noise. In case of permanent
failure is however necessary to change the CNC.
4.3 Device Debug
To execute a complete debug of the device (test of serial lines , digital Input and Output , Encoder input
etc. ) use as reference the “Diagnostic Manual” where are detailed all the necessary operations.
Esa/Gv 123
124 Esa/Gv

S500 Installation Manual - 2009

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S500 – CNC

Hardware Manual (HW)

Products: S 500.R0001, S 500.R0011, S

Edition: December 2009

Evolution of the document

1 Notes for the reader......................................................................................................6

2 General Info ................................................................................................................10

3.5.1 Indications and rules to be respected on building cables............................................74

1 Notes for the reader

Users This document contains information for:

Explanation of the symbols

Keyboard and video The following conventions are used.

Text The following conventions are used.

NC Represents the Normally Closed status of an input or an output.

NO Represents the Normally Open status of an input or an output.

2.1 Product description

The NC version S 500 R0001 main specifications are:

Microprocessor AMD 5x86 133MHz.,

Microprocessor Celeron M 600MHz (S 500 R0011) , Pentium M 1,8 GHz

2.2 CNC Front view

Figure 2.1 - S 500 R0011/ R0021 Front view

Figure 2.2 - S 500 R0001 front view

2.3 CNC right side view

PC104 Expansion Module Connector

Figure 2.3– CNC right side view

2.4 Top view

Figure 2.4 – CNC top view

2.5 CNC bottom view

Figure 2.5 – CNC bottom view

2.6 CNC front view with two expansion modules installed

Figure 2.6 – CNC with 2 expansion modules installed – Front view

2.7 CNC identification label

Figure 2.7 – Product identification label

1) Model (Example: S 500 Rack)

CODE QUANTITY DESCRIPTION

3.1 CNC mounting

Figure 3.1 –CNC base unit dimensions

Figure 3.2 – Template to be respected to fix the CNC

3.2 Environmental Conditions

Climatic Working Conditions

Specifications Limit Values

To guarantee the CNC cooling and the above declared specifications, is

Transportation and Storing Conditions

Specifications Limit Values

Product end of life

It is mandatory to consign it to an authorized centre specialized on recycling and

Emission EN50081-2 – Generic standard for industrial environment .

Immunity EN50082-2 – Generic standard for industrial environment

To reduce radiofrequency interference is very important to study carefully the cable’s

3.2.5 Protection against external contaminants

3.3 Electrical Prescriptions

Electrical The CNC supply has to respect the following characteristics:

Specifications Limit Value

3.4 Device Setup

3.4.1 Main Module configuration

3.4.1.1 SW1 - System Dip-switches

Figure 3.3 – System SW1 location

• SW1.1: Reserved use

AUTOSETUP enabled by DISABLED ENABLED

SERVICE Mode DISABLED ENABLED

BIOS Loading From FLASH From Silicon Disk

3.4.1.2 Analogue Input Setup Dip-switches

Figure 3.4 SW2 Analogue Input set-up dip-switches location