DC3IOB Revision 080910 User Guide
Updated 3/29/10
Overview
The DC3IOB is a three axis DC brush motor drive with an integrated PLC. A range of motor drive
currents are selectable with jumper blocks. The integrated PLC includes 30 inputs, 31 digital outputs, and one
analog output (see “PLC Section” for details).
Drive current is set using jumpers for each axis, rather than changing current sensors. The 6, 9, and 12
amp current settings can be selected on any DC3IOB. The 3 amp setting is no longer a standard option. The 15
amp current setting will only take effect on high power DC3IOBs that have heavy duty drive components.
DC3IOB Features
Drive Application: DC Brush Motors
Number of Axes: 3
Current rating per axis: 6 to 15 Amps
Motor Voltage: 20 to 120 Volts
PLC Inputs: 30
PLC Outputs: 31
Spindle Analog resolution: 12 bits
Control Interface: 5 fiber optics to CPU10 compatible motion
control card with IO2PIC
or
4 fiber optics to MPU11 motion control
card
Dimensions (W*D*H): 16 * 8 * 5.25 inches
Logic Power Connection
An ATX style PC power supply provides voltage for DC3IOB logic circuits. The power supply
connector may have 20 pins or 24 pins on units equipped with an ATX 2.2 compatible supply. The -5V and
+5VSB pins are not used by the DC3IOB, but all other pins should be checked if troubleshooting a supply
problem.
DC3IOB Revision 080910 User Guide Page 1 of 14
ATX 2.0 Power Connector (H14) Optional ATX 2.2 Power Connector (H14)
COMMON
COMMON
+5V
COMMON
+12V
COMMON
+5V
+5V
+3.3V
-12V
COMMON
+5VSB
+5V
COMMON
+3.3V
+5V
POWER OK
+3.3V
+3.3V
COMMON
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
COMMON
/POWER ON
+12V
J11J11 J12 J12 J12J12J11 J11
POWER OK
-12V
COMMON
COMMON
+5V
COMMON
+5V
+3.3V+3.3V
/POWER ON
COMMON
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
COMMON
-5V
COMMON
+5VSB
+12V
+3.3V
+5V
COMMON
+5V
Drive Section
The DC3IOB drive section is based on Centroid’s proven DC brush motor drive technology. Several
built in features allow for easy integration with a variety of hardware.
Each axis can be built with a range of current ratings determined by jumper settings and drive hardware.
Current ratings of 6, 9, 12, and 15 amps can be provided on the DC3IOB. The following examples show the
various current settings for the first, or “X”, axis. The second axis uses jumpers J13 and J14, while the third
axis uses jumpers J9 and J10 for current setting.
6 Amp Setting 9 Amp Setting 12 Amp Setting 15 Amp Setting
Open collector output drivers are provided for a brake on each axis (see “DC3IOB Connections” and
“PLC Section” for wiring details). The brake output drivers can be wired to a 5 volt relay to release motor
brakes when each axis is enabled.
A drive fault relay output is provided for connection of the E-stop power loop. The relay contacts stay
closed as long as communication is valid and no serious faults exist.
An analog current request output is provided on the 3rd (Z on a mill) axis for running third party drives.
This feature is particularly useful for C axis lathe applications. The current request signal swings from –10
volts to +10 volts and is centered at 0 volts. This signal is used for spindle control in positioning mode. See the
“DC3IOB Connections” page to locate the C axis analog and C axis common pins.
PLC Section
The DC3IOB has 30 inputs, 31 digital outputs, and one analog output. Some I/O is dedicated to a
particular function, but 21 inputs and 29 digital outputs can be used for any purpose. See the “DC3IO I/O Map”
for an overview.
Twelve inputs are configurable types, 16 are sourcing, and 2 are internally wired. The internal drive
fault and error check inputs are dedicated and not user definable. X-, X+, Y-, Y+, Z-, and Z+ limit inputs are
not configurable for other uses since they are hard wired to drive circuitry that inhibits axis motion. The
emergency stop input is also dedicated, has increased pull up current, and disables spindle analog output when it
is high. The 21 remaining inputs can be configured for special purposes if necessary.
Signal relays are used on spindle outputs to provide a reliable connection on low level outputs when connecting
an inverter. Fused power relays are provided for the rotary clamp and other higher level outputs. Outputs that
DC3IOB Revision 080910 User Guide Page 2 of 14
Several output types are used on the DC3IOB. Relay outputs are provided for common functions.
are not used on many systems are open collector type. These outputs will usually need to drive an external 5
Sou rcing Input
5 GROUN D
IN P UT COM MON
+5 VDC
Internal Circuitry
IN P UT
IN P UT
Internal Circuitry
Configurable Input
CO MMO N
Internal Circuitry
Outp ut
Open Collector Outpu t
5 GROUND
+5 VDC
Fus ed SPST Output
Internal Circuitry
Outp ut Com mo n
Out put
Outp ut Co mm o n
NO
Internal Circuitry
NC
SPDT Sign al Output
Outp ut Commo n
NC
Fus ed SPDT Output
NO
Internal Circuitry
Analog Outpu t
-1 2 VD C
An alog Outp ut
An alog Gro un d
+1 2 VDC
Internal Circuitry
ANALO G
GROUND
-
+
volt relay to interface with higher power devices. Check the “DC3IOB I/O Map” and “DC3IOB Specifications”
sections to determine an output’s type and capability.
The spindle direction output is not available for other uses. The spindle analog section uses this output
to determine polarity when configured as a bipolar output (-5 to +5 or –10 to +10). Internal error checking
output and spindle speed bits are also dedicated, leaving 29 outputs definable for custom uses.
The DC3IOB analog output for spindle control has a 12bit resolution. This should not be confused with
the C axis analog output described in the “Drive Section”. Four analog output ranges can be selected. See the
“Spindle Analog Output Adjustment” section for jumper settings.
DC3IOB Revision 080910 User Guide Page 3 of 14
Auxiliary Configurable Inputs
J24
+24 VDC
IN20
Sinking (NPN) Sensor Wiring Example
H18
1
2
3
4
5
6
7
8
+24 CO M
Sourcing (PNP) Sensor Wiring Example
LOGIC GN D
Sensor
+24 CO M
J27
Sensor
+24 CO M
IN32
IN22
SIP 4
IN8
DC3IOB Auxiliary Inputs
+24 VDC
LOGIC +5V
Remove jumpers J24
and J25 when using
external supply
+24 CO M
IN7
External Power Supply
Remove jumpers J26
and J27 when using
external supply
LOGIC GN D
+24 VDC
IN21
SIP 3
IN26
+24 VDC
IN19
J25
IN28
SIP 1
IN27
H19
1
2
3
4
5
6
7
8
J26
External Power Supply
LOGIC +5V
SIP 2
IN17
IN10
Configurable inputs are available through the auxiliary input connectors for custom applications. These
inputs can be used with 5, 12, or 24 VDC sensors or switches. Compare the specifications of sensors to the
“DC3IOB Specifications” chart to ensure reliable operation. Resistor packs SIP1, SIP2, SIP3, and SIP4 must be
changed to match the input voltage for auxiliary inputs. Sinking or sourcing operation is determined by the
wiring configuration.
Jumpers J24 through J27 may be installed to power the inputs from the DC3IO’s logic power supply.
External power may be wired through pins 7 and 8 of H18 and H19. Make sure there are no jumper blocks on
J24, J25, J26, or J27 before applying external power, or the DC3IOB will be damaged.
Auxiliary Inputs Schematic
DC3IOB Revision 080910 User Guide Page 4 of 14
SIP Identification – XXX Indicates Value SIP Internal Wiring / Pinout
4308R-102
-XXX
J3
Pin 1
J4J2J1
J3J2J1 J4
Pin 1
J4J3J1
Pin 1
J2
J1 J4J2
Pin 1
J3
SIP Input Reference SIP Input Voltage Selection
SIP Value
SIP Designator Related Inputs
SIP1 17,19 471 470 5
SIP2 22,26,27,28 102 1.0k 12
SIP3 20,21 222 2.2k 24
SIP4 7,8,32,10
Marking Resistor Value (Ohms) Input Voltage
Spindle Analog Output Adjustment
Output voltage range can be set to 0 to +5VDC, 0 to +10VDC, -5 to +5VDC, or -10 to +10VDC by
setting jumpers J1, J2, J3, and J4 according to the diagrams below. Trimming the output can be accomplished
with VR1 and VR2 potentiometers. See the “DC3IOB Connections” diagram for the location of adjustment
hardware. The analog levels are adjusted at the factory for the 0 to +10VDC range, so only slight adjustments
should be needed for each installation. Only adjust the “OFFSET” potentiometer (pot) (VR2) at the minimum
possible spindle speed. This adjustment is intended only to null the voltage level when 0 RPM is commanded.
The “GAIN” pot (VR1) should be used at maximum speed to match actual RPM with commanded RPM.
Adjustments to the analog output should be very minor and cannot be used to compensate for incorrect inverter
or control settings.
0 to 10 VDC Jumper Settings 0 to 5 VDC Jumper Settings
-5 to +5 VDC Jumper Settings -10 to +10 VDC Jumper Settings
DC3IOB Revision 080910 User Guide Page 5 of 14
Fast I/O Operation
OUT40
6mS
OUT31
INP26
30mS
OUT31
OUT40
INP26
The Fast I/O is a hard-coded function that is enabled in legacy mode when output 40 is turned on in the
PLC program. The Fast I/O immediately turns off output 31 when a falling edge is detected on input 26. This is
done immediately before sending any data back to the control. The function is self-resetting - after output 31 is
turned off, output 40 must be turned on again in order to reactivate the Fast I/O. The Fast I/O feature was
developed to prevent a tool carousel from moving too far due to communication delays. When output 40 is off,
output 31 and input 26 work normally. Output 40 is not a physical output in legacy mode, since using this
output for purposes other than Fast I/O enable could cause confusion. In MPU11 mode, the Fast I/O feature is
not available, and output 40 is an open collector output.
Legacy Mode Timing - Fast I/O Enabled Legacy Mode Timing - Normal PLC Operation
DC3IOB Revision 080910 User Guide Page 6 of 14
Drive Features
Fiber 4
Fiber 5
Fiber 4
MPU11
Drive
Communication In
Drive
Communication Out
Fiber 4
Drive
Communication Out
Drive
Communication In
DC3IOB
DC3IOB
Fiber MPU11 5
Fiber MPU11 5
*J20 DRIVE SLAVE open
*J20 DRIVE SLAVE jumper block installed
Axis 1 - Axis 3
Axis 4 - Axis 6
Other drives may be connected to the DC3IOB through the “Drive Communication In” and “Drive
Communication Out” connectors. The “Drive Communication Out” goes to drives further away from the
MPU11 in the communication chain, and is always active. The “Drive Communication In” connector gets data
from drives closer to MPU11, and must be enabled by installing a jumper block on J20 “DRIVE SLAVE” pins.
Shorting the pins of J20 will cause the drive to look for communication on the “Drive Communication In” cable
connection rather than fiber optic connections “4” and “MPU11 5”.
LED1 status display will show the base or first axis number for the drive. For example, a DC3IOB that
is running axes 3, 4, and 5 will display 3 on LED1 as long as no error codes are present. The axis farthest from
the MPU11 in the communication chain will always be axis 1. Axis numbers increase along the chain toward
the MPU11, up to a maximum axis number of 8.
If error codes exist, the decimal point on LED1 will light and an error number will flash. See the “LED1
Error Codes” chart for information on error codes.
Drive Communication Connection for Two DC3IOBs
DC3IOB Revision 080910 User Guide Page 7 of 14
PLC Features
MPU11
Fiber 1
Fiber 3
Fiber 1
Fiber 3
I/O to PLC
PLC ADD 1
PLC ADD 2
PLC ADD 3
PLC ADD 4
Fiber 1
Fiber 3
I/O to PLC
PLC ADD 1
PLC ADD 2
PLC ADD 3
PLC ADD 4
I/O to PLC
Typical I/O expansion board
DC3IOB
*J19 PLC SLAVE open
*DC3IOB acts as main PLC
DC3IOB
*J19 PLC SLAVE jumper
block installed
*DC3IOB acts as I/O
expansion board
DATA TO EXPANSION CARD -
+12V *
CLOCK +
5V RETURN
DATA TO PLC -DATA TO PLC +
CLOCK -
* Power supply voltages are noted as part of the standard, but are
not used by the DC3IOB since it has its own power supply.
+5V * +12V AND -12V RETURN *
DATA TO EXPANSION CARD +
-12V *
5V RETURN
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
+12V AND -12V RETURN *
5V RETURN *
DATA TO PL C CLOCK -CLOCK +
+12V -12V
DATA TO EXPANSION CARD +
* +12V AND -12V RETURN and 5V RETURN are connected on the DC3IOB
+5V
DATA TO EXPANSION CARD -
DATA TO PLC +
5V RETURN *
1 2
3 4
5 6
7 8
9 10
11 12
PLC I/O expansion is possible through the four “PLC ADD” connectors. Each PLC expansion port can
accept 16 – 128 inputs, outputs, or inputs and outputs in 16 bit increments. This allows for digital I/O, DACs,
ADCs, or other devices to be added to the system as needed.
If two DC3IOB units are used in a system, one DC3IOB PLC may act as an expansion board to the other
DC3IOB to double the system’s I/O. The DC3IOB connected to the MPU11 through fibers 1 and 3 will act as
the main PLC card. The second DC3IOB must have a jumper block on the pins of J19 “PLC SLAVE” to
communicate through the “I/O to PLC” connector H6. An expansion cable may then be run from the “I/O to
PLC” connector to any of the four “PLC ADD” connectors on the DC3IOB communicating with MPU11.
PLC Communication Connection for Two DC3IOBs
I/O TO PLC Connector Pinout PLC ADD 1 – 4 Connector Pinouts
PLC I/O is arranged in 16 bit groups or slots. As a general rule, slots 0-14 are used for individual I/Os
such as switches and have a programmable debounce time for the inputs. Slots 15-47 are reserved for ADCs,
DACs, or other devices that do not require debounce. Every device using I/O space must use space in 16 bit
multiples by reserving slots. A DC3IOB operating as a PLC uses 2 slots for its inputs and 4 slots for outputs.
PLC expansion boards with inputs and outputs must have a matching number of input and output slots.
Therefore, a DC3IOB acting as an expansion board (PLC slave jumper installed) will use 4 slots for inputs and
4 slots for outputs. The I/O map remains unchanged for a DC3IOB working as an expansion card, except that it
is shifted up in the I/O space based on the slots it is assigned to.
Assignment of I/O slots occurs in a linear fashion starting at the main PLC, then “PLC ADD” port 1,
“PLC ADD” port 2, etc. In the following general example, local inputs and outputs represent a DC3IOB
working as the main PLC. Devices plugged into the “PLC ADD” ports that require debounce will be assigned
starting at the slots marked “A”, while devices that do not require debounce will start being assigned at the slots
marked “B”.
DC3IOB Revision 080910 User Guide Page 8 of 14
PLC Expansion Details
PLC Expansion Location Assignment General Example
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 47
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 47
ALocal Outputs
B
B
ALocal Inputs
Output Space
Input Space
Slot 16 Slot 17 Slot 18 Slot 19 Slot 20
Slot 15 Slot 16 Slot 17 Slot 18 Slot 19 Slot 20
Slot 15
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4
Input Space
DC3IOB DC3IOB
DC3IOB DC3IOB
Slot 5 Slot 6
16/16 ADD
16/16 ADD
Output Space
Slot 7 Slot 8
Slot 6 Slot 7 Slot 8
Slot 47
Slot 47
ADC / DAC Card
ADC / DAC Card
Slot 15 Slot 16 Slot 17
Slot 15 Slot 16 Slot 17
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4
Input Space
DC3IOB
DC3IOB
Slot 5 Slot 6
Output Space
Slot 7 Slot 8
Slot 6 Slot 7 Slot 8
Slot 47
Slot 47
ADC / DAC Card
ADC / DAC Card
16/16 ADD
16/16 ADD
DC3IOB
DC3IOB
Slot 15 Slot 16 Slot 17
Slot 15 Slot 16 Slot 17
Example 2 illustrates I/O assignments on a system that has a DC3IOB main PLC, a DC3IOB plugged into “PLC
ADD 1”, a 16/16 digital I/O expansion card connected to “PLC ADD 2”, and an ADC/DAC expansion card
plugged into PLC ADD 3. Note that the ADC/DAC expansion card is assigned starting at slot 15 since it does
not require debounce.
PLC Expansion Example 2
Example 3 shows the results of plugging an ADC/DAC expansion card into “PLC ADD 1”, a 16/16 digital I/O
expansion card into “PLC ADD 2”, and a DC3IOB into “PLC ADD 3”. The location of the ADC/DAC
expansion card I/O is unaffected since it is the only device in the example that does not require debounce. The
16/16 digital I/O expansion card and DC3IOB have changed locations since the 16/16 is plugged into a lower
number “PLC ADD” port and is therefore assigned I/O locations before the DC3IOB.
PLC Expansion Example 3
DC3IOB Revision 080910 User Guide Page 9 of 14
DC3IOB I/O MAP
Number Function Type Use Connector Pin Number Function Type Connector Pin
1 X- Limit Sourcing Dedicated H21 1 1 Emergency Stop Open Collector H9 1
2 X+ Limit Sourcing Dedicated H21 2 2 Lube Pump Fused Relay SPST H16 7,8
3 Y- Limit Sourcing Dedicated H21 4 3 Flood Pump Fused Relay SPST H16 9,10
4 Y+ Limit Sourcing Dedicated H21 5 4 Mist Solenoid Fused Relay SPST H17 7,8
5 Z- Limit Sourcing Dedicated H21 7 5 Carousel Direction Open Collector H9 2
6 Z+ Limit Sourcing Dedicated H21 8 6 Carousel Out Solenoid Open Collector H9 3
7 W- Limit
8 W+ Limit
9 Range Sourcing General H20 11 9 Carousel In Solenoid Open Collector H9 6
10 5th+ Limit
11 Emergency Stop Sourcing Dedicated H21 10 11 Spindle Chiller Open Collector H9 8
12 Servo Drive Fault Internal Dedicated N/A N/A 12 Spindle Cooling Fan Open Collector H7 1
13 TT1 Sourcing General H21 11 13 Spindle Direction Signal Relay SPDT H16 1,2,3
14 Probe Sourcing General H20 1 14 Spindle Enable Signal Relay SPDT H17 1,2,3
15 Probe Detect Sourcing General H20 2 15 Inverter Reset Signal Relay SPDT H16 4,5,6
16 Error Check Internal Dedicated N/A N/A 16 Error Check Internal N/A N/A
17 Door Interlock
18 Low Lube Sourcing General H20 4 18 Spin. Speed Bit 1 Internal N/A N/A
19 Spindle Zero Speed
20 Spindle At Speed
21 Spindle Orient Complete
22 Tool Clamped
23 NOT USED N/A N/A N/A N/A 23 Spin. Speed Bit 6 Internal N/A N/A
24 Tool Release Switch Sourcing General H20 5 24 Spin. Speed Bit 7 Internal N/A N/A
25 Spindle Drive Fault Sourcing General H20 7 25 Spin. Speed Bit 8 Internal N/A N/A
26 Tool Counter *
27 Carousel Out / TP Up
28 Carousel In / TP Dwn
29 NOT USED N/A N/A N/A N/A 29 Gear Change Open Collector H7 2
30 Rotary Home Sourcing General H20 8 30 Rotary Clamp Solenoid Fused Relay SPDT H17 4,5,6
31 Rotary Clamped Sourcing General H20 10 31 Carousel Enable * Open Collector H7 3
32 Air Pressure Low
33 NOT USED N/A N/A N/A N/A 33 Green Light Open Collector H7 5
34 NOT USED N/A N/A N/A N/A 34 Yellow Light Open Collector H7 6
35 NOT USED N/A N/A N/A N/A 35 Worklight Open Collector H7 7
36 NOT USED N/A N/A N/A N/A 36 Auxiliary 1 Open Collector H7 8
37 NOT USED N/A N/A N/A N/A 37 Auxiliary 2 Open Collector H5 1
38 NOT USED N/A N/A N/A N/A 38 Auxiliary 3 Open Collector H5 2
39 NOT USED N/A N/A N/A N/A 39 Auxiliary 4 Open Collector H5 3
40 NOT USED N/A N/A N/A N/A 40 Fast I/O Enable * N/A N/A N/A
41 NOT USED N/A N/A N/A N/A 41 NOT USED N/A N/A N/A
42 NOT USED N/A N/A N/A N/A 42 NOT USED N/A N/A N/A
43 NOT USED N/A N/A N/A N/A 43 NOT USED N/A N/A N/A
44 NOT USED N/A N/A N/A N/A 44 NOT USED N/A N/A N/A
45 NOT USED N/A N/A N/A N/A 45 NOT USED N/A N/A N/A
46 NOT USED N/A N/A N/A N/A 46 NOT USED N/A N/A N/A
47 NOT USED N/A N/A N/A N/A 47 NOT USED N/A N/A N/A
48 NOT USED N/A N/A N/A N/A 48 NOT USED N/A N/A N/A
49 NOT USED N/A N/A N/A N/A 49 NOT USED N/A N/A N/A
50 NOT USED N/A N/A N/A N/A 50 NOT USED N/A N/A N/A
51 NOT USED N/A N/A N/A N/A 51 NOT USED N/A N/A N/A
52 NOT USED N/A N/A N/A N/A 52 NOT USED N/A N/A N/A
53 NOT USED N/A N/A N/A N/A 53 NOT USED N/A N/A N/A
54 NOT USED N/A N/A N/A N/A 54 NOT USED N/A N/A N/A
55 NOT USED N/A N/A N/A N/A 55 NOT USED N/A N/A N/A
56 NOT USED N/A N/A N/A N/A 56 NOT USED N/A N/A N/A
57 NOT USED N/A N/A N/A N/A 57 NOT USED N/A N/A N/A
58 NOT USED N/A N/A N/A N/A 58 NOT USED N/A N/A N/A
59 NOT USED N/A N/A N/A N/A 59 Auxiliary 13 Open Collector H5 4
60 NOT USED N/A N/A N/A N/A 60 Auxiliary 14 Open Collector H5 5
61 NOT USED N/A N/A N/A N/A 61 Auxiliary 15 Open Collector H5 6
62 NOT USED N/A N/A N/A N/A 62 Auxiliary 16 Open Collector H5 7
* Fast I/O Related
*In MPU11 compatibility mode, Output 40 is Auxiliary 17 Open Collector on H5 pin 8
Input Specification Input Location Output Specification Output Location
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
Configurable
General H18 1 7 Tool Clamp Solenoid Open Collector H9 4
General H18 2 8 Air Blow Through Open Collector H9 5
General H18 4 10 Orient Open Collector H9 7
General H18 5 17 Spin. Speed Bit 0 Internal N/A N/A
General H18 6 19 Spin. Speed Bit 2 Internal N/A N/A
General H19 1 20 Spin. Speed Bit 3 Internal N/A N/A
General H19 2 21 Spin. Speed Bit 4 Internal N/A N/A
General H19 3 22 Spin. Speed Bit 5 Internal N/A N/A
General H19 4 26 Spin. Speed Bit 9 Internal N/A N/A
General H19 5 27 Spin. Speed Bit 10 Internal N/A N/A
General H19 6 28 Spin. Speed Bit 11 Internal N/A N/A
General H18 3 32 Red Light Open Collector H7 4
Drive Fault Power Relay SPST H17 9,10
X Brake Open Collector H1 1
Y Brake Open Collector H1 2
Z Brake Open Collector H1 3
DC3IOB Revision 080910 User Guide Page 10 of 14
DC3IOB Specifications
Characteristic Min. Typ. Max. Unit
3.3 Volt Supply Current 1 - - A
5 Volt Supply Current 2 - - A
12 Volt Supply Current 0.2 - - A
-12 Volt Supply Current 0.2 - - A
Input Pullup Voltage (Vinp) - 5 - VDC
Input On Voltage Vinp-1.25 - - VDC
Input Off Voltage - - 1.25 VDC
Power Relay Output Current 0.01 - 10 A @ 125VAC
Power Relay Output Current 0.01 - 5 A @ 30VDC
Signal Relay Output Current 0.001 - 0.5 A @ 125VAC
Signal Relay Output Current 0.001 - 1 A @ 24VDC
Open Collector Output Current - 10 90 mA
Open Collector Output Voltage - 5 5 VDC
Input Operating current 9 11 15 mA
Analog Output Resolution - 12 - bits
Analog Output Voltage -10 - 10 VDC
Analog Output Current 0 1 20 mA
Motor Output Current Settings 6 12 15 A
Motor Supply Voltage 20 115 130 VDC
MPU11 Mode Fiber Length - - 100 feet
Size: 16 * 8 * 5.25 (W*D*H) Inches
DC3IOB General Troubleshooting
Symptom Possible Cause Corrective Action
All status LEDs out Logic power not applied Measure AC coming into power supply,
correct wiring or supply problems
5, 3.3, or 12 LED out Power supply or connection problem Measure AC coming into power supply,
correct wiring or supply problems
5 LED out, 3.3 and 12 LEDs lit 5 volt logic supply missing Damage has probably been done due to
incorrect connection to the AUX OUTPUTS
headers, return for repair
+12V, -12V, or +5V LED out Analog section power loss If other power LEDs are lit, the analog section
has probably been damaged by incorrect
connection, return for repair
XVCC LED out PLC input supply missing If 5 LED is lit, the PLC input section has
probably been damaged by incorrect
connection, return for repair
LED1 display flashing with
decimal point lit
LEDs on, but motor doesn't run Axis Fuse blown Check fuses with a meter, replace as necessary
Limits tripped Check limit switch wiring or pull up the limit
Input doesn't work with sensor Incorrect wiring Correct wiring for sensor type (sinking or
Voltage drop across sensor is too high Use 3-wire sensors with lower voltage drop
An error condition has been detected See the "LED1 Error Codes" section for details
on the error
defeat switches
sourcing), check that SIP values are
appropriate for the input voltage
spec.
DC3IOB Revision 080910 User Guide Page 11 of 14
DC3IOB Legacy Mode Troubleshooting
Symptom Possible Cause Corrective Action
DF LED out Motion control card hasn't booted up Start software, wait for the main screen to load
Fibers 4 and 5 connected incorrectly or
faulty
"Servo Power Removed" due to fault Restart system to reset runaway or other
Incorrect .HEX file Make sure CNC8.HEX is loading
PLC OK LED out Motion control card hasn't booted up Start software, wait for the main screen to load
Fibers 1, 2, or 3 connected incorrectly or
No analog output or non-linear
output
faulty
Incorrect PIC on CPU7 Install IO2PIC
Incorrect Parameter 31 setting Set P31 to -1
Check connections one at a time, swap with a
known good set of fibers
serious fault condition
Check connections one at a time, swap with a
known good set of fibers
DC3IOB MPU11 Mode Troubleshooting
Symptom Possible Cause Corrective Action
DF LED out Motion control card hasn't booted up Start software, wait for the main screen to load
Fibers 4 and MPU11 5 connected
incorrectly or faulty
"Servo Power Removed" due to fault Restart system to reset runaway or other
PLC OK LED out Motion control card hasn't booted up Start software, wait for the main screen to load
Fibers 1 or 3 connected incorrectly or
faulty
Check connections one at a time, swap with a
known good set of fibers
serious fault condition
Check connections one at a time, swap with a
known good set of fibers
LED1 Error Codes
Error
Number Meaning Cause Corrective Action
1 Power Failure the logic power supply is indicating to
the DC3IOB that it is operating out of
specification
2 15A Not Available current selection jumpers on any axis are
set to 15A, but the drive is not equipped
with the appropriate FETs for long term
use at 15A, so the drive will drop back to
12A
3 Null Error the self adjust routine has detected too
large an offset on the current feedback
4 Limit Tripped any limit switch is tripped move away from the limit,
Check power supply wiring
(the grey wire and AC input
in particular), replace power
supply
Select 12A or lower current
settings or use a high power
DC3IOB
Send the drive back for
repair. There is likely an
internal failure causing the
large offset
check limit switch wiring, or
use the limit defeat switches
if a limit switch is not
required
DC3IOB Revision 080910 User Guide Page 12 of 14
DC3IOB Connections
+5V
X- Limit Input (1)
* Auxiliary 17 only available in
MPU11 compatibility mode
J24
PLC Expansion 2
D C3 IOB 080 910
Aux. In. 1 Common +
1
Tool Counter (26)
Spindle Enable N.O. (14)
SIP3
J14
Y Motor -
Drive Out TX-
Drive Fault LED
Spindle Direction Common
Gear Change (29)
PLC Expansion 3
MPU11 5
Tool Clamp (7)
Aux. In. 1 Common -
J4
X Motor +
+5VDC
X+ Limit Input (2)
Rotary Home Input (30)
PLC Expansion 1
Spindle Common
Internal Power Jumpers
for Auxiliary Inputs
Chassis Ground
SIP4
Car. Direction (5)
Spindle Reset N.O. (15)
3
Drive Fault Common
I/O to External PLC
2
INT
Pin 1
Auxiliary 14 (60)
Y Brake Driver
J9
Chassis Ground
Drive
Communication
Out
Pin 1
5V LED
Air Blow (8)
C Axis Common
Pin 1
Rotary Clamp N.C.
PLC OK LED
J25
Door Switch (17)
+5VDC
Spin. Chiller (11)
J2
Red Light (32)
Pin 1
Pin 1
Current Setting Z
Auxiliary 16 (62)
Drive
Communication
In
Flood Pump Out (3)
Tool Clamped (22)
Pin 1
Auxiliary 4 (39)
Car. Enable (31)
2
J11
Drive Fault Out
X Brake Driver
Pin 1
Motor Ground
Z Brake Driver
Logic GND
X+ Limit Defeat
Car. Out (6)
3.3V LED
LED1
Logic GND
Mister Out (4)
Auxiliary 2 (37)
Yellow Light (34)
Pin 1
Z+ Limit Input (6)
Logic GND
+5VDC
Pin 1
Rotary Clamp Common
Lube Pump Out (2)
J26
12V LED
Pin 1
Z- Limit Input (5)
Current Setting X
Drive In RX+
J10
N/C
DP4 Input (14)
Tool Release Input (24)
Auxiliary Input Connector 2
1
+5V LED
J12
Logic GND
Car. In (9)
Spindle Enable N.C.
W- Limit (7)
Pin 1
Auxiliary 15 (61)
Pin 1
X Motor -
Orient (10)
Drive In RX-
Work Light (35)
Spindle Direction CCW (13)
Auxiliary Input Connector 1
+12V LED
+5VDC
Auxiliary 1 (36)
Logic GND
Spin. Cooling Fan (12)
Range Input (9)
J1
W+ Limit (8)
Low Lube Input (18)
Y+ Limit Input (4)
Spindle Reset Common
Inverter Fault Input (25)
J27
J3
Drive In TX-
Z+ Limit Defeat
-12V LED
Estop Input
Auxiliary 3 (38)
Logic GND
Spin. at Spd. (20)
Z- Limit Defeat
Current Setting Y
DP4 Detect Input (15)
Mister Common
PWR
Drive In TX+
Z Motor -
Spindle Enable Common
INT
Status Display
Air Low (32)
Pin 1
N/C
Aux. In. 2 Common +
Lube Pump Common
GA IN
Y- Limit Defeat
+5VDC
Logic GND
4
X- Limit Defeat
Drive Out TX+
Emergency Stop (1)
TT1 Input (13)
C Axis Analog
VR1
PLC Fiber
Connectors
XVCC LED
Pin 1
+5VDC
Logic GND
Y- Limit Input (3)
SIP2
Car. In (28)
Motor Voltage
Spindle Reset N.C.
Car. Out (27)
Z Motor +
VR2
OF FS ET
5
Flood Pump Common
+5VDC
Aux. In. 2 Common -
ATX Power Supply Connection
Rotary Clamp N.O. (30)
PWR
Green Light (33)
J13
Pin 1
Spindle Analog
Y Motor +
Drive Out RX+
* Auxiliary 17 (40)
Spindle Direction CW
Y+ Limit Defeat
PLC Expansion 4
5th+ Limit (10)
N/C
Spin. Zero Spd. (19)
Drive Fiber
Connectors
Rotary Clamp Ack. Input (31)
Auxiliary 13 (59)
SIP1
+5VDC
Spin. Orient Comp. (21)
Chassis Ground
Drive Out RX-
DC3IOB Revision 080910 User Guide Page 13 of 14
DC3IOB Mounting Footprint
Pin 1
J10
PWR
J27
J9
Pin 1
-12V LED
Aux. In. 1 Common -
16.000"
12V LED
J13
Pin 1
LED1
Current Setting Y Current Setting X
5V LED
J26
Pin 1
PWR
SIP1
(396.9mm)
J12
PLC Expansion 3
OF FS E T
Drive
Communication
In
15.625"
J4
2
PLC Expansion 2
Current Setting Z
Pin 1
J14
SIP2
Spin. Zero Spd. (19)
+12V LED
Pin 1
J25
SIP4
(406.4mm)
J1
INT
Pin 1
5th+ Limit (10)
Internal Power Jumpers
for Auxiliary Inputs
Aux. In. 1 Common +
+5V LED
Auxiliary Input Connector 1
PLC Expansion 4
Pin 1
Drive
Communication
Out
J24
Pin 1
Pin 1
PLC Expansion 1
(203.2mm)
Door Switch (17)
Pin 1
VR1
INT
8.000"
3.3V LED
1
W- Limit (7)
J11
7.250"
J2
(184.2mm)
Pin 1
VR2
GA IN
D C 3IO B 0 8091 0
Pin 1
SIP3
Auxiliary Input Connector 2
J3
W+ Limit (8)
Status Display
Pin 1
Pin 1
Air Low (32)
I/O to External PLC
DC3IOB Revision 080910 User Guide Page 14 of 14
Loading...