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iCON-PC System

Technical Manual- Hardware DOC. TMH-D13-03C-PC

VER: 3.7

Disclaimer:

We have made a sincere effort to ensure the accuracy of the material described herein; however the

author and System Electronics Pty Ltd make no warranty expressed or implied with respect to the

quality, correctness, reliability, currentness, accuracy or freedom of error of this documentation of

the product it describes. We make no representation or warranty with respect to the contents

hereof and specifically disclaim any implied warranties of fitness for any purpose. The author and

System Electronics Pty Ltd disclaim all liability for any direct, indirect, incidental or consequential,

special or exemplary damages resulting from the use of this product or from the use of any other

products described within this document.

Please refer to our website http://www.icontrol.net.au for any corrections or improvements to this

manual.

© 2013: System Electronics Pty. Ltd.

Contents:

Page No.

Introduction 1

iCON-F Basics and documents for the iCON system 2

iCON Connectors and Mini Cards 2

HMI Human Machine Interface 3

Dimensions iCON-L / Mounting 4

General configuration and Functionality 5

Supervisory functionality for iCON controllers 6

Environmental Specifications for iCON equipment 6

Electrical Specifications for iCON equipment 6

Power (24V DC) connections CON5 7

Comms connections CON8 8

Inputs connections CON3 and CON4 8

Digital Encoder / Scale inputs CON1 9

Servo Drive outputs CON2 10

Relay Drive Outputs CON6 and CON7 10

OPTION CARD PWD-A D13-01B CON9 and CON11 and CON12 11

OPTION CARD PWD-D D13-02B 12

Earthing Techniques 13

Cable Types 13

Emergency Stop 13

Connector Wiring 14

Overall connection 4 Axis 14

Overall connections 6 Axis 14

Technical Manual- Hardware

© System Electronics Pty. Ltd. 2013 See www.icontrol.net.au for more information about iCON Page 1

Introduction:

The range of iCON controllers offers comprehensive automation solutions to many of the control

problems found across industry today with the various machine tools found on the factory floor. To

solve these multiple problems System Electronics Pty Ltd. chose to utilise the static work platform of

the iCON controller hardware combined with variable software customised for each individual

application as required.

New applications in each family group are constantly being considered and developed. The current

range of applications are listed on our web site. More applications are being added all the time:

Full details of each application can be found on our website – www.icontrol.net.au.

Every iCON application, utilises the iCON Motion controller. PN: iCON-D13-03C. This device is

described fully in this manual. The system is complete when an HMI is added. The HMI should be a

PC based product of at least 800x480 pixel resolution and be running Win CE 5 or CE 6. An RS232 link

sets up the communications link between the iCON Motion controller and the HMI.



iCON Application Range:

Descriptions and Documents:

Full application descriptions can be referenced on www.icontrol.net.au refer to the “APPLICATIONS”

drop menu on the home page.

Standard Documents:

Application documents are provided which will assist the engineer to design and document the

project.

1. The Application graphic description

2. Typical application “Wiring Circuit” connections. Could be several of these with various options.

3. Operator’s manuals see specific application.

4. Wiring Schedule for each application.

5. Hardware Technical Manual (this document).

6. Software Technical Manual.

All of these documents are on the www.icontrol.net.au for download. They are updated as required.

iCON-Motion Controller showing 6 axis option

Each connector facilitates a specific function see details:

CON 1 Page 9 CON 9 Page 11




CON 5 Page 7

CON 6 Page 10

CON 7 Page 10

CON 8 Page 8



iCON Hardware: The HMI (Human Machine Interface) Touch Screen

The iCON HMI is a 7” or a 10.2” embedded all in one PC running WinCE OS version 5 or 6.

Connections to the iCON-L controller see CON8. Screen resolution is set at 800 x 480 pixels with a

resistive touch screen. Ethernet, USB and at least 1 x RS232 is required.

7” Screen (HMI-7):

10.2” Screen (HMI-10):



iCON Controller Dimensions:

iCON Motion controller:

iCON Controller Mounting:

The iCON-L are supplied with DIN rail mounting.

The HMI is supplied as a surface mount item to fit into an electrical enclosure.

The electrical enclosure used should be rated to at least IP55.

This mounting technique is for a stationary low vibration environment and is not recommended for

mobile applications.

Note: It is very important to appreciate that iCON is not simply a controller but a precision measuring

instrument designed to ensure as high a level of accuracy and control as possible within the limits of

the machinery and workshop environment. It is, therefore, imperative that the iCON is installed in

most suitable location to avoid EMC from mains and air borne sources. Avoid locating within 500mm

from any inverter type system.

Typical noise avoidance techniques should be used such as screened cables and earthing

considerations. Route iCON cables away from mains cable to motors and high current loads.



iCON General Configuration and Functionality:



iCON Supervisory Functions (iCS):

iCON is self supervising for correct software and hardware and system operation.

1. Software Supervision is continuous and perpetual in the form of software and hardware

Watchdog timers.

2. Hardware Supervision( iCS) is continuous and perpetual and is performed on all output drive

electronics to detect no load and overload conditions. These checks are on the iCON

controller itself and the optional expansion hardware cards when installed.

3. System Supervision (iCS) consists of on board temperature and input voltage monitoring and

logging. System current is monitored at the DC USER 24V output to the field devices. Thus

each I/O field device can be assigned a current level. If such a value is found in use to be

outside limits then that I/O device will be flagged as Not Available. Generally such a

malfunction will result in iCON forcing and software E Stop condition.

4. The interconnection between iCON and its HMI is monitored. Should a malfunction occur

then it will flagged via the indicator lamp flash on the controller front panel.

5. For further information about these “testing” and supervisory functions refer to the

“Technical Manual- Software”.

iCON Environmental Specifications

• Protection rating: IP20 (requires enclosure)

• Temperature Range Storage and Transport: -20 to +70deg. C

• Temperature Range operation: 0 to 55 deg. C

• Humidity Range for operation: 15 – 95% non-condensing.

iCON Electrical Specifications

• Input power supply 24V dc +/-5% at a current range of 1 to 6Amps.

• It is required that the power supply be sourced from a 110/240AC to 24V DC switched supply

to the current capacity required. This power supply should be accredited to CE and UL or any

other standards required by the power authorities in the territory of use.

• Note that to preserve full Supervisory functions field devices (up to6 amps) will be operated

from the DC USER supply terminal on the iCON controller. See figure below.

• Minimum iCON system current 1A.



Power Input Connections

Connect at terminal CON5.

For power calculations consider all field equipment and allow500mA. for iCON itself. This figure

includes the HMI at 300mA.

Note:

• Power for the outboard systems such as relays and valves and actuators can be taken from

the “DC USER” terminal. This supply is through the ESTOP contact. The ESTOP contact is

internally supervised by ISOIN01 (internal connection). The ESTOP normally closed contact

opens and isolates the DC USER supply from the field actuating devices. As the contact is also

monitored by iCON it will initiate a controlled stop on the servos and actuating devices by

removing enable signals and servo output drive signals.

• The A ammeter shown monitors current out to DC USER. This feature can be configured to

monitor field current under various operational modes. Refer “Supervisory functions”.

Page5.

• Encoder supply voltage selection is set at 5V or 24V. Linking CON5/6 to CON5/2 selects 24V

as encoder power. Linking CON5/3 to CON5/2 selects 5V.



HMI / Comms Connections

Isolated Inputs

• Connect communications at

CON8

• iCON to HMI interconnect not

grater that 20 Meters in

distance.

• Cable to be sized 24V at 0.4A.

CON8/8, CON8/7,

• Use aluminium shielded cable

and connect drain wire as

shown. Max

capacitance=1000pf..

• CON8/6, CON8/5 signal wires to

HMI DB9 connector.

• RS485 reserved for Modbus and

ICON extension options.

• Connections at CON3 and

CON4.

• All inputs to iCON controllers

are “pull high” exciting an opto

isolator . Thus a current of

about 4 to 5Ma will flow

through the input contact when

it is closed.

• 16 Opto Isolated inputs are

provided with iCON-L at

terminals CON 3 and CON4.

• General purpose inputs are

usually active when pulled high

(closed circuit to activate

change of state). The important

exceptions are the Emergency

Stop and the Over-travel Limit

switches, which change state

when the change is from closed

to open contact.

• I max= 30mA.

• I min=5mA.

• V max = DC USER +0.5V.

CON3/1.



Encoders/transducers Quadrature Inputs :

• Connect at terminals CON1

• ICON receives up to 4 Quadrature Count Inputs.

• Transducer excitation is selectable as 5V or 24V. For selection see CON5 page 7.

Specifications

Transducer Excitation: 5V at 100mA each total 450mA. 24V at 100mA each to total 450mA.CK1;

CK2 and Index: +5V to 24V

Vmax low :300mV

Vmin high:5V

Max count frequency: 150Khz

On board pull up resistor: 3K3

Filtering :Low pass on input. Digital filtering at counter.

Scaling: x1, x2 , x4 see software parameters.

NOTE: INDEX is normally high with LOW GOING PULSE.



Servo Drive Outputs:

Relay Drive Outputs

• Connect at CON2

• iCON delivers 4 analog output

signals

• SERVO 1 to 4 at 12 bit +/-10V at

max current 10mA.

Each output can be configured for

unipolar or bipolar operation. See

parameters.

Connect at CON6 and CON7

• 16 Relay drive outputs are available

with iCON from terminals CON7 and

CON6.

• Each output is driven high to 24V (DC

USER). With respect to USER GND.

• Outputs are current limited and

temperature limited. Max current per

output 0.15A.

• Output drivers are supervised for

open circuit and short circuit

conditions.

• Output drivers are supervised for

error outputs from iCON commands.

• These outputs are part of the iCON

supervisory system.



iCON Option Modules:

OPTION: PWD-A (4 channel 16 Bit ADC, 8 x PWM at 2A, 4 PWR at 2A).

PWM Drivers:

PWR Drivers:

• Connect to CON9

• 4 channel 16 bit ADC. Usually

reserved for applications which

use resistive transducers for

position feedback.. Inputs to low

pass filter.

• The 5.00V and the -5.00V

excitation outputs sink and

source 10mA max.

• Scale span to distance see

parameters settings.

Connect to CON11

• An active (application specific)

module type. It offers 8 high side

Mosfet drivers. Type IPS6031.

• Monitored Mosfet driver. (iCS)

• However this module is rated at

Max per driver 2A with a total

input current of 6A through the

card at any time. The module is

designed to drive PWM at 1Khz

with a resolution of 2000.

Connect to CON12

• An active high side Mosfet driver

(IPS6031.

• Monitored Mosfet driver . (iCS).

• However this module is rated at Max

per driver 2A with a total input

current of 6A through the card at any

time.



OPTION: PWD-D (2 Channel Servo CH5 and CH6 , 8 x PWM at 2A, 4 PWR at 2A).

See CON11 and CON 12 above for connections of the PWM and the PWR driver outputs.

Connect to CON10 for

SERVO5.

Connect to CON9 for SERVO6.

• Refer to CON2 and CON 3 for

connections and

specifications.



Electrical Connections:

Earthing Techniques

• Sound earthing techniques will facilitate robust operation of the iCON system. Generally all

signal cables (Analog out, Quadrature and Analog In) should be shielded.

• NOTE: At least 1 terminal labeled as DRAIN should be connected to EARTH. (the building

earth or earth stake).

• Generally an aluminum foil shield with drain wire is preferred, with the drain wire connected

to the terminal provided at the CON terminals on iCON. This drain should be connected at

the iCON end only.

• iCON will operate slightly differently from install to install with respect to noise immunity and

other general interference exciters.

Cable Types

• The 12 and 8 way connector plugs which mate with the iCON CONs (Connectors

1,2,3,4,5,6,7,8) are designed to accept cable diameters from 16 to 28 AWG (1.2mm to

0.3cm). The cable should be stripped back to 7mm fix with 2.0 to 2.5 mm screwdriver.

• Maximum current for a signal terminal is 200mA.

• Maximum current for a power terminal is 6 amps.

• Low current carrying instrument cables should be used whenever possible.

• High input current drives, 1mm dia. (minimum) multistrand cable. Cables for power PWM

drive should be shielded.

Emergency Stop

Emergency stop connections are to be in accord with the legislative rules set out in the territory I

which the iCON system is to be used. But the following is a minimum guide to the requirements.

iCON 24V power connections are set up to facilitate the breaking of DC USER power to all output

field devices when E Stop is active.

This function can be accomplished with a E Stop relay which will open when Emergency stop

switches become active. Often it is legal requirement that the main power to the machine tool is also

interrupted. (the main hydraulic pump for example).

Emergency Stop causes the main motor to stop and enabling relays are de-energised by power

removal. On opening of any Emergency Stop contact, it is imperative that the machine tool stops.

This action is the responsibility of the installer of the iCON system.

iCON monitors the Emergency Stop relay and will report “EMERGENCY STOP” and all iCON

movement requests will be cancelled.

The placement of Emergency Stop devices is beyond the scope of this manual; however, at least ONE

(1) emergency stop switch should be within easy reach of an operator during operation.



Connector Wiring

Each iCON application requires special iCON connections for that application. By reference to that

application at www.icontrol.net.au. The document “Wiring Schedule” is used on site for reference. If

complete as designed then this document becomes part of the “As built” for the project. Refer also

to the application “Wiring Circuit”. More than one of these example circuits may be published for

the application in order to detail various options and features.

Connections 4 Axis iCON Motion controller

Connections 6 Axis iCON Motion controller

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