Table (1) summarizes the internal circuitry of the Radonix controller board.
|
Terminals |
Terminal Identification |
Description |
|
Ethernet connection |
Computer Connection |
To communicate with a computer under TCP/IP protocol, please refer to section 2.2.1 for more information. |
|
DC24V, DC0V |
Power Supply |
For the main power supply of the controller, please refer to section 2.2.2 for more information. |
|
Input connector |
Digital Inputs |
For communication with external controllers, please refer to section 2.2.3 for more information. |
|
Output connector |
Digital Outputs |
For communication with external controlled devices, please refer to section 2.2.4 for more information. |
|
Output Analog & PWM |
Analog and PWM Outputs |
For communication with external controlled devices, these outputs create a continuous value between 0 and 10 volts. Please refer to section 2.2.5 for more information. |
|
Axis |
Axis |
For communication between the controller’s axes and servo and stepper motors, please refer to section 2.2.7 for more information. |
|
Handwheel |
Handwheel |
It is designed for communication with a handwheel, please refer to section 2.2.7 for more information. |
|
RS485 communication connector |
RS485 |
For communication with RS_485, please refer to section 2.2.7 for more information. |
Table (1) – Wiring and Internal Circuit of the Controller
Communication with a Computer
The PC-Pro-Lan and PC-Smart series Radonix controllers communicate with a computer using the TCP/IP protocol and are connected through an Ethernet connection in a standard manner. (Refer to Figure 2) Standard CAT5 and CAT6 cables, up to 30 meters in length, can be used for communication. The wiring on both sides of the cables is depicted in Figure 3.
⚠️ Keep in Mind that it is advisable for the path of the communication cable to not be in close proximity to high voltage cables and to not be exposed to pressure or impact along its route.
Figure (2) – LAN cable
Figure (3) – Wiring of LAN cable
Power Supply
Power Supply The Radonix controllers are connected to the power supply via a 3-pin terminal. The positive terminal (24+) is connected to the positive pole of the power source, and the negative terminal (GND) is connected to the negative pole. (Refer to Figure 4 for the GND connection)
Figure (4) – Power Supply Connector
⚠️ Power Connector The positive pole of the controller is protected by a diode, which prevents damage to the controller if the poles are switched. The electronic circuit diagram of the controller is depicted in Figure 5.
Figure (5) – Schematic of the Electronic Power Supply Circuit
The power supply voltage for PC-Pro models should be between 18 and 28 volts, and for PC-Smart models it should be between 12 and 24 volts, requiring a current of fewer than 0.5 amps. Switching power supplies are the most suitable type for the Radonix controllers because they are not significantly affected by changes in network voltage. It is recommended to use 24V switching power supplies to power the Radonix controllers. Calculating Power Supply Current To determine the required power supply current in the electrical panel, the current consumption of each element connected to the power supply must be calculated. For example, if there are 4 relays, 3 pneumatic solenoid valves, and a controller in a switchboard, the current consumption can be determined using Ohm’s law (V=I*R).
The electric currents should be calculated and their sum considered as the current of the power supply, along with a confidence factor of a few percent. For example, if the current consumption of the relays is 0.1A and that of the solenoid valves is 0.25A, the total current can be calculated as follows:
Total current = controller current + relay current + solenoid valve current IT = 0.5 + 4 * 0.1 + 3 * 0.25 = 1.65A
Therefore, by choosing a 2A pow`er supply, a good reliability factor will be maintained.
Power Consumption of Significant Elements
It is important to calculate the current consumption of elements that impose a significant load on the power supply. Elements such as brakes, servo motors, and pneumatic valves are examples of such elements. The power consumption of these elements can be calculated using an ammeter or by using Ohm’s law (V=I*R). The ohmic resistance of each element can be measured using an ohmmeter and then, considering the source voltage, the equivalent current consumed by each element (I=24R) can be calculated.
Digital Inputs
The digital inputs of Radonix controllers are named as I.[n], where n is a number greater than zero and represents the input number. These inputs are isolated by optical couplers and have low noise tolerance due to their low impedance. (Figure 6)
Figure (6) – Digital Inputs
The digital inputs on Radonix controllers have the capability to switch between NPN and PNP modes depending on the output of the device or sensor. The mode changeover switch must be set to PNP position for devices with PNP output and NPN position for devices with NPN output. The internal circuit schematics for both NPN and PNP modes on PC-Pro and PC-Smart models can be seen in Figures 7 and 8.
Digital input schematic in NPN mode for PC-Pro models:
Digital input schematic in PNP mode for PC-Pro models:
Figure (7) – Schematic of Digital Inputs in NPN and PNP Mode in PC-Pro Models
Digital Input Schematic in NPN and PNP modes in PC-Smart models:
Figure (8) – Schematic of digital inputs in NPN and PNP modes in PC-Smart models.
In various branches of industrial automation, there are equivalent terms for PNP and NPN. Some examples of these terms include:
NPN = Sink = Low Active
PNP = Source = High Active
Is done by connecting the positive terminal of the device to the input terminal and the negative terminal to the common terminal (GND). In PNP mode, the connection is done by connecting the negative terminal of the device to the input terminal and the positive terminal to the positive power supply (+Vcc). The wiring diagrams for these connections are shown in Figures 9 and 10.
Connection of digital inputs with switchboard elements in NPN mode in PC-Pro models:
Connection of digital inputs with switchboard elements in PNP mode in PC-Pro models:
Figure (9) – Connection of digital inputs with electrical panel elements in NPN and PNP mode in PC-Pro models
Connection of digital inputs with electrical panel elements in NPN mode in PC-Smart models
Connection of digital inputs with electrical panel elements in PNP mode in PC-Smart models
Figure (10) – Connection of digital inputs with electrical panel elements in NPN and PNP mode in PC-Smart models
Digital Outputs
The digital outputs of radial Radonix controllers are named O.[n], where n is a numerical identifier greater than zero and represents the output number (Figure 11). These outputs are protected in PC-Pro models against short-circuits and heat generated by high currents. If any of these events occur, an O-Error error is indicated on the board by the red LED, and all outputs are disabled by the controller. In PC-Smart models, the outputs are relays with a 1-amp contact and 24-volt bipolar zener diodes are taken into consideration for protection against overloading.
PC-Pro Models:
PC-Smart Models:
Figure (11) – Digital Outputs
⚠️ In PC-Pro models, under no circumstances should the outputs be connected to each other for high current flow or to create circuit paths, as the controller considers this as an error and will immediately turn off all outputs.
The maximum current output for PC-Pro models is around mA300, and for PC-Smart models is approximately 1A. Therefore, if we plan to set up a device with a higher current, we must use a relay.
The digital outputs of the Radonix controllers in PC-Pro models are all NPN, which means they are Low Active or Sink, so when activated, the output is connected to zero voltage or GND.
The electrical schematic of the Radonix controller outputs is shown in Figure 12
The internal circuit of the digital outputs in PC-Pro models:
Figure (12) – Internal circuit of digital outputs.
In the connection to relays, a diode is not needed to eliminate back current. The way of connecting the outputs to multiple devices is shown in Figure 13.
⚠️ Please note that all peripheral devices such as PLCs and inverters must be connected to a common or mutually powered ground in the connection. In fact, even if multiple power supplies are used, the ground of the power supplies must be connected to each other.
Connection of digital outputs with electrical panel elements in PC-Pro models:
Connection of digital outputs with electrical panel elements in NPN mode in PC-Smart models:
Connection of digital outputs with electrical panel elements in PNP mode in PC-Smart models:
Figure (13) – Connection of digital outputs with electrical panel elements
Analog and Bandwidth Modulation Outputs
Radonix controllers in PC-Pro models have analog and PWM outputs which are shown as AO.[n] and PWM.[n] respectively, while PC-Smart models only have analog outputs shown as A[n], where n is a number greater than zero.
The analog outputs produce a continuous value between 0 and 10 volts. (Figure 14)
PC-Pro models:
PC-Smart Models:
Figure (14) – Analog and PWM outputs
⚠️ These outputs are protected against a short connection to the negative power supply terminal and grounded electricity, but a direct connection to a voltage higher than 10 volts will cause damage to them.
The electrical circuit diagram of the analog outputs is shown in figure (15).
Electronic circuit schematic of analog outputs in PC-Pro models:
Electronic circuit schematic of analog outputs in PC-Smart models:
Figure (15) – Electronic Circuit Diagram of Analog Outputs
How to connect the analog outputs is shown in Figure 16.
Figure (16) – Analog Output Connection
⚠️ Please note that the analog inputs and outputs are highly sensitive to noise due to their high impedance. Therefore, it is better to keep the analog communication cables away from strong voltage cables and noisy components. Use a twisted pair cable to establish communication and avoid using single-wire cables for analog communication, preferably use multi-wire or twisted pair cables.
Analog Inputs
Radonix controllers in the PC-Smart models have analog inputs named A[n], where n represents a number greater than zero. The voltage range of these analog inputs is 0 to 10 volts, as shown in Figure 17.
PC-Smart Models:
Figure (17) – Analog Inputs
The electronic circuit schematic of analog inputs in PC-Smart models
Figure (18) – Analog Inputs
Axes
Axes in Radonix controllers are numbered and named Axis[n]. Only active axes are allowed and inactive axes are not. The connection between the controller and the DB servo motors or stepper motors for the axes is established through connector 15, as shown in Table 2 and Figure 19.
Figure (19) – Connector
| 1 | +VCC | 9 | Alarm Reset |
| 2 | Direction – | 10 | GND |
| 3 | Direction + | 11 | GND |
| 4 | Pulse – | 12 | GND |
| 5 | Pulse + | 13 | GND |
| 6 | Servo On | 14 | GND |
| 7 | Servo Ready | 15 | GND |
| 8 | Encoder Zero |
Table (2) – Pinouts
The function of axle pins in Radonix controllers
+VCC
This pin is the source voltage output pin through the controller connector. It has a maximum current capacity of 100mA and is used to power the COM+.
Direction+ & Direction-
These two pins determine the direction of the motor. The connection type is line drive and they have a maximum current capacity of 25mA. They can control up to two motors simultaneously and in parallel.
Pulse+ & Pulse-
These two pins determine the amount of movement and the speed of the motor through a digital pulse with line drive output. They have a maximum current capacity of 25mA and can control up to two motors at the same time. The electronic circuit schematic for Pulse and Direction outputs is shown in Figure 20.
Figure (20) – Internal Circuit of Pulse and Direction Pins.
Servo On
Servo On Pin The Servo On pin is an output pin that is used to turn on the servo motor when the CNC controller is activated. If activated, the SON LED, which is located on the controller near each axis connector, will illuminate. The internal circuit of the Servo On pin is shown in Figure 21. It is important to note that the Servo On pin is not used in stepper motor systems.
Figure (21) – Internal Circuit of the Servo On Pin.
Servo Ready
Servo-Ready Pin The Servo Ready pin is an input pin isolated by a photo coupler that checks the readiness of the servo motor. In the case of an error or problem with the servo motor’s power supply, connection, or encoder, the pin reports the status to the controller, preventing the axes from continuing to move, and an axis error can be displayed on the interface (Figure 22). The Servo Ready pin is not used in stepper motors.
Figure (21) – Internal Circuit of the Servo On Pin.
Servo Ready
Servo-Ready Pin The Servo Ready pin is an input pin isolated by a photo coupler that checks the readiness of the servo motor. In the case of an error or problem with the servo motor’s power supply, connection, or encoder, the pin reports the status to the controller, preventing the axes from continuing to move, and an axis error can be displayed on the interface (Figure 22). The Servo Ready pin is not used in stepper motors.
Figure (22) – Internal Circuit of the Servo Ready Pin.
Encoder Zero
This pin is an input pin isolated by Photo Coupler, which is only available in PC-Smart models.
And the zero point of the encoder in the servo motor is announced to the controller as a pulse. The use of this pin to find the Home point.
It is accurate on some devices. (Figure 23)
Encoder Zero pin is not used in steppers.
Figure (23) – Internal Circuit of the Encoder Zero Pin.
Alarm Reset
This pin is an output pin used to clear the drive error. If the drive reports an error and it is resolved, the error can be cleared without the need to disconnect the electrical circuit, by using this output pin, and the drive can be put back into normal operation. (Figure 24
Figure (24) – Internal alarm reset circuit.
GND
The Ground (GND) of the CNC controller is connected to six pins of the axis connector. These pins provide the ground connection required to connect to the drive, ensuring proper electrical signaling and stability of the system.
⚠️ Please note that the Direction and Pulse output pins are digital and be careful when connecting them to other pins, especially pin 1.
- The Reset and Servo On output pins of the Radonix controller are open collector and NPN, meaning that when activated, Ground is switched to the pin. The driver connected to these pins must be NPN.
- The Ready and Encoder Zero input pins are also NPN, and the servo drive connected to these pins must connect Ground to these pins, making it NPN as well.
- Only the Direction+, Direction-, Pulse+, and Pulse- pins are used to connect the controller to the stepper motors. No other pins are needed. If the cable is disconnected, the axis error may appear as the controller sees this as an error. You can check pins 6 and 7 in the DB15 connector to detect any errors
- For the user’s convenience, wiring between Radonix controllers and servo motors is provided in Appendix 1.”
Handwheel and serial communication
The 9-pin connector in the Radonix controllers (PC-Pro models, excluding the Pro LAN 3AS model) is used for communication with the handwheel and RS485 connection. In the PC-Smart models, there are two separate connectors (6 and 4 pins respectively) for handwheel and RS485 communication (Figure 25)
Handwheels with 5V encoder and differential outputs are compatible for communication with the Radonix controller. The schematic pin connection with the handwheel is shown in Figure 27. RS485 communication, a type of serial communication, is transmitted through pins A.485 and B.485.
PC-Smart Models :
PC-Pro Models :
Figure (25) – Communication pins with the Encoder and RS485
The internal circuit of the RS485 communication pins in the PC-Smart and PC-Pro models:
Figure (26) – Internal circuit of RS485 communication pins
The internal circuit of the handwheel communication pins in the PC-Pro models:
The internal circuit of the handwheel communication pins in the PC-Smart models:
Figure (27) – Internal circuit for communication pins with handheld.
Figure (28) – The schematic equivalent of the internal circuit of the controller for communication with the handwheel.
Figure 29 shows the handwheel encoder communication pins on the controller in two differential and open collector modes. In the PC-Pro models, if the handwheel encoder is an open collector, the HW.A+ and HW.B+ pins should be connected to the +5V pin of the 9-pin connector. The other switches of the handwheel should be connected to the digital inputs of the controller, which is shown in Figure 29.
Figure (29) – Connection of handwheel with Radonix controller
Note that the analog input is only available in the PC-Smart model controllers