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1、 Mx1100 UMI Serial BTR Installation&Users Manual For Fanuc Tape Readers Copyright 2006 All rights reserved.Memex Automation Inc.777 Walkers Line Burlington,Ontario Canada L7N 2G1 Mx1100 UMI Serial Fanuc BTR Contents _III Table of Contents Introduction.VII About This Manual.VII History of the BTR.VII
2、 Installation Instructions.1 Package Contents.1 Installing the Mx1100 UMI BTR.2 Operating The BTR.5 Layout Diagram of the Mx1100 UMI Serial BTR.6 Reference.7 General Troubleshooting.7 Memex Technical Support&Service.11 Users Notes.12 Glossary.13 Appendix A:Configuration&Settings.17 DNC Software Conf
3、iguration Information.17 Mx1100 Option Jumper Settings.17 Mx1100 Serial Port Pin Configuration.18 Serial Data Cable Configurations.18 Appendix B:ASCII Code Reference Table.19 Contents _IV Introduction_ V Introduction Thank you for purchasing the Mx1100 UMI(Universal Machine Interface)BTR.At Memex we
4、 invest a great deal of effort in the design,manufacture and testing of each unit we build,and back it with a three-year limited warranty.We are confident you will find the Mx1100 an important component of your shop floor communications system.About this Manual This manual explains how to install an
5、d operate the Mx1100,and consists of the following sections:Installation Instructions explains how to install the Mx1100 UMI BTR interface board.Reference contains a troubleshooting section,notes area and contact information for customer service and technical support.Appendix A,Configuration&Setting
6、s provides information for software(DNC)configuration,BTR jumper settings and serial cable configuration(“pin-out”)charts.Appendix B,ASCII Table lists ASCII values in both Decimal and Hex formats,their corresponding symbol,and keyboard key where applicable.This may be helpful in configuring DNC soft
7、ware in some cases.The History of the BTR The“Behind the Tape Reader”board,or BTR as it is commonly called,is an electronic signal processor designed to emulate the function of a paper Tape Reader and provide an RS232 serial port as an alternate method of data entry to an NC or CNC control.RS232 is
8、an international standard for electronic communications,and is a faster and more reliable means of data input than using punch tape or Manual Data Input(MDI).Originally,the only one way that a part program(the“G-code”)could be entered into a machine tool was through MDI mode,which allowed the progra
9、m to be input using a keypad at the control.The MDI process was fine for small programs,but it was time consuming and error prone for longer programs.It Introduction_ VI took time to set up and to prove the MDI code before operation could commence.Machine flexibility was low,since each new program r
10、equired time to input.With all the wasted time and lack of flexibility,it was not very long before someone invented an alternate form of control input,the paper Tape Reader.The paper Tape Reader provided a faster,more reliable form of data input to the numerical control.However,these Tape Readers we
11、re mechanical in nature,and required regular maintenance and care to perform properly.Tape Readers allowed data and programs that were punched out on a paper tape to be read in by the control at a rate of approximately 300 to 400 characters per second.A few problems inherent in the Tape Reader are:i
12、t has limited ability to accept commands and inform the operator of problems and status;it is prone to mechanical problems;it requires cleaning,lubrication and other maintenance;it has a limited capacity of 1000 feet(305 metres)of tape.It was commonly suggested that a busy shop keep a spare reader i
13、n inventory in preparation for the time when one broke down.The process of punching data tapes(whether paper,Mylar or metal)was expensive,time-consuming and brought up storage concerns.Because of the absolute nature of a punched tape,the process had to be redone for every program revision.The progra
14、mmer and operator had to work closely together to keep the tape accurate and up to date.Old tapes had to be filed or destroyed and the latest version had to be carefully marked and stored.Finally,the tape itself had to be handled with care since it was prone to damage.Later machine controls had a ne
15、w mode of operation that allowed their Tape Readers“endless”spool of tape to surmount memory constraints.Originating on Numerical Controls(NC)that had no memory,Direct Numeric Control(DNC)allowed execution of a program while it was being read.This“drip-feed”method meant that the program was limited
16、in size only by the length of tape used.This Introduction_ VII type of operation was very much appreciated later on with the advent of Computerized Numeric Controls(CNC).With true onboard memory the CNC had much greater capabilities and inevitably programs got longer and the need for more memory gre
17、w.With control memory being expensive and limited,DNC has remained the only way some modern manufacturers can operate.Tape Readers are still commonplace on modern controls today.However,thanks to serial DNC capabilities,many shops use Tape Readers for backup purposes only.The modern equivalent of a
18、Tape Reader is the BTR interface board,which emulates paper Tape Readers.The Mx1100 UMI BTR is a microcontroller-based interface board that allows communications with a machine control for the purposes of loading programs into memory or running DNC.BTRs generally connect to a computer and permit a p
19、rogrammer to send a complete,formatted program to the machine control.The machine then loads the program as if from tape,either to memory for later execution,or for immediate block-by-block execution(DNC).Because the Mx1100 UMI BTR emulates the Tape Reader,the control really has no way of knowing th
20、at the source of the program is a computer port instead of a tape.The Mx1100 UMI BTR eliminates punching of tape,has no moving parts,can handle transfer speeds that exceed that of a Tape Reader,uses the programmed(source)file,is less expensive than a Tape Reader,allows the Tape Reader to still be us
21、ed,supports the use of the controls punch capability,and does not require maintenance.Its no wonder that the BTR,in combination with DNC software,has become the preferred alternative to using the Tape Reader and(in many cases)to upgrading CNC memory.While the Memex BTR gives the machine control the
22、ability to receive programs from a PC,it has nothing to do with the specifics of what is being sent to the control.DNC software,or at the very least some form of serial communications software,is responsible for transmitting the data to the control,and the control expects that data to be in a specif
23、ic format.The part program must be formatted just as it would be for punching to tape,and the DNC software must be configured to send it as if it were a tape.The BTR acts only as a gateway or port to the control.The required program format is usually described in the controls Operations Manual.Pleas
24、e consult the manual for information on how to configure the part code programs for the control.Chapter 1:Installation Instructions _ 1 Installation Instructions Unpacking the Mx1100 UMI BTR Package Contents 1 x Memex Mx1100 UMI Serial BTR.Supplied 1 x Fanuc Ribbon Interface Cable.Supplied 1 x Insta
25、llation&Users Manual.Supplied Optional Items Facit 4070 Punch Port Interface Cable.Optional(Memex SKU-5100:Punch Cable for Fanuc only)Serial Interface Cable(PC BTR).Optional Serial Transfer(DNC)Software.Optional Before You Begin Please read all instructions before proceeding.We recommended first mak
26、ing a temporary installation,becoming familiarized with the components and orientation of the assembly,testing the functionality,and then making the installation permanent by mounting the BTR and routing and securing the cables where they are out of harms way.A shot of our old Mx1000 BTR(now built i
27、nto the Mx1100)connected to Fanuc 6(with punch)&to a laptop running Multi-DNC.Chapter 1:Installation Instructions _ 2 Installing the Mx1100 UMI BTR General The Memex Mx1100 UMI BTR installation procedure is straightforward and relatively easy to complete connect the BTR to the CNC where the Tape Rea
28、der was connected,optionally connect the Tape Reader to the BTR,and mount the BTR on the inside of the Tape Reader door.All the hardware and accessories are provided.All thats needed are some basic skills and hand tools.Estimated time required:45 minutes.1.Prepare the site.Ensure that the Tape Reade
29、r and control are working properly before beginning the installation.When ready,turn OFF all power to the control,machine and computer system.2.Access the Tape Reader.Locate the panel on the control that has the Tape Reader mounted on it.Open this door to gain access to the back of the Reader.3.Disc
30、onnect the Tape Reader.Locate the Tape Reader printed circuit board directly behind the Reader.It has two 50-pin connectors,labelled CNT1 and CNT2.The second(CNT2)has wires going to the Tape Reader head.The cable on CNT1 is a 50-conductor ribbon cable that goes to the CNC.Note which side of this con
31、nector the cables red stripe goes on.Disconnect this cable from CNT1.4.Connect the BTR.Connect the cable disconnected in Step 3 to the BTRs 50-pin connector at top right*,labelled“FANUC CONTROL A”,without twisting the cable.Make sure the cables red stripe is on the left,where Pin 1 is marked with a
32、white square(see diagram,page 6).This connects the BTRs Fanuc control port to the control.Caution It is very important that the cables are installed properly with the correct orientation.If one of the cables is plugged in upside down,severe damage will occur to the BTR,to the Tape Reader and to the
33、controls Master Board.Chapter 1:Installation Instructions _ 3 5.Mount the BTR.Locate a safe spot on the back of the door and magnetically mount the Mx1100 UMI BTR.6.Option:Connect the Tape Reader to the BTR.If you wish to enable the paper Tape Reader,take the new 50-conductor ribbon cable and plug i
34、t onto the JP5 connector(labelled“FANUC TAPE READER A”)at the bottom right of the BTR.*The red side of the cable goes on pin 1 of the connector (see diagram,page 6).Plug the other end of the cable onto the CNT1 connector on the Fanuc Tape Reader board,from which the cable was removed in Step 3 ensur
35、ing the red wire on the ribbon cable goes on pin 1 of the connector,as noted in Step 3.7.Option:Punch Cable.If you would like to punch part programs,parameters,etc.from the control to the computer,and you have purchased the optional Fanuc Facit 4070 Punch Cable,connect the controls punch port to the
36、 BTR.Locate the punch port on the control.Its usually a blue rectangular 20-pin(Honda)connector.Plug the Punch Cable into this port.Plug the 26-pin end onto the BTRs JP4 connector,labelled“PUNCH IN”.The red stripe goes on the side with Pin 1(see diagram on page 6).Remove the JP17 jumper(labelled“PUN
37、CH DISABLE”)in the upper right corner of the BTR.8.Configure the BTR.Set the jumpers on the BTR to configure the communications parameters required for your DNC system.The option jumpers,listed on page 17,include the following:Jumper A1 and A2 set the Baud rate.Typically 9600 baud(both jumpers ON)is
38、 used unless your cable doesnt support that rate reliably.The RS232 specification supports 9600 Baud(Even parity,7 data bits and 1 stop bit)with a cable length up to 50 feet(15 metres),but it is often possible to exceed that.Its important to use cable specifically designed for RS232 serial data,22 A
39、WG,twisted pair,stranded wire(not solid),shielded,low capacitance(a rating of 11 to 15 pF per foot)is best.If you have a long cable run or are have unreliable data transmission,try lowering the Baud rate.Note:In our opinion,CAT3 or CAT5 UTP Ethernet cable is not suitable for reliable machine tool se
40、rial communications.Use shielded cable.Chapter 2:Operating the Mx1100 _ 4 Jumper A3 OFF adds hardware(RTS/CTS)handshaking.A3 ON is software(Xon/Xoff)only.Generally it is preferable to use both,which means setting A3 OFF and making sure your cable supports hardware handshaking(see Note 6 on p 9).Jump
41、er A4 OFF uses the standard Xoff character,$13 Hex.Set A4 ON if your terminal software uses$93 Hex for Xoff.Jumper A5 OFF uses the standard Xon/Xoff handshaking method(a Single Xoff).Setting A5 ON sends a continuous stream of Xoff back to the computer until the next Xon.This enables the BTR to be us
42、ed with some terminal programs that were intended for use with a modem,such as PROCOMM although we recommend the use of proper DNC software.Jumper A6 OFF will echo incoming data back to the PC for diagnostic purposes.On reset,the software version is outputted for instance.Set A6 ON for normal use.Ju
43、mper A7 OFF is ISO data,and ON converts incoming ISO data to EIA format for controls that require EIA data.Jumper A8 overrides the Tape Readers selection of BTR or Tape mode.If the Tape Reader wasnt reconnected to the BTR,or if the Tape Reader isnt intended to be used often and the BTR will usually
44、in Tape mode,set A8 ON.(Remember to remove it when a tape needs to be read.)_ SG JMPR OFF=COM1 Signal Ground surge suppression.PWR P9 DBL ON activates power output on COM1s pin 9,for use with devices such as buffers(see note on page 18).Punch Disable if you are not using a Facit 4070 punch port(SKU-
45、5100 cable),keep this jumper ON.9.Connect to the Computer.Connect a serial cable from the 9-pin COM1 on the BTR to the computers serial port(see page 18 for cable configurations).10.Test the Functionality.Refer to“Operating the Mx1100 UMI BTR”(page 5),and if necessary,“Reference”(page 7).Chapter 2:O
46、perating the Mx1100 _ 5 Operating the Mx1100 UMI BTR To use the controls new serial port:Make sure the cables are connected correctly and prepare your DNC software.Press Reset on the Fanuc control to reset the BTR and ensure that no residual data is present in its input buffer.If BTR option jumper A
47、8 is OFF(switch enabled),and the Tape Reader is connected,switch the BTR into BTR mode either by turning off the Tape Reader or by switching the Tape Reader to Release mode.Start an upload to the control from your DNC software,and then load a program at the control as if from tape.You can put the co
48、ntrol in Tape mode and press READ or INPUT to load the program into memory(if it will fit),or put the control in DNC(or External)mode and press Cycle Start to run it in DNC mode also known as“drip feeding”.(These mode names and key names will vary according to the control model.)If you have any diff
49、iculty or concerns,please refer to“General Troubleshooting”on page 7.Helpful hints Adding a couple of Carriage Returns to the end of the file will ensure that the entire file is transmitted.Some combinations of DNC software and CNC control sometimes miss the end of a file,so its a good idea to provi
50、de some harmless extra characters as a buffer.The BTR responds to the Break character by resetting and clearing its buffer.The Break character is ASCII value 3,or HEX 03(see Appendix B,page 19).If your DNC software can be configured to send control codes,its a good idea to have it send a Break chara