Technical Specifications:

• Number of Controlled Axes: 4 axes (X, Y, Z, A or X, Y, Z, B)
• Interpolation Modes: Linear (G01), Circular (G02/G03), Helical (G02/G03 + Z), 4-axis simultaneous contouring
• Maximum Feed Rate: Up to 100 m/min (per axis, configurable)
• Position Resolution: 0.001 mm (1 µm) minimum increment
• Look-Ahead: Up to 200 blocks
• Simultaneous Axes: 4 axes (full 4-axis contouring)
• PLC Integration: CODESYS V3.5 PLC runtime, up to 2,000 I/O points
• Safety Integration: B&R SafeLogic, SIL 2 / PL c capable (integrated in Power Panel 200/300)
• Communication Interfaces: 2 × Ethernet (10/100 Mbit/s), 1 × RS-232, 1 × USB, 1 × CANopen, 1 × SERCOS III (optional)
• Power Supply: 24 V DC (via Power Panel or dedicated supply)
• Operating Temperature: 0 °C to +55 °C
• Protection Rating: IP65 (in Power Panel enclosure)
• Dimensions (Controller Module): Approximately 160 mm × 100 mm × 55 mm
• Weight: Approximately 1.0 kg (controller module only)

Functional Features:

• 4-axis simultaneous G-code interpolation (ISO 6983)
• RTCP (Rotary Tool Center Point) compensation for 4/5-axis machines
• Tool management: Up to 255 tools with length/radius/orientation compensation
• Macro B programming (parametric programming, user macro variables)
• Spindle orientation control (C-axis function) for 4th axis indexing
• Cycle programming: Drilling cycles (G81-G89), boring cycles (G76-G89), tapping cycles (G84)
• B&R CNC HMI with 3D toolpath simulation
• OPC UA server for Industry 4.0 connectivity
• Remote diagnostics via Ethernet/VPN

Structural Characteristics:

• DIN rail TS 35 mountable module
• Aluminum housing with EMI shielding gasket
• Front panel: Status LEDs (Power, Run, Alarm, Axis Active), MPG connector, USB port for program transfer
• Rear panel: Ethernet ×2, RS-232, CAN, encoder feedback connectors (X20-compatible), limit switch connectors, spindle control outputs
• Conformal coated PCB for industrial environmental protection

Material Composition:

• Housing: Die-cast aluminum, anodized silver finish
• PCB: 6-layer FR-4, ENIG surface finish, conformally coated
• Connectors: MIL-DTL-38999 series or equivalent, gold-plated
• Terminal blocks: Phoenix Contact or Weidmüller, rated 10 A, 600 V

Applicable Industries:

• 4-axis milling centers (rotary table indexing)
• 4-axis lathes (live tooling, C-axis milling)
• 5-face machining centers (4+1 configuration)
• Woodworking CNC (4-axis routing)
• Stone and marble processing (4-axis profiling)
• Aerospace component machining

Installation Requirements:

• Mount on DIN rail TS 35 inside B&R Power Panel 150/200/300 or standalone cabinet
• 4 axis encoder feedback: incremental 1 Vpp RS-422 (A/B/Z per axis), shielded cable, max 10 m
• Limit switches: 2 per axis (positive and negative), wired in series for safety (NC contacts)
• Spindle connection: 0-10 V analog speed command + M-code for direction/start/stop
• Coolant control: 2 digital outputs (M08/M09) via relay/contactor
• Protective earth connection mandatory — minimum 4 mm² copper wire

Usage Notes:

• Always perform reference return (homing) on all 4 axes before first program execution — use G28.1 command
• 4th axis (A/B) must be homed independently — do not assume it follows X/Y/Z home position
• For safety-rated applications (SIL 2 / PL c), use B&R SafeLogic with certified safety I/O modules only
• Program backup to USB flash drive or network share must be performed before every production run
• Servo gain tuning for 4th axis requires separate optimization — do not copy X/Y/Z tuning parameters
• Maximum look-ahead of 200 blocks requires sufficient PLC scan time — verify cycle time < 4 ms