BREAKOUT BOARD DESCRIPTION
Contents
1. 8 a 5 Breakout board 103 Y Axis 69 5 eae DCS 3010 es 2i 9 8 Qs O Ole O F 3 g 5 F L HIGH VOLTAGE m i D COE wm v 2 To PC s FH Q es ET esp paraller 1 Be LPT port 88 20 Em ELE P Hp 2H eer B S gt Switches r E Ole Q3 E Ee O gt Cj Printer y EN L kabl Cc hcm 3 4 Q s l L 18 o D D XS SII J IO Gab O O r oc2 mnnn S G ID mot Nf encoder Ll u Figure 5 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 7 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA Using breakout board 103 with Mach 32. DESCRIPTION OF INPUT OUTPUT PINS Pin number on the side Line type on Description function of PC connector DB25 the ibus of PC Annotation X axis STEP 2 Output X axis DIR 3 Output Y axis STEP 4 Output Y axis DIR 5 Output Z axis STEP 6 Output Z axis DIR 7 Output A axis STEP 8 Output A axis DIR 9 Output ENA enable 17 Output Can be optionally Safety signal charge pump 14 Output switched n and ott t Optionally analog output Spindle Relay 1 1 Output of 0 5 V or of 0 10 V Coolant Relay 2 16 Output Limit switch 1 SW1 10 Input Limit switch 2 SW2 11 Input Limit switch 3 SW3 12 Input Limit switch 4 SW4 13 Input E Stop Limit switch 5 SW5 15 Input Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 1 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc 103 man en Ver 1 January 2014 by PRIZMA SPECIFICATIONS Number of axis 4 X Y Z and A axis Axes control By STEP DIR command lines separately for each axis common ENA enable line for all axis Output current of STEP DIR command lines 15 mA max Number of limit switches 5 Number of relay outputs 2 Analog output Choice 0 5 V DC or 0 10 V DC via jumper The capacity of one relay output 250 V AC 8 Supply voltage 15 24 V DC 500 mA Dimensions W x L x H 173 mm x 63
3. IO3 BREAKOUT BOARD DESCRIPTION Breakout board 103 has digital buffer for STEP DIR ENA command signals and as such it is particularly suitable for the connection up to 4 microstep drives MST 107 and or to connect DC servo drives DCS 3010 directly to PC This breakout board can also be used with all drives that have opto isolated STEP DIR ENA inputs On board charge pump prevents undesirable state changes in case of loss of communication with computer Breakout board lOS has two relay outputs that can be used to activate the two customers electric motor for the main spindle and or electric motor for vacuuming chips etc Indication of the relay is performed using the two LEDs which are located on the board One of the relay outputs can optionally be converted to analog output with a range of 0 5 V or 0 10 V which allows software to control of spindle motor revolution speed Up to 5 limit switches can be connect to the breakout board PC connection is performed via the parallel printer LPT port Breakout board has centronics IEEE1284 connector so that connection to the PC uses a standard printer cable Breakout board IO3 is specially developed to be used with software for generating STEP DIR command signals via parallel port such as Mach2 Mach3 TurboCNC free KCam etc For power supply of the card uses the source 15 24 V DOC 500 mA The breakout board has the voltage regulator for the proper operation
4. ToolPath Alt4 Offsets Alt5 Settings Diagnostics Alt7 Mil G15 G80 G17 G40 G21 G90 G94 G34 G49 G99 G64 G97 File JNo File Loaded Edit G Code Recent File Close G Code Load G Code Set Next Line Line 0 Run From Here E13 Eg Dwell E CV Mode G Codes M Codes Program Run lt Alt R gt eed Hold Spc Reset History Clear Error Rewind Ctrl W Single BLK Alt N E Reverse Run Block Delete M1 Optional Stop JJ Flood Ctl F JE Change Tool a Dia 0 0000 0 0000 Auto Tool Zero U Remember Return U Elansed 00 00 00 ll Jog ON OFF Ctrl Alt J fl 0 000 Load Wizard Last Wizard W al Spindle CW F5 RPM 0 S 1000 nits Min i g Incrernent y nits Rev 0 00 Fomor _ MultiPass Loop 0 Times on maol Z Inhibit Lower Z Inhibit by _ 50 0000 on each pass Figure 17 3Mach3Mill Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Page 13 of 14 Doc lO3 man en Ver 1 January 2014 by PRIZMA DOCUMENT REVISION HISTORY January 2014 English version Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 14 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA
5. Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Step Pin Dir Pin Dir LowActive Step Low Ac Step Port 2 1 4 1 6 1 Figure 7 Setup for ENA enable command line is shown in Figure 15 Setup of step motor parameters depends of great number of factors step motor type applied drive choice of microstep options type of transmission screw spindle timing belt etc mass of the moving parts of the machine etc One potential setup is shown in Figure 8 Dialogue is opened by selecting Config Motor Tuning Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 8 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc 103 man en Ver 1 January 2014 by PRIZMA Motor Tuning and Setup r Axis Selection X AXIS MOTOR MOVEMENT PROFILE Velocity 8437 5 m Y Axis ES 421875 2 Axis 3375 2531 25 1687 5 2 g s gt E 3 a an o 2 3 E 025 03 Time in Seconds Accel _J oaa sh n T J vWY F Velocity Acceleration StepPulse Dir Pulse Steps per In s or mm s per min in s or mm s sec sec 1 5us 0 5 po m F f e Figure 8 Proposal for setting the limit switches via option Config Ports and Pins Input Signals is shown in Figure 9 and 10 Setup refers to the connection of lim
6. Immediate Relay off before delay Spindle Speed Averaging Figure 12 Safety signal Charge Pump When you start the computer and when you start the software Mach3 state of the output pins of the parallel port are not clearly defined So for example a logic zero at the output pins 1 and 16 activates relay on the breakout board IO3 namely spindle motor or some other output device which in some cases may be a dangerous event In order to avoid this situation use the safety signal charge pump signal that represents pulse trains that are generated after the successful start up of management software in case of using Mach3 software frequency of the charge pump signal is 12 5 kHz To activate the use of the security signal it is necessary to set the jumper J1 to position Charge Pump ON see Table 1 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 10 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc 1O3_man_en Ver 1 January 2014 by PRIZMA TABLE 1 Jumper position J1 Charge Pump OFF Circuit for charge pump signal is switched off The output signals Step Dir Enable and Analog out are active no matter the charge pump signal is present or not LED diode Charge Pump is switched on Charge Pump ON Circuit for charge pump signal is switched on In the absence of the charge pump signal all logic outputs Step Dir and Enable will be at logic zero state while the A
7. AUDI QHMS MST 107 Microstepping Stepper Motor Controller Z Axis UDI HMS MST 107 Microstepping Stepper Motor Controller Y Axis AUDI HMS MST 107 Microstepping Stepper Motor Controller X Axis AUDI HMS MST 107 Microstepping Stepper Motor Controller Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Page 4 of 14 Doc 103 man en Ver 1 January 2014 by PRIZMA A Axis UDI HMS MST 107 Microstepping Stepper Motor Controller Power supply 80228010 fos nafa has Z Axis AUDI HMS MST 107 Microstepping Stepper Motor Controller Y Axis UDI HMS MST 107 Microstepping Stepper Motor Controller Z nan nor looong mem X Axis AUDI HMS MST 107 Microstepping Stepper Motor Controller SISISSSSISSISISSIS SISISSISISISISISISSIS SISISSISSISSISISSIS SISISSSSISSISSISIS Je ar fae Arche ei eg o asua as fon ne Jeter i fes uo ono ar Area tieu p 80 aaa ka fone ar Figure 3 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 5 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA Installation of breakout board with PC connection of end switches connection of relays output and analog output is shown in Figure 4 NOTE On the displayed sch
8. F BREAKOUT BOARD 103 WITH DC SERVO DRIVES DCS 3010 Recommended installation diagram of breakout board 103 with DC servo drives DCS 3010 is shown Figure 5 More details about this configuration can be found in user manual for DC servo drive DCS 3010 TIA DCS 3010 Logic Power Supply X Axis B80C1500 j X A eo 1 1 aia M G B80C1500 55 15 18VAC O SA ver Supply DCS 3010 bs LOGIC GNDZ D
9. Mist 7 Flood M8 Enabled Max ADC Count 16380 Output Output Output Signal s 1 6 Flood Mist Control iv Disable Flood Mist relays Dutput Output a Output Signal s 1 6 ModBus Spindle Use Step Dir as well Motor Control Use Spindle Motor Output PwM Control Step Dir Motor Torch Volts Control PwMBase Freg 250 MinimumPwM fo 2 n m General Parameters Cw Delay Spin UP 1 Seconds CCW Delay Spin UP 1 Seconds Cw Delay Spind DOWN f Seconds Reg 64 64 127 Delay Spin DOWN 1 Seconds Immediate Relay off before delay Figure 16 Pulley Ratios Current Pulley Set Pulley Ratio 1 Pulley Ratio 2 Pulley Ratio 3 Min Speed Pulley Ratio 4 Special Functions Laser Mode freq by Feedrate Use Spindle Feedback in Sync Mode Closed Loop Spindle Control 025 1 D 03 Spindle Speed Averaging Commands related to the Spindle are on the main screen in the section called Spindle Speed framed part in Figure 17 In the S field is required to enter the desired RPM in Figure 15 it is 1000 RPM Starting the spindle is achieved by pressing the Spindle CW F5 button or by pressing the F5 key on the computer keyboard By pressing the and there is a continuous increase or reduction of RPM of the spindle for the size of specified increment Mach3 CNC Control Application File Config View Wizards Operator Help Program Run Alt 1 MDI Alt2
10. eme each axis has two limit switches which are connected in parallel When it is performed Home positioning on that axis one of switches has Home switch function In any other case the activation of any of the two switches leads to stopping the machine E Stop switch is placed at the switch SW5 To PC s parallel port LPT as Printer cable Breakout board IO3 I O Board IO3 Rel2 www audiohms com 3 8 A max Coolant Motor 10 A max 220 VAC 8 A max Spindle Motor INZI NVA Spindle motor revolution speed control Limit X Home Y Limit Y Home Z Limit Z Home A Limit A E Stop PHP E me ias os os os oso Ssssssssssessssssss O 5 ao a skuoq jaus X Maximum allowable current through each relay is 8 max where total electric current should be over 10A max It is recommended that for electric current above 5A to be used external relays with larger capacity or contactors and in that case contactors will be switched on by relays that are placed on breakout board IO3 NOTE Negative output of Analog out is connected to the ground of breakout board 1 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Page 6 of 14 Doc lO3 man en Ver 1 January 2014 by PRIZMA DIAGRAM O
11. it switches as shown in Figure 4 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Dutput Signals Encoder MPG s Spindle Setup Mill Options m a a Pin Number Active Low ARAAAAAAAAAA M E OE OE OE X OE OE RC S S RAAAAAAAAAA 13 Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen x 9 Figure 9 Engine Configuration Ports amp Pins m 2 C q a Pin Number Active Low Limit Ovrd _ m K OE OE s OE OE OE K X A 8 OE RC S OE S OE S x x x x x x x x x 2 ojJojojojojojojojojo n Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen x 19 Figure 10 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 9 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc 103 man en Ver 1 January 2014 by PRIZMA Setup of relay outputs is performed in two steps The first by choosing the option Config Ports and Pins Output Signals Figure 11 selects outputs that is used in this particular case Output 2 i Output 3 Then it is needed to set the parameters under Config Ports and Pins Spindle Setup Figure 12 area indicated by rectangle Engine Configuration Ports amp Pins Port Setup and Axis Selection Moto
12. mm x 20 mm Weight 120 g NOTE specifications are subject to change without notice WIRING DIAGRAM OF BREAKOUT BOARD IO3 WITH MICROSTEP DRIVES MST 107 On the breakout board IO3 is possible to connect from 1 to 4 microstep drives MST 107 Connection of STEP DIR ENABLE command lines to microstep drives MST 107 is shown on Figure 1 For power supply of breakout board IO3 and to 4 microstep drives MST 107 it is recommended usage of power supply board with motor brake PSB 1 Figure 2 More details about this power supply board and the way of installation can be found in the PSB 1 user manual Users can also provide their own power source In that case on Figure 3 is shown recommended power supply connection for breakout board 103 and to 4 drives MST 107 Power supply must have two independent isolated power sources one for power supply of breakout board IO3 15 24VDC 500mA and other for power supply of MST 107 drives with supply voltage 20 40VDC electric current of this power supply depends on the used step motors see manual for microstep drive MST 107 On V supply wire for each drive MST 107 is recommended usage of fast blow fuse to protect drives in case of overload Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 2 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA A Axis UDI HMS MST 107 amp Microstepping Stepper Mo
13. nal pause ratio If the width of the signal is for example 1096 and width of the pause 90 analog voltage will be 1096 of maximum voltage This analog signal can be used as a control spindle motor revolution speed The use of analog output requires hardware setup of breakout board IO3 via jumpers which are in Table 2 and setting up of parameters in Mach3 software TABLE 2 Jumpers position J2 and J3 if it is chosen analog signal OFF ON Jumper J2 should be switched to OFF Spindle soy 03 2 Jumper J3 defines the voltage level on the analog output It can be in range of 0 5 V or J3 0 10 V ENEI Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 11 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA Software setup is performed by selecting Config Ports and Pins Output Signals as it is showed in Figure 14 15 and 16 NOTE If it is used analog output than it is not possible to use relay output named Spindle For that reason it is necessary to put the jumper J2 in OFF position Otherwise the PWM signal would go to the coil of the relay and buzzing from this relay will be heard Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Dutput Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Step Pin Dir Pint Dir LowActive Step Low Ac Ste
14. nalog out voltage will be OV LED diode Charge Pump is Switched off When the charge pump signal is present safety circuit will be activated and the output signals Step Dir Enable and Analog out will be active LED diode Charge Pump is switched on Setup the security signal charge pump signal is performed by selecting Config Ports and Pins Output Signals Figure 13 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Dutputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Port Pin Number Active Low Output 4 Output 5 Output 6 Charge Pump Charge Pump2 Current Hi Low Output 7 Output 8 Output 9 Output 10 Output 11 OE OG X S S OE S A S S N ME OE X OE OE OE OE OE OE OE Pins 2 9 1 14 16 and 1 are output pins No other pin numbers should be used x Figure 13 Analog output Software Mach3 has the capability of generating Pulse width modulation PWM signal Pulse width modulation is a method of control in which the frequency of the control signal does not change Regulation is done by changing of the signal pause ratio To convert the PWM signal to a analog signal voltage level breakout board IOS use active low pass filter This filter smooth out the signal filling in the gaps during the off periods of the PWM The level of the analog signal depends on the sig
15. p Port Dir Port x Axis 1 1 Y Axis 1 1 z Axis Axis _ _ B Axis X NAA x x X X X C Axis Spindle A e e HR Figure 14 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Port Pin Number Active Low Digit Trig 0 Enable1 Enable2 Enable3 Enable4 Enable5 Enable6 Output 1 Output 2 Output 4 _ X AC X X s s OE A NC Li d x r 4 x x f x ocogoj 40j o0jojojojoj jo ogo ooo oo 4 v Pins 2 8 1 14 16 and 17 are output pins other pin numbers should be used HR Figure 15 In Figure 16 it is seen that chosen fundamental frequency of PWM signal 250 Hz It is important to notice the parameters relating to the Pulley Ratio 1 which is here set from 0 3000 RPM This means that for signal pause ratio of 096 RPM will be 0 for 10 it will be 300 RPM and so on while for 100 the spindle revolution speed will be 3000 RPM Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 12 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA Engine Configuration Ports amp Pins Port Setup and Axis Selection Relay Control Disable Spindle Relays Clockwise M3 CCw M4
16. r Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Port Pin Number 0 17 gt n tive Low Digit Trig Enable1 Enable2 Enable3 Enable4 Enable5 Enable6 Output 1 Output 2 Output 3 Output 4 MAA MMM MRA MEA A OE OE OE OE OE OE AL Pins 2 8 1 14 16 and 17 are output pins No other pin numbers should be used Figure 11 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Dutput Signals Encoder MPG s Spindle Setup Mill Options Relay Control Motor Control Pulley Ratios Disable Spindle Relays Use Spindle Motor Output Current Pulley Set Max Speed Clockwise M3 Output P C Pulley Ratio 1 1000 COWIM Output T Torch Volts Control C Pulley Ratio 2 2000 Output Signal s 1 6 PWMBase Freq B C Pulley Ratio 3 4000 Flood Mist Control ini 2 Pulley Ratio 4 8000 Disable Flood Mist relays xo irpo uH Mist M7 Output B General Parameters Special Functions Flood M8 Dutput 4 Cw Delay Spin UP 1 Seconds Laser Mode freq by Feedrate RPM Output Signal s 1 6 CCW Delay pen UP 1 Seconds Use Spindle Feedback in Sync Mode ModBus Spindle Use Step Dir as well C Delay Spind DOWN 1 Seconds Closed Loop Spindle Control Enabled 64 64 127 Delay Spin DOWN f1 Seconds 025 1 ft Doo Max ADC Count 16380
17. setup Demo version of the software Mach3 can be downloaded from the official site www machsupport com As it is already mentioned breakout board IOS is connected with PC by using parallel LPT port For proper operation it is necessary to perform the required settings All settings are in accordance with the schedule of input output pins which is shown in Table 1 Selection of the parallel port is performed in dialog box Config Ports and Pins Figure 6 Engine Configuration Ports amp Pins Part Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Port 1 Port 2 MaxNC Mode Port Enabled Pott Enabled CL Mode enabled 0x378 Port Address 0x278 Port Address Max NC 10 Wave Drive Entry in Hex 0 9 A F only Entry in Hex 0 9 A F only Program restart necessary Pins 2 3 as inputs Sherline 1 2 Pulse mode Kernel Speed ModBus InputOutput 5 t C 25000Hz C 35000Hz 45000Hz kei ac ud Event Driven Serial Control Servo Serial Link Feedback Figure 6 Setting of the STEP DIR command lines for all axes is performed in dialog that opens by choosing option Config Ports and Pins gt Motor Outputs Figure 7 In case of using microstep drive MST 107 considering that its step occurs on falling edge of STEP signal it is necessary to select option Step Low Active Figure 7 Engine Configuration Ports amp Pins Port Setup and
18. tor Controller Breakout board 103 o VO Board Io3 E Re 2 WWW audiohms com be ssssssissssss ssssssissssss ssssssissssss Bic asua as ae fest se fone ae Jaga Gif oss foe fone ar aee aei ossi oe enfo pets 2 AUDI HMS MST 107 R Microstepping Stepper Motor Y Axis AUDI HMS MST 107 dung Microstepping Stepper Motor X Axis AUDIQHMS 5 MST 107 R Microstepping Stepper Motor a Figure 1 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 3 of 14 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc lO3 man en Ver 1 January 2014 by PRIZMA 220 V AC Power supply board with motor brake PSB 1 dung Breakout board 103 SIXV A Sxv v sixy Z sssssssssissessssisss nor 6 TRANSFORMER 250 400 VA SSSGSSSSSSSSS SSSSSSISSSSSS S sia eus Eyed sic eus V X ox 12 v ovo aA ag ovo a arae a tag So foro exile ei se ovo a ata sasa s pes Figure 2 1 18 10 14 AC2 12 18 V 350 mA
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