User Manual
Contents
1. 3 LED s 5 V logic Good LED Outputs to Controller e Drive Board Ready Signal e Drive Board Fault Signal e Motor Power Supply Ready Signal 6 Specifications Table 6 1 Motor Driver Board Specification Part Number Motor Driver Board Input Motor 12 48 VDC Voltage Vm Output Current Output Current adjustable from 2 to 4 7 Amps Phase Motor Input Voltage 120 240 VAC Driver Board Voltage 5VDC 12VDC 24VDC 5 of rated voltage Regulation Current Dual H Bridge Bipolar Chopper Controller Input Signal High Speed Opto coupled input for step and direction Circuit Opto Isolated inputs for all other signals Step A low to high transition on the STEP input Advances the motor one step The size of the step is determined by the MSx inputs Direction Determines the direction of motor rotation Input Signals Low clockwise High counterclockwise Enable Turns off all Power MOSFET s Logic High outputs are disabled Logic Low internal control enables outputs as required Reset Active low control input used to minimize power consumption when not in use Logic High normal operation When coming out of Sleep wait Ims before issuing STEP command MS2 MSI Micro step select inputs are used to select the micro stepping mode per table 1 Jumper PFD2 PFD Percent of Fast Decay according to Table 2 Selectable SR Synchronous Rectification Mode Low Enabled Functions High Disabled Driver Board Ready Lets the controller2. depending upon current axis on the up and down buttons As stated above if the function button is pressed when main screen is shown the pendant screen will move to the main sub screen as shown below Subscreens Offsets Parameters Soft Limits Thumb Drive Figure 4 3 Sub screen menu The user now has access to offsets parameters or soft limits sub screen Functions available through main sub screen e Use up and down to move between different sub screens e Use accept button to move to new sub screen e Use cancel button to return to main screen If offsets sub screen is chosen from main sub screen menu its screen will appear as seen below Offsets Home Position Park Position Work Offset 1 Work Offset 2 Figure 4 4 Offset Menu The user now has access to the home position park position work offset 1 and work offset 2 sub screens Functions available through offsets sub screen e Use up and down button to navigate to different sub screens e Use accept button to move to new sub screen e Use cancel button to return to main screen e Use function button to return to main sub screen If parameter sub screen is chosen from main sub screen menu its screen will appear as seen below Parameters Machine Parameters TCPIP Configuration Com Port Figure 4 5 Parameters Menu The user now has access to the machine parameters TCPIP Configurati
3. equipment when a tool head is attached and machine is running e Never allow the machine to accelerate too quickly if this occurs lower the acceleration using the CPU e Clean machine surfaces and lead screws periodically to remove any foreign material e Use light oil such as a 3 in 1 to lubricate the ball screws nuts and thrust bearings e Donotexcessively tighten screws in table surface as screws can warp the table and may strip the threads e Avoid use of screws that protrude more than 1 16 inch through surface for each axis e Do not use wrong size screws as the screw heads and or threads may be permanently damaged e Donotlift the powered down machine unless there is adequate manpower or equipment available for dealing with this amount of weight e When connecting the stepper motor to the Motor Drive Board be sure that the power supply is turned off e When using different motors than the SureStep motors that are supplied with your CNC secure any unused motor leads so that they can not short out anything e When using different motors other than the SureStep motors that are supplied with your CNC secure any unused motor leads so that they can not short out anything e Do disconnect motor while the driver is powered up e Never connect motor leads to connectors other then the motor connections e Supply Voltages of 45 Volts are present on the driver board so use caution when performing adjustments when power is appl
4. General Appendices Appendix A User s Manual CNC Machine Prototype User s Manual Table of Contents EG 2 2 ns me 3 5 4 Hand MES 7 5 Motor Driver Board 225 18 19 T Settmne Phase 20 8 Adjustment of Motor Phase Current cccscssccsssssessccrcausersccncaussrscatcausarsenteaucarsenseaucarsenseaseares 21 Connectne the MOTOT Nom 22 10 Internal Motor connection to Motor Driver 4 004000 22 11 Connecting the Motor Power 5 ennemis 23 12 Connecting the Motor Driver Board Power Supply 23 13 micis eerie TET T 23 14 MEN 219 em 24 1 Overview The CNC Machine is designed for multi purpose uses such as milling routing paste dispensing air brushing and soldering where different tool heads are attached for their specific purposes This system is a hybrid system composed of a plastic and metal frame to reduce the machine weight and vibration while the machine is in operation and can support up to a 10 Ib tool head The CNC also travels in three dimensions by means of a ballscrew drive system which c
5. Part 4 B 34 and bolt the holder securely to the spindle plate Part B 33 3 Place the spindle plate Part 4 B 33 onto the Z Axis Mounting Plate Part B 8 and fasten it securely with bolts 4 Connect the motor connectors from each motor already attached to the machine to the control panel box Part BB 5 as well as connecting the control panel box to a 120 Volt AC Outlet and connect 12 VDC power Supply to input jack on the bottom right of control box 5 Power on the control panel box Part BB 5 by turning on the power switch 6 Loadthe operation files using USB flash drive and hand pendent by plugging to the designated port in the control panel box Part BB 5 7 Use the Hand Pendent Controller Part B 43 to adjust the table position to the initial starting point before implementing the program code to initiate the operation task 14 Maintenance In order to keep machine at optimum working conditions regular checkups and maintenance must be done on the mechanics Several conditions should be checked before each job to prevent any breakdown of the machine These conditions are listed below Maintain e Belt Tightness e Grease on thrust bearings e Rod Cleanliness e Motor running temperature e Screw tightness e Tool head re torque If at any time changes in the motor or driver system are wanted consult a technician with expertise in CNC machines
6. e connections labeled A A B B See the digram below to connect the Motor leads to the terminal block Hed A 4 Lead Motor A White Green Black B B Figure 10 1 Thumb Drive Screen 11 Connecting the Motor Power Supply The power supply comes fully connected internal to the Electrical Unit There are 4 power supply connections and are located in the upper right corner of the Motor Driver Board The AC input is label ACI and The DC power is label Vm and Vm See Fig for location of AC and DC input power Note Make sure that the wires Vm and Vm are connected to the correct Thermal Block connectors A reversal of polarity will destroy the board 12 Connecting the Motor Driver Board Power Supply The power supply comes fully connected internal to the Electrical Unit Your CNC Motor Driver Board is setup for 120 VAC It can also be used be used with 240 VAC See table 4 for configuration settings Table 12 1 Configuration for 120VAC 240AC AC Input Voltage Therminal Block Connections Connected Wires 120 VAC P1 Hot P2 and P4 Netural 240 VAC P1 P2 Hot P3 and P4 Netural 13 First Set Up Operation 1 With the CNC Machine Part BB 3 set up at the work station grease the fittings located on the thrust bearing blocks Part B 2 Part B 13 versa blocks Part B 11 and Y axis bushings Part amp B 27 2 Place the spindle Part B 35 inside the spindle Holder
7. eft and right buttons to move between accept and cancel panes e Use accept button when placed on accept to change set positions to current position e Use cancel button when placed on cancel to return to main screen e Use function button to return to main sub screen If thumb drive is chosen from the main sub screen menu the screen will appear as seen below Root mm Folder Name File Name Figure 4 12 Thumb Drive Screen The title of the drive will be displayed at the top of the screen Below the title there will be an icon for the folders followed by each folder s name in the directory After opening the folder there will be a file icon followed by each file s name in the folder Functions available through thumb drive screen e Use up and down buttons to navigate through the list of folders or after a folder is chosen the list of files e Use accept right and left buttons to confirm a choice for the folder or file wanted e Use cancel button to return to main screen e Use function button to return to main sub screen 5 Motor Driver Board Features Pulse width modulation MOSFET H Bridge switching ampifilers Phase current from 2 to 4 7 amps adjustable High Speed Optically Coupled Step and Direction Inputs All other inputs Optically Isolated Full Half 1 4 1 16 step resolution Over Current Protection Overtemperature and undervoltage protection Sychronous Rectification Fuse Blown Indicators
8. f V Table 7 1 Pre Calculated Values for V Motor Phase Current Vref Amps VDC 2 0 688 2 5 86 2 8 9632 3 0 1 032 3 5 1 204 3 8 1 3072 4 0 1 376 4 5 1 548 4 7 1 6168 8 Adjustment of Motor Phase Current The motor phase current is set by adjusting resistors VR1 VR6 for the voltage level calculated from the above formula 1 or Table 3 VR3 VR4 VR6 are the coarse adjustment resistors VR1 VR2 VR5 are the fine adjustment resistors See Fig for location of test points and adjustment resistors Figure 8 1 Adjustment of Motor Phase Current The following steps are used to set V for each axis Calculate V for each axis using the above formula Turn on the power Connect a voltmeter set forV5c between TP and GND and adjust VRI and VR3 for the desired voltage V 3 Repeat step 2 for TP2 Y V 7 using VR2 and VR4 4 Repeat step 2 for Z V ef using VR5 and VR6 5 Turn off the power 9 Connecting the Motor The CNC comes with 3 sureStep motors wich are 4 lead biploar motors The cables for each motor come with quick connect adapters that are connected to the Electrial Unit See Fig for motor connector location Internal connections from the quick connects to the Motor Driver Board come pre connected 10 Internal Motor connection to Motor Driver Board The quick connect cables connect to 3 inpendent therminal blocks labeled X axis Y axis Z axis Each terminal block has 4 wir
9. gh any offset screen e Use left and right buttons to move between accept and cancel panes e Use accept button when placed on accept to change set positions to current position e Use cancel button when placed on cancel to return to main screen e Use function button to return to main sub screen If machine parameters sub screen is chosen from the parameters sub screen the screen will appear as seen below Machine Parameters Max Speed Acceleration Rapid Max Rapid Min Deceleration Jog Speed Max Jog Speed Max Feed Min Feed Jog Increment Figure 4 8 Machine Parameters Screen The variables shown are the machine s current parameters based upon either a current job or jogging through pendant controls Functions available through machine parameters screen Use cancel button to return to main screen Use function button to return to main sub screen If TCPIP configuration sub screen is chosen from parameters sub screen menu the screen will appear as seen below TCP IP Configuration Ip Address XXX XXX XXX XXX Subnet Mask XXX XXX XXX XXX Default Gateway XXX XXX XXX XXX Primary DNS XXX XXX XXX XXX Secondary DNS XXX XXX XXX XXX Figure 4 9 TCP IP Configuration Screen The variables displayed will be based upon the incoming data received through the Ethernet connection Functions available t
10. hrough machine TCPIP configuration screen Use cancel button to return to main screen Use function button to return to main sub screen If communications port sub screen is chosen from the parameters sub screen menu its screen will appear as seen below Com Port Communications Baud Rate Stop Bits Flow Control Parity Xon Char Xoff Char Figure 4 10 Communication Port Screen The variables displayed will be based upon the incoming data received through the serial connection Functions available through machine communications configuration screen e Use cancel button to return to main screen e Use function button to return to main sub screen If either upper or lower limit screen is chosen from soft limits sub screen the screen will have the same appearance with only different titles The screens will appear as seen below Upper Limits Lower Limits Set Current Position Pos X Y Z A Accept Cancel Figure 4 11 Limits Screen The left variables are the set positions of the axes and acceleration based upon those previously set by user or provided by a job The right variables are the positions of the axes and acceleration that are positioned currently on the machine Functions available through any soft limit screen e Use l
11. ied e Never perform adjustments without the presence of a person that can perform CPR e When power is turned off voltages above 45 volts may still exist so allow time for filter capacitors to discharge or use a shorting probe to short the voltage to ground 4 Hand Pendent Operation Access to certain parameters and functions of the CNC are provided to the user through the machine s hand pendant The hand pendant is shown in the format shown below Dial 1 LED Screen Button 1 Button 2 Button 3 Button 4 C 5 C E Button 5 C UJ co S IIO Q g 5 3 E Button 7 Figure 4 1 Pendent Schematic Legend Button 5 Button 6 Button 8 Dial 1 Feed Speed Override Button 7 Each button s process definition is listed below Function Brings up the main sub screen menu to allow the user to access and change lower level functions and access different screens Cancel Stops any action taken on the machine and brings the machine to rest until either a new task is initiated through a job or through the pendant Accept Accepts a task initiated by the user through the hand pendant Axis Switch Changes axes between y and z axis on the up and down buttons Up Move up on any sub screen or change direction on either y or z axis when jogging Right Move to the right part of any sub screen or change directi
12. know that the Driver is Ready Output Signals to the Controller Motor Voltage Available Lets the controller know the Motor voltage is available Driver Board Fault Lets the controller know that there is a Fault on the Driver Board See Users Manual to configure for 240 VAC SR must be enabled Low Table 6 2 Microstep Resolution Truth Table MS2 MSI Microstep Resolution 0 0 Full Step 0 1 Half Step 1 0 Quarter Step 1 1 Sixteenth Step Table 6 2 Mixed Decay Selection Truth Table PFD2 PFD2 Percentage of Fast decay 0 0 0 Slow Decay 0 1 8 1 0 26 1 1 100 Fast Decay Note The Driver Board is set by default to 100 fast Decay Mode This mode provides fast current control when the motor is stepping at very high speeds 0 will maintain the H bridge in slow decay at all times Use this option to keep the phase current ripple low when the motors are stepping at very low rates Choose the option that gives the motors the best response for the given application 7 Setting Phase Current Before you use your CNC you need to set the drivers for the proper motor phase current The rated current is usually printed on the motor label Current Setting Formula Vref 344 X Itrip max 1 ltrip max rated current of the motor Using the above formula you can calculate the Voltage Reference needed to set the maximum trip current Each motor has its own Voltage Reference See table for a list of calculated values o
13. on and communications port sub screens Functions available through parameters sub screen e Use up and down buttons to navigate to different sub screens e Use accept button to move to a new sub screen e Use cancel button to return to main screen e Use function button to return to main sub screen If soft limits sub screen is chosen from main sub screen its screen will appear as seen below Soft Limits Upper Limits Lower Limits Figure 4 6 Soft Limits Menu The user now has access to upper and lower soft limits screens Functions available through soft limits sub screen e Use up and down buttons to navigate to different screens e Use accept button to move to new screen e Use cancel button to return to main screen e Use function button to return to main sub screen If any offset is chosen from offsets sub screen menu the screen will appear in the same format except it will have a different title based upon which offset was chosen It appears as seen below Title Set Current Position Pos X Y Z A Accept Cancel Figure 4 7 Offset Screen The left variables are the set positions of the axes and acceleration based upon those previously set by user or provided by a job The right variables are the positions of the axes and acceleration that are positioned currently on the machine Functions available throu
14. on on the x axis when jogging Down Move down on any sub screen or change direction on either y or z axis when jogging Left Move to the left part of any sub screen or change direction on the x axis when jogging Feed Speed Override Increase or decrease speed feed rate of a job 50 of its given speed feed rate Before any buttons are pressed on the pendant the main screen of the pendant will always be shown as seen below 00000 AA Figure 4 2 Main Screen The left pane represents the locations of all axes according to the tool head s placement on the table top and the current acceleration rate of the machine The bottom left area contains the five limit switch section that is set using circles When a circle is red that limit is turned off and when it is green it is turned on The top right dial represents the change in feed speed rates The bottom right pane will tell the user if the machine is jogging running a job or idling Functions available through main screen e Use function button to immediately change main screen to main sub screen e Use feed speed override dial to show where rate was changed from original position in either positive or negative direction e Use any directional button to begin jogging in direction of pressed button according to tool head placement on table top and move to idle state after movement is complete e Use axis switch button to switch from either y to z or z to y axis
15. onverts rotational motion of the ballscrew into linear motion and gives the machine a total acceleration rate of 4 The CNC can operate online on offline use through the use of a flash drive port and pendent commands to access the operation file il il 1l i i bi 111281 33 ae TTE LEY ms N R Fanai UNA Figure 2 1 CNC Machine Assembly 5 End B 20 B ZL 2 Base Assembly Figure 2 PARTS LIST We mm por i a my vn Xx Motor Momrfor Alumim Kand Y iai E 1H X Axis Back Pan a id 7 EE 25 mim a Alumni rhe rp Puky Hub Pulley Hub PME LEE Gary Aluminum T E B 14 X Axis Ball Mut Aluminum Flange Figure 2 4 X Axis Assembly PARTS LIST T MLM L IEME MARME T Axes Bolom Fanz T Ais Back Pore Pere pee Wersa cina pun inneren sa m 20 2 p mim a a Slee I Ak Bal Mut Flange Z Axk Eaker Stet Z SEmewicHt E Nx Thrust Exarire Foley m 2 2 a a p p F EE 7 de Figure 2 5 Z Axis Assembly 3 Safety In order to prevent injuries to the user and to keep the machine from being pushed beyond its restriction boundaries certain safety measures must be followed The machine must
16. operate at specified conditions These ratings are listed below Table 3 1 Machine Ratings 110 F Speed Tool head weight os 10 Ibs When running the machine will generate a baseline amount of noise due to the motor rotation If a tool head is attached an extra amount of noise will be added to the baseline value Due to the large amount of extra noise that will be added from the tool head it is recommended that the user wear hearing protection to prevent permanent hearing loss Table3 2 Noise Ratings When working with the machine there are general cautionary procedures that must be avoided in order to maintain the machine and prevent injury or death to the user These cautionary procedures are listed below e Do not put hands any axis when machine is running e Do not have food or drink near the machine Do not try move tool head until it is ready to be removed from the machine e Do not move the machine while it is powered on e Do not try to open machine unless you are a trained technician with a first aid kit in the near vicinity e Do not work alone Do not touch driver board immediately after shutting down machine due to remaining charge in chassis mounted capacitors that may cause electrocution e Always wear eye protective equipment when using drill or milling tool functions e Always turn machine off before performing maintenance unless otherwise stated e Always wear ear protective
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