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RCS4AXIS v1.5 breakout board

1. 29 Wiring Information and Schematics 31 Case R 37 Front Panel LED s ESTOP etc 41 Crate Dimension and Weight sese 42 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Safety Personal Safety An Important Issue Always remember your safety is of the greatest importance Please make sure that you are familiar with your machine and its tools as well as the material you are working on Failure to be knowledgeable may result in serious personal injury or damage to the machine Common sense will be your greatest defens 1 2 3 4 Personal Clothing and Jewelry Clothing must be kept away from the machine Make sure to keep sleeves away from rotating bits gears and belts Frayed strips of clothing or tie straps on shop aprons are especially dangerous so you must be aware of these at all times and should cut them short or tuck them out of the way Jewelry has absolutely no place in the workshop Watches bracelets and necklaces may get caught in the machine or in the tool bit Ear and Facial Protection Eye protection is mandatory Safety glasses or a face shield must be used at all times Appropriate measures must also be taken to protect the ears from loud noise Over a period of time permanent hearing damage may occur Others who work near the machine should also wear ea
2. is touching the tip of The spindle and VFD should have proper grounding otherwise the probe will not function With Automatic Tool Change system a jumper wire with a small magnet at the end of it should be put on spindle collet to close the ground connection as the ATC spindle collet is electrically isolated from spindle body ESTOP ESTOP 15AFUSE 4 SERVO CONTROLLER 115 3 001 ON OFF Figure 29 Photo from the front and left side of controller case The machine will be stopped by pushing the additional ESTOP s on the side of gantry FUSE ESTOP pushbutton There might be The front panel fuse should be rated for the correct voltage and amperage Disconnect the power plug to the controller when you replace or test the fuse Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 ON OFF After turning the controller ON you should see the light in the switch to turn ON If this light is not ON check the power coming to the controller The receptacle that powers the controller and also the fuse or circuit breaker should be rated for the correct voltage and amperage of the controller Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Crate Dimension and Weight The dimension of finished connector is 19 x 24 x 5 1 2 Add 1 2 on each side for bubble wrap The inside dimensi
3. 2 E 2 E 4 5v 120 ALY 10 2 PC POWER SUPPLY O L 10 Figure 6 RS232 is used for MODBUS communication to implement same function as LPT2 Connectors Description Function LIMIT SWITCHES Limit or home switch connector Header 8x2 1 EN4 Encoder header to DB15 encoder connector Header 8x2 E5 Special header replacing 1 EN2 and EN3 Header 20x2 compatible with older systems encoder board 1 LPT2 Parallel port one and two Header 13x2 RS232 Serial communication for MODBUS Header 5x2 FPC 1 FPC2 Front panel LED connectors Header 8x2 Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Jumpers and Potentiometer RCSAAXIS 1 5 LIMIT SWACHES j C RC LT 512 L2 10 554 AUuXi DL PC POWER SUPPLY 3 O cow Fei up 2 00 0 c Coo Figure 7 The potentiometer RV1 black is used for adjusting the 0 10VDC for spindle speed control In rare cases there is a need to adjust this potentiometer in the field Jumper s Description JP1 JP2 green Table ESTOP Jumper if no ESTOP pushbutton on gantry JP3 yellow Tool release should happen only when spindle has stopped Jumper if not used JP4 blue Only in position B 1 red E
4. Jojou ACT YOLOW 28 NIV Agr gt H3MOd SAH YAGOON Jojow X c A8 gt H3dd3lS HLOOWS 3MOd YOLOW 9 4 H30O0DN3 011 9 40153 35 AV I38 9 550309 0432 AV 133 gt ZM3dO2N3 Ajddng 4 24 7 19poou3 A Jepo2u3 X 19po2u3 2141 AS 87 2 xnv Lon xnv Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Power Supplies 5VDC 5V _ POWER RED WIRE SUPPLY 12VDC 12V POWER YELLOW WIRE SUPPLY AC INPUT AS PER NAMEPLATE Figure 23 Turn ON the PC first then controller After the controller switched ON both 5VDC and 12VDC should be available at the board UNREGULATED 48V DC POWER SUPPLY L q lt HV AC INPUT AS PER NAMEPLATE q FUSE RATING AS PER NAMEPLATE Figure 24 The HV 48 VDC should be available only when ESTOP s are pulled out and the charge pump signal is sent to the controller 48 VDC is used to drive DC brush motors For drive wiring see the manufacturer s user manual Ridge Coutrol Systems Tel 1 888 493 6165 Email Contact ridgecontrolsystems com Fax 1 888 493 6165 34 1 T T GANTRY 2 ESTOP 9 7 Z HOME 13 6 X2 A HOME 12 16 MISTER SOLENOID 17 10 PROBE Z TOUCH PLATE 23 Figure 25 LIMIT SWITCH connector signals Internal connections of LIMIT SWITCH receptacle TOOL
5. coming from Automatic Tool Changer spindle Ridge Tel 1 888 493 6165 Control Systems Email Contact ridgecontrolsystems com Fax 1 888 493 6165 Spindle Stop S S This LED should be ON when the spindle is stopped The signal is coming from VFD and used with Automatic Tool Change systems Mister This LED should be ON when you enable th LED is ON you should have 12 VDC provided to the solenoid valve mister from software When the Spindle This LED should be ON when you enable the spindle from software This can be either a small spindle router connected thru spindle control thru AUX I O 1 With Automatic Tool Changer systems ATC you should see spindle fan running when the spindle is turned ON controlled thru RELAY CONTROLLED AUX POWER collector thru RELAY CONTROLLED AUX POWER you should see it turn ON at the same time as spindle Brake This LED should be ON when all the ESTOP If you are RELAY CONTROLLED AUX POWER or S are pulled out The spindle fan is controlling a dust and System is enabled from software It indicates that the 24 VDC has been supplied to magnetic brake of Z motor If the system has a magnetic brake and this LI ED does not turn ON it means that brake is still engaged The machine should be stopped and problem fixed Z0 This LED should be ON when the prob Z touch plate router bit in spindle
6. r x OTOOTO NFM Tria 1 NE Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs Figure 18 Input 15 is hard wired for probe Z touch plate and input 10 for ESTOP Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 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 Pin Number Enable6 0 Output 1 14 Output 2 16 Output 3 Output 4 Output 5 Output 6 Charge Pump Charge Pump2 Current Hi Low Output 7 gt ctive Low X X KA N N NAA BE OE OE OE OE AE Pins 2 3 1 14 16 and 17 are output pins other pin numbers should be used Figure 19 Output 41 is hard wired to spindle ON OFF output 42 to mister ON OFF Pin 17 generates the charge pump signal Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mil Options m Relay Control Motor Control Special Functions Disable Spindle Relays Use Spindle Motor Output Use Spindle Feedback in Sync Made Clockwise M3 T PWM Closed Lo
7. 20 The VFD control signal will be 0 10 VDC Set the maximum spindle speed by selecting Config gt Spindle pulleys Pulley Selection Current Pulley Min Speed Max Speed Ratio Pulley Number 1 0 18000 1 Reversed Figure 11 Set the maximum spindle speed Motor Tuning and Setup Axis Selection x Axis Y Axis 2 Axis cen Velocity inches per Minute DEM 0 05 0 1 0 15 0 2 0 25 0 3 0 35 0 4 0 45 0 Time in Seconds SPINDLE MOTOR MOVEMENT PROFILE 5 Spindle Accel Velocity Acceleration Step Pulse Dir Pulse Steps per In s or mm s per min in s or mm sisec fsec G s 1 Sus 1500 49 998 10 0 025901 0 0 Figure 12 Steps rev speed and acceleration values for spindle Verify the actual spindle speed at 25 50 75 and 100 Minor adjustment to Steps per revolution should bring you close to 1 accuracy In rare cases you need to adjust the potentiometer on the board see Figure7 Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Probe or Z touch plate setup Please follow the steps below for activating and setup of probe Z touch plate l Make sure pin 15 is setup as per Figure8 Click Config gt Ports amp Pins gt Inputs and configure pin 15 as the Probe input making it Active Low 2 Verify the operation of the probe by touching the router bit with the Z touch
8. RELEASE SOLENOID LIMIT SWITCH Signal Description Limit Switch Connector PIN Breack out board connection Gantry ESTOP 1 amp 2 ES2 PIN 1 amp 2 X HOME 9 amp 15 LIMIT SWITCH 1 amp 2 Y HOME 8 amp 14 LIMIT SWITCH 3 amp 4 Z HOME 7 amp 13 LIMIT SWITCH 5 amp 6 X2 A HOME 6 amp 12 LIMIT SWITCH 7 amp 8 MISTER SOLENOID 16 amp 17 5 PROBE Z TOUCH PLATE 1104 23 Z0 TOOL RELEASE SOLENOID 34 amp 35 TRS Ridge Coutrol Systems Tel 1 888 493 6165 Email Contact ridgecontrolsystems com Fax 1 888 493 6165 Figure 26 AUX 1 connector Internal connections of AUX T O 1 Signal Description AUX I O 1 PIN Break out board connection Spindle ON OFF 6 amp 10 AUX I O 1 MOLEX PIN 1 amp 2 Spindle Speed 0 10 VDC 12 amp 13 AUX I O 1 MOLEX PIN 3 amp 4 10 VDC Reference voltage 14 AUX I O 1 MOLEX PIN 5 Spindle stop 7 amp 11 SS Encoder signals DB15 Signal D Sub Pin Renco Q Phase MCG Index 2 Brown Brown Yellow ChA 3 Yellow Yellow White ChB 5 Blue Blue Green Sheild 8 Bare Bare Bare GND 9 Black Black Black Index 10 Orange Orange Orange ChA 11 White White Brown 12 Ch B 13 Green Green Blue Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Motor power conn
9. Replace the controller case cover and tighten the screws 8 Plug the table connectors for motor power encoder limit switch connector AUX I O and also power as per nameplate of controller see Case Connectors 9 Connect the controller to the PC parallel port For Smooth Stepper TM the connector will be either USB or Ethernet 10 verify that steps per inch for all axes are correct see Motor Tuning chapter 11 verify that spindle speed is correct see Spindle Speed Tuning chapter 12 Verify the normal operation of the machine see Normal Operation chapter 13 verify the operation of Z touch plate see Probe Chapter idge Email Contact ridqecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Board Setup Connector Definitions and Jumpers z d E m q 2 Figure 1 RCSAAXIS v1 5 has support for 4 motors spindle mister and limit switches Normal operation of the board As soon as the board is powered up D2 yellow and D4 green LED s should turn on This indicates that 5VDC and 12VDC are available for operation of the board D1 red LED will turn on for three seconds and will turn off again When all ESTOP s are pulled out system has been enabled from Mach3 and there are no fault on amplifiers drives the Dl will blink on for 1 second and off for 1 second D2 yellow is ON 5VDC s
10. is the same ground coming to the controller case thru power plug If the machine is not connected to a proper grounding there is a high risk for electrical shocks You will also experience problems with spindle speed control Signals supported by this connector are Spindle ON OFF Spindle stop signal used with Automatic Tool change systems ATC Spindle speed control 0 10VDC AUX I O 2 This connector is used with Automatic Tool change systems ATC Signals supported by this connector are Tool Release T R Tool Clamp T C e Manual tool release by pressing the green button on the tool should be released AUX I O 3 This connector is used with systems with additional control board such as smooth stepper systems It provides USB or Ethernet connection to the control board Encoders X Y Z X2 A These connectors are used to bring encoder feedback to amplifiers drives X2 A may not be available on all systems Parallel Port Male or Female DB25 parallel port connection to controller s computer It is not connected if the system is controlled by additional control board such as smooth stepper Serial Port Male or Female DB9 serial port connection to controller s computer This connector is used for MODBUS communication It is not available on all systems Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Front Panel LE
11. 0000hz ModBus Plugin Supported B5000hz 7500052 100khz TCP Modbus support Event Driven Serial Control Note Software must be restarted and motors retuned if kernel speed is changed Apply Figure 15 Enable port s MODBUS and select Kernel speed Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Enabled Step Pin Dir Pin Dir LowActive Step Low Ac Spindle Figure 16 Spindle X Y Z and A motor settings Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Engine Configuration Ports amp Pins Enabled Active Low ME OE OE OE OE OE S S 95 2 c oj ojojojojojojojo r df df x df x Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs Apply Figure 17 Input 11 12 1nd 13 are hard wired to limit switches on X Y and Z axis Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Engine Configuration Ports amp Pins ctive Low Emulated gt Limit Ovrd M X OE OE OE OE OE A OE S S M OE OE OE OE OE OE OE S OE S 1 Dd df 1 f x 1
12. Analyse Current limit 14 95 Ap 350 Ad 5000 12 Li 65000 Sampling time 5 SAVE TO EEPROM DOWNLOAD RELOAD Try to connect Data from drive loaded Figure 21 Typical PID values for Whale 3 servo drive For the actual values used with your machine see chart below For detalied info regarding the tuning and PID setting of this drive see manufacturer s user manual The setting used for Astromec T31 25 and MagMotor C33 E 300FE and C33 E 300FEB were as the picture below Encodermode 2X Stepmultiplier 4 Stepmultiplier 4 Stepmultiplier 4 LockoutError 1000 LockoutError 1000 LockoutError 1000 PWMlimit 512 PWMlimit 512 PWMlimit 512 Currentlimit 15 0 Currentlimit 15 0 Currentlimit 15 0 Ap 440 350 440 Ad 7000 Ad 5000 Ad 7000 Ai 12 Ai 12 Ai 12 Li 55000 Li 65000 Li 55000 Sampling 4 Sampling 5 Sampling 4 Email Contact ridgecontrolsystems com Ridge Control Systems Fax 1 888 493 6165 Tel 1 888 493 6165 DG2S DG3S and DG4S Servo Drives Parameters For detalied info regarding the tuning and PID setting of this drive see manufacturer s user manual The setting used for Astromec T31 25 and MagMotor C33 E 300FE and C33 E 300FEB were as the picture below 5 Servoconfigurator Connection PID tuning Error viewer Analisator Diagnostics Firmware update Visi
13. Axis 323 57 287 618 Y Axis 251 666 215 714 2 Axis 179 761 143 809 107 857 71 3045 35 9523 0 0 01 0 2 0 3 0 4 0 5 0 6 0 7 Time in Seconds Velocity inches per Minute Spindle Accel Velocity Acceleration Step Pulse Dir Pulse Steps per In s or mm s per min in s or mm s sec sec Gs 1 5us 0 5 2086 1 250 02 10 0 025901 0 0 Cancel OK Figure 9 Figure 8 Steps in speed and acceleration used for Y axis on a 5 x10 rack and pinion table Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Motor Tuning and Setup Axis Selection Z AXIS MOTOR MOVEMENT PROFILE vcio 288 355 x Axis 25952 230 684 Y Axis 201 849 173 013 Z Axis 144 178 115 342 86 5065 57 671 28 8355 0 1 0 2 0 3 0 4 05 06 0 7 0 8 0 9 Time in Seconds ao o a e lt o s gt o 2 o gt Spindle Accel Velocity Acceleration Step Pulse Dir Pulse Steps per In s or mm s per min in s or mm s sec sec Gs 1 5us meta 5201 92 250 02 10 0 025901 0 OK Figure 10 Steps in speed and acceleration for a 6 Z axis holding a 5HP 18000 RPM max speed Perske spindle Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Spindle Tuning Spindle speed is controlled by step signals on pin 1 as per illustrations 11 and
14. D s ESTOP etc ESTOP NIV r iu a Bet EVE A Figure 28 LED s are showing the status of the machine FAULT If this LED is ON it indicates an amplifier drive fault This can be due to either no encoder feedback or a collision After a fault due to collision the machine position is not correct any more and it should be homed again To clear a FAULT error push the ESTOP button and wait till HV light is OFF This will reset the drives Then by pulling the ESTOP you will get back the HV light while the FAULT is OFF You can home the machine now If you still have FAULT light ON then there is an encoder feedback problem ESTOP When all ESTOP pushbuttons are pulled out this LED is ON HV This LED is ON when the 48 Volt DC is available to power the drives If after enabling the system thru software there is no HV light check the front panel fuse LIM X LIM Y LIM Z LIM X2 A These LED s show the status of limit or home switch If the machine is away from its home position on that particular axis the LED should be ON If you use a screw driver and push the lever on the side of the limit switch you should see the status of LED change on the related axis Tool Release T R This LED should be ON when the tool is released The signal is coming from Automatic Tool Changer spindle Tool Clamp T C This LED should be ON when the tool is clamped The signal is
15. DC for disengaging the magnetic brake on the Z axis RELAY CONTROLLED AUX POWER These two power receptacles work together The rating is limited to 10A at 250 Volt AC VAC You need an additional power input to the receptacle on the right The relay switchs the power ON and OFF with spindle ON and OFF command This arrangement has been used to control Small handheld routers such as Kress Porter cable etc or Vacuum dust collector or Spindle fan on larger spindles such as the ones installed on Automatic Tool change systems ATC LIMIT SWITCH This connector will bring signals from limit switches back to the controller Othe signals that use this connector are Gantry ESTOP signal Power and signal to probe Z touch plate Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Power to mister solenoid Power to tool release solenoid on Automatic Tool change systems ATC AUX I O 1 This connector is used to control spindles connected to a Variable Frequency Drive VFD also known as inveter The spindle ON OFF signal is controlled by an on board relay inside the controller The 0 to 10 Volt DC VDC reference signal is generated out of the 24 VDC power from VFD At 10 VDC the spindle should run at its maximum RPM This connector makes the controller electrically isolated from VFD For proper operation VFD should be grounded to the building ground which
16. Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 DC Servo Controller based on RCS4AXIS version 1 5 Document version 1 04 For Technical Support latest version of the user manual downloading setup files and Parts Sales visit http ridgecontrolsystems com Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 ci S 3 El ctrical Safety 4 Quick P 5 Board Setup Connector Definitions and Jumpers 6 Drive Connectors on the Top of the Board 8 Molex Connectors on the Left Edge 9 Molex Connectors on the Right Edge 10 Ribbon Cables to Box Headers ser rei ins 11 Jumpers and Potentiometer 12 Motor TUNG siccus thui ra YE DURUM 13 Spindle Tuning 16 Probe or Z touch Plate SODUD 17 Magh 3 Software SD educat ones oni us exuta E 20 Normal Operation of Controller 27 Drive Tuning Parameters PID Values esce oH HERE PIPER RUE 28 Wahle 3 Servo Drive Parameters 28 DG2S DG3S and DG4S Servo Drive Parameters
17. Y ard supports 4 axes Each group of connectors with same color are going to control one axis Rl control the X axis R2 control the Y axis EN3 and E 4 and R3 control the Z axis ERA control the A axis Encoder for X axis RJ45 DRV1 Main for X axis RJ45 EN1 ER1 jumper pin 1 8 ERI must b jumpered either enabled Encoder for X axis Header 8x2 connecting to DB15 receptacle cas connector To enable jumper center pin and EN To disable jumper center pin and top two pins or disabled bottom two The three other groups of connectors are defined in a similar way for use with Y Z and A axis Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Molex Connectors on the Left Edge BRAKE 1 1 1 El Figure 4 AUX I O 1 is a 5 AUX I O 2 is a 10 connector All others are 2 connectors AUX 1 0 2 TRS SS AUXI O1i1 VFD4 5 B 124 20 Connectors Description Function Z0 Probe connector 12V 12 VDC supply max 1A MST2 Normally open relay controlled continiuty for Mister control MST Mister control signal 12 VDC to activate solenoid valve or relay VFD Spindle control signal 12 VDC to relay AUX I O 1 Normally open spindle control and 0 10 VDC spindle speed si
18. be OFF 5 MISTER should be OFF 6 SPINDLE STOP should be ON 7 If any of the ESTOP buttons one at the front of controller and possibly two on the side of gantry is pushed in then FAULT ON ESTOP OFF HV OFF At this time there is no power to the drives therefore X and Y axis can be easily pushed by hand back and forth However the Z axis should hold if the magnetic brake is engaged By pulling all ESTOP buttons out you should see that FAULT OFF ESTOP ON HV ON Now the drives are powered and all axes should be holding their positions The magnetic brake on the Z axis is still engaged At this time the Reset button in Mach software can be pushed You should see BRAKE ON Which means that magnetic brake is released and all axes are ready for JOG or move command Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Drive tuning parameters PID values In case the drives need a programmer the drive programmer will be shipped inside a tagged plastic bag in the controller Whale 3 Servo Drive Parameters 23 Servoconfigurator x Connection PID tuning Error viewer Analisator Diagnostics Firmware update Visit website Help Drive settings Step active high Step multiplier n 3 Encoder Steps to move Max Error 1000 2xmode 100 PWM limit 512 C 4xmode
19. ded Figure 14 Main setttings of RCS4AXIS parameters with Mach3 software 1 Setup the Port 1 Port 2 address and Kernel speed as per Mach 3 user manual 2 If you use MODBUS support of RCS4AXIS check ModBus Input Output Support and check ModBus PlugIn Supported see Figurel10 3 Enable only those motors that are used on your machine The board supports up Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 to 4 axes plus spindle If the the machine JOG is not working in the intended direction you need to reverse the direction of motion by changing Active Low from checked to unchecked or vice versa The port pins are hard wired to RJ45 plugs on the board Each pair of ports 2 amp 3 4 amp 5 6 amp 7 and 8 amp 9 control one axis The controller is built to use the suggested setup Figurell Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Port 1 Port 82 MaxNC v Port Enabled Port Enabled Max CL Mode enabled 0378 Port Address 0x278 Port Address Max NC 10 Wave Drive Entry in Hex 0 9 A F only Entry in Hex 0 9 F only Program restart necessary Pins 2 3 as inputs m Restart if changed Sherline 172 Pulse mode Kernel Speed ModBus InputOutput Support e 25000Hz 35000Hz 45000Hz 6
20. ector Figure 27 Motor power connector Pin Description 1 Black Power GND ARMI 2 Red Power 48V ARM2 3 Magnetic brake GND 4 Magnetic brake 24 VDC Note Pin 3 and 74 are only wired for Z axis Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 AUX 2 Figure 28 AUX I O 2 used with automatic tool changers ATC Pin Description Manual Release GND 12 VDC Tool Release Sensor GND 12 VDC Tool Clamp Sensor GND eN Nn WIN Re Ridge Coatrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Case Connectors gt ENCODERS ini SX Figure 27 This is a photo of a fully populated connector plate Some of these connectors may not be available on your system SERVO POWER This is the power for energizing the amplifiers and boards inside the controller case The power rating of the cable is dependent on the customer machine type and requirements s the nameplate In the picture above the power needed is 15A at 115 Volt AC VAC The system is delivered with appropriate power plug International customer may receive the system without power plug MOTORS X Y Z X2 A The four pin black connectors deliver power to CNC motors X2 A may not be avialable on all controllers Z axis motor connector is providing 24V
21. ermined using the relative option of the digital read out DRO located in the upper left corner of the screen 8 Compare this number in the DRO to the value against the tape measure For most signing applications 1 32 or 1 64 is sufficiently accurate Using our two distance values we will create a ratio by which we will adjust out default steps in Corrected Steps inch 014 Steps inch desired distance measured distance Example The Steps inch on X axis is 1928 A command to X axis by 10 inches move the machine by only 7 5 The correct steps will be Corrected Steps inch 1928 10 7 5 2570 6 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Motor Tuning and Setup Axis Selection X AXIS MOTOR MOVEMENT PROFILE Velocity 359 523 x Axis 323 57 287 618 Y Axis 251 656 215714 Z Axis 179 761 143 809 107 857 71 9045 35 9523 er Minute o a a amp oa E gt 02 04 05 06 Time in Seconds Spindle Accel Velocity Acceleration Step Pulse Dir Pulse Steps per In s or mm s per min in s or mm s sec sec G s 1 5us 0 5 2086 1 250 02 10 0 025901 0 0 Figure 8 Figure 8 Steps in speed and acceleration used for X axis on a 5 x10 rack and pinion table Motor Tuning and Setup Axis Selection Y AXIS MOTOR MOVEMENT PROFILE VERE 359 523 x
22. gnal SS VFD signal indicating spindle stop 24VDC or spindle running 0 VDC TRS Tool release signal 12 VDC to activate solenoid valve or relay AUX I O 2 Tool changer control signals Magnetic brake 24 VDC when enabled max Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Molex Connectors on the Right Edge 2 LE Lx QI Ex je e 1 3 1 1 HV PC POWER SUPPLY 5V 12V ES1 ES2 ES3 ZCR Figure 5 ES3 connects to controller case ESTOP ESTOP s on the side of gantry connect to ES2 If there are no ESTOPS on the side of gantry JP2 must be jumpered 51 has a similar function as ES2 Jumper JP1 if ESI is not used Connectors Description Function ZCR Enable Zero Crossing Relay 12 VDC ES3 ESTOP pushbutton on controller case ES2 ESTOP pushbutton on gantry jumper if there is no pushbuttons on gantry ES1 Extra ESTOP jumper if not used 12V 12 VDC supply max 1A 5V 5 VDC supply max 1A PC POWER SUPPLY Standard PC Power supply connector providing 12 and 5 VDC Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Ribbon Cables to Box Headers RC54AXIS v1 5 LIMIT SWACHES Tj IL IL oo 14 eo ds e MEN Hc i M514 512 L2 10 E51 E52 59 1 2
23. nable only if the axis is used Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Motor Tuning Mach3 user manual explains the procedure for motor tuning If the encoder gain values from the old system are known the Steps in values can be calculated by Steps inch 1 8 Enc_gain This equation is valid for all axes as well as belt and rack and pinion machines Example Z axis encoder gain for a 5mm 0 197 pitch ballscrew and 2048 line encoder will be ENC_GAIN 0 197 2048 4 0 00002400344488 The steps per inch will be Steps in 1 8 0 00002400344488 5207 6 You can also verify adjust the value of steps in for each axis by measurements 1 Start the controller and allow to boot normally 2 Home the router 3 Install a sharply pointed tool in an appropriate collet a small cutting tool or pencil etc 4 Find a known accurate measuring device a new high quality tape measure Lay the tape measure on the router table surface extend tape measure to the full effective length of the table surface 5 Position the pointed tool to the front of the machine over an easily read index on the tape measur lin 2in 5in etc 6 Set this value to be the machine origin 7 Jog the machine down the length of the table a desired distance round numbers ar asier 40in 50in 100in etc longer distances provide better accuracy this distance should be det
24. not do anything if the probe is already grounded If GetOemLed ProbeLED 0 Then Wait a few seconds for user to get the touch plate in place Code G4 P2 Save the current value of feedrate CurrentFeed GetOemDRO FeedrateDRO Save the current coordinate mode AbsMode GetOemLED AbsoluteModeLED Set the absolute coordinate mode Code G90 Zero Z DRO Call SetDro ZDRO 0 0000 Pause for DRO to update Code G4 P0 5 Do the touch move Code G31 2 0 5 F amp ProbeFeed Wait for it to complete i e moving down slowly till router biy touches the plate While IsMoving Wend Delay for a little bit Code G4 5 Get the Z position where probe input triggered ZProbePos GetVar ZTouchDRO Retract to touch position Code G0 2 amp ZProbePos Wait for it to complete While IsMoving Wend Set Z DRO to touch plate thickness Call SetDro ZDRO PlateThickness Pause for DRO to update Code G4 P0 5 Ridge Coutrol Systems Email Contact 2ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Retract Z to SafeZ if enabled else to RetractClearance above plate If IsSafeZ 1 Then SafeZ GetSafeZ SafeZ gt PlateThickness Then GotoSafeZ End If Else RetractHeight PlateThickness RetractClearance Code GO Z amp RetractHeight End If Display the message Code Z axis is now zeroed Restore feedrate to original
25. on of wood crate should be 20 x 25 x 6 1 2 The weight is 50 Lbs for a standard 3 axis controller and 52 Lbs for a 4 axis controller Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Parts Description Part number Breakout board RCS4AXIS v1 5 Slow Blow fuse for 110VAC controller MDA 15 Slow Blow fuse for 220VAC controller MDA 7 48V DC control Relay Crydom D2425 AUX Relay for control of dust collector small spindle or spindle fan T92S11D22 12 DC Servo Drive DG3S 08020 Power Supply 5VDC 5 25 5 Power Supply 12VDC 5 60 12 Power Supply Dual output 5VDC and 12VDC D 60A
26. op Spindle Control Step Dir Mot 4 1 d 0251 ft fos Output Signal 1 6 Spindle Speed Averaging Flood Mist Control CN Me rur qo MinmumPwM Disable Flood Mist relays Delay Mist M7 Output 2 0 General Parameters Special Options Usually Off Flood M8 Output tt 2 0 CW Delay Spin UP Seconds Hotwire Heat for Jog Output Signal s 1 6 CCW Delay Spin UP _ Seconds 7 Laser Mode freq ModBus Spindle Use Step Dir as well CW Delay Spind DOWN 1 Seconds Torch Volts Control Enabled 54 64 127 CCW Delay Spin DOWN Seconds Torch Auto Off ADC Count 6380 Immediate Relay off before delay Figure 20 M3 and M4 will turn the spindle ON The router spindle will always turn only in one direction M7 and M8 will turn the mister ON Under motor control check the boxes for Use Spindle Motor Output and Step Dir Motor Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Normal Operation of Controller At power up you should see the following 1 The light of ON OFF switch should turn ON 2 If machine is away from home position of any axis the LIM status light for that axis should be ON otherwise OFF 3 If Z touch plate Probe is plugged in th Z0 light should be ON 4 SPINDLE should
27. ost of a new bit is usually less than the cost of labor and material to repeat a job Use the Proper Tool Each material requires use of the proper tool bit Incorrect selection of bit may result in damage to bit motor and or material Keep an Organized Workspace Before starting any job ensure the operator s area is clear Remove material and secure wires hoses and cords from operator s area Inspect cords for proper connections and damage Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Electrical Safety Grounded equipment must be plugged into an outlet properly installed and grounded in accordance with all codes and ordinances Never remov th grounding prong or modify the plug in anyway Do not use any adapter plugs Check with UL approved tester or a qualified electrician if you are in doubt as to whether the outlet is properly grounded If the equipment should electrically malfunction or break down grounding provides a low resistance path to carry electricity away from user Don t expose electrical equipment to rain or wet conditions Water entering electrical equipment will increase the risk of electrical shock Do not abuse cord Never use the cord to carry the equoipment or pull the plug from an outlet Keep cord away from heat oil sharp edges or moving parts Replace damaged cords immediately Damaged cords increase the ri
28. plate The ZO LED on the front of case should turn ON 3 Click to the Offsets screen and in the top left corner set the touch plate thickness to the exact thickness of your plate 0 250 or measure the plat thickness 4 Click on Operator gt EditButtonScript then click on the AutoToolZero button When the VB editor opens delete the lines of code and paste in the macro explained below Engine Configuration Ports amp Pins Enabled Active Low Emulated Input 2 Input 3 Input 4 Limit Ovrd THC Down AFM Trin 1 OE OE S STOT OTO OOO OTOT 1 f ar 54 r r aP v Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs Figure 13 Probe Z touch plate is hard wired to Pin 15 Tool Zero Setting Macro PlateThickness 0 250 Thickness of touch plate RetractClearance 0 100 Clearance above touch plate to retract to ProbeFeed 5 Feedrate to use for probing Mach3 DRO constants ZDRO 2 7 Axis DRO Ridge Coutrol Systems Email Contact ridqecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 AbsoluteModeLED 48 Absolute Coordinate Mode LED IncrementalModeLED 49 Incremental Coordinate Mode LED FeedrateDRO 818 OEM code for feedrate DRO ProbeLED 825 OEM code for probe input LED ZTouchDRO 2002 OEM code for DRO that holds Z touch position Do
29. r protection while the machine is running Working Close to the Router Bit Use a push stick to clear away debris near the router bit never your hands Make sure that under no circumstances is any part of your body or any foreign items such as extra router bits pens or tools in the tool path while the machine is running Air Quality When cutting certain materials the chips may become airborne particles and be inhaled by the operator Many materials are carcinogenic and will be inhaled unless the operator takes the proper precautionary measures Face masks rebreathers or respirators may be required specially when working with foam materials Check face masks as many filter different types of materials and may not trap the particles of the material that is currently being machined Misting systems may spray dangerous chemicals or coolants into the air these must not be inhaled Never use flammable or corrosive liquids in a mister or a sprayer Before Running the Machine 1 2 3 Inspect the Tool Bit Before starting any job a visual inspection of the machine and the tool bit should be done Any tool that is damaged must be replaced before using the table Pay particular attention to the use of carbide bits as they may shatter when damaged pay attention to long bits over 2 exposed used at speeds over 8k RPM If must be used at speeds under 8k RPM use dial indicator Runout 0 004 The c
30. sk of electrical shock Use proper extension cords Insufficient conductor size will cause excessive voltage drop and loss of power Use only three wir xtension cords which have three prong grounding plugs and three pole receptacles which accept the equipment s plug Use of other extension cords will not ground the equipment and increase the risk of electrical shock The controller should only be opened for troubleshooting by certified electrician Both AC and DC voltages inside the controller box are dangerous Please pay attention to warning sign for RISK OF ELECTRIC SHOCK Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Quick Setup 1 Install Mach3 Software For Mach 3 software download minimum requirement for PC and installation and instructions visit http www machsupport com 2 Install the registration key of Mach3 software if you have one 3 Download the Mach3Mill xml from http ridgecontrolsystems com CNC controller Mach3Mill xml Right click with the mouse and select Save Link as 4 Replace the default Mach3Mill xml with one that you downloaded 5 Open the controller case and verify all connectors are fully plugged and there is nothing unplugged due to shipping or shipping related inspections 6 If there are ESTOP push buttons on the side of gantry remove the jumper JP2 see Board Setup chapter 7
31. t website Help Drive settings Step active high Step multiplier Encoder x Steps to move hoo 2 Max Error 2x mode PWM limit C 4x mode Current lirnit Ap Ad Ai Li Sampling time SAVE TO EEPROM DOWNLOAD Drive type DG25 08020 Try to connect Data From drive loaded Figure 22 Typical PID values for DG2S servo drive For the actual values used with vour machine see chart below PID settings Stepactive True Encodermode 2X Stepmultiplier 4 LockoutError 2000 PWMlimit 512 Currentlimit 20 Ap 170 Ad 2000 Ai 8500 Li 2500 Sampling 4 PID settings Stepactive True Encodermode 2X Stepmultiplier 4 LockoutError 2000 PWMlimit 512 Currentlimit 20 Ap 170 Ad 2000 Ai 8500 Li 2500 Sampling 4 PID settings Stepactive True Encodermode 2X Stepmultiplier 4 LockoutError 2000 PWMlimit 512 Currentlimit 20 Ap 170 Ad 2000 Ai 8500 Li 2500 Sampling 4 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 The same values can be used for Dynetic motors on X and Y axes For Dynetic motors on Z axis change Ap to 145 and Ai to 8000 for better performance Email Contact ridgecontrolsystems com Fax 1 888 493 6165 Wiring Information and Schematics Ridge Coutrol Systems Tel 1 888 493 6165 1030W y zX lt NOLOW 7 9 4 YAGOON MOLOW
32. upply is available D4 green is ON 12VDC supply is available D1 is blinking No ESTOPS No drive fault System enabled from software D18 yellow is blinking MODBUS communication D19 red is ON MODBUS error The location of the LED s are marked on the next illustration Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 RCSAAXIS v1 5 LIMIT Sw CHES 1111111 T EINER NS RR c no o 457 r 1 51 512 HN 10 AUX 120 L vFD E51 E52 E53 554 B 4 12v T2 114 C AUY 1 02 PC POWER SUPPLY A c e Sg Figure 2 RCS4AXIS v1 5 Breakout board There five LED s on the board RCS4AXIS is designed for easy replacement and maintenance The connectors are box headers Molex and RJ45 Ridge Coutrol Systems Tel 1 888 493 6165 Email Contact ridgecontrolsystems com Fax 1 888 493 6165 Drive Connectors on the Top of the Board M514 MSI2 L2 10 5 1 2 E4 El all aS LIMIT 5 RCS54AXIS v1 5 K 10 i Figure 3 DRV1 DRV2 DRV3 DRV4 1 and E EN2 and E The bo ei 8 4 darin LPT2 pp lx ag o 551 E52 53 5 12 Lem ma PC POWER SUPPL
33. value Code FP amp CurrentFeed Restore coordinate mode to original value If AbsMode 0 Then Code G91 End If Else Code Z touch plate is grounded check connection and try again End If Exit Sub Ridge Coutrol Systems Email Contact ridqecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Mach 3 Software Setup The parallel ports pins are hard wired to the RCS4AXIS connectors Pins have defined functions as per this document You need to install Mach 3 on a Windows based computer with parallel port For Mach 3 software download minimum requirement for PC and installation instructions visit http www machsupport com If you replace the original Mach3Mill xml with the one from the link http ridgecontrolsystems com CNC controller Mach3Mill xml Right click with the mouse and select Save Link as You should have your machine setup as per explained below In order to assign parallel port pins to correct values click on Config and select Ports and Pins see Figure9 Mach3 CNC Demo File Function Cfg s View Wizards Operator PlugIn Control Help Pr Select Native Units Ait 2 Tool Pati Offsets Ports and Pins _Offsets Alt 5 Motor Tuning General Config System Hotkeys Homing Limits ToolPath Slave Axis Backlash Fixtures ToolTable Config Plugins Spindle Pulleys Safe Z Setup Save Settings File No File Loa

RCS4AXIS v1.5 breakout board

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