DC Servo Controller based on RCS4AXIS version 1.7
Contents
1. D1 green is ON 12VDC supply is available D2 yellow is ON 5VDC supply is available 04 red is blinking No ESTOPS No drive fault System enabled from software The location of the LED s are marked on Figure 2 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 RC mi Figure 2 RCS4AXIS v1 7 Breakout board There are three LED s on the board RCS4AXIS is designed for easy replacement and maintenance The connectors are box headers Molex and RJ45 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Drive Connectors on the Top of the Board 20 RR B Aux 1 0 2 BRAKE Him Figure 3 The board supports 4 axes Each group of connectors with same color are going to control one axis ENCODER1 MAIN1 EN1 and control the X axis ENCODER2 MAIN2 EN2 and ER2 control the Y axis ENCODER3 MAIN3 EN3 and ER3 control the Z axis ENCODER4 MAIN4 and control the X2 A axis ENCODER1 Encoder for X axis RJ45 MAIN1 Main for X axis RJ45 EN1 Encoder for X axis Header 8x2 connecting to DB15 receptacle case connector jumper To enable jumper center pin and ENABLE To disable jumper center pin and ERI ER1 must be jumpered eith2. the drive programmer will be shipped inside a tagged plastic bag in the controller Whale 3 Servo Drive Parameters Servoconfigurator x Connection PID tuning Error viewer Analisator Diagnostics Firmware update Visit website Help Drive settings Step active high Step multiplier 4 Steps to move Max Error 1000 2 mode 100 PWM limit 512 C 4xmode Analyse Current limit 14 95 350 Ad 5000 12 Li 65000 Sampling time 5 SAVE TO EEPROM DOWNLOAD RELOAD Try to connect Data from drive loaded Figure 23 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 Ap 350 Ap 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 6
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4. 7 Replace the controller case cover and tigh 8 Plug the table connectors for motor powe ten the screws r encoder limit switch connector AUX I O and also power per nameplate of controller see Case Connectors 9 Connect the controller to the PC parallel Ethernet connector will be either USB or port For Smooth Stepper TM the 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 Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Board Setup Connector Definitions and Jumpers RCS4AXI V1 7 8 Figure 1 RCS4AXIS v1 7 has support for 4 motors spindle mister 2 probe tool changer sensor inputs tool release and limit switches Normal operation of the board As soon as the board is powered up D1 green and D2 yellow LED s should turn on This indicates that 5VDC and 12VDC are available for operation of the board D4 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 D4 will blink on for 1 second and off for 1 second
5. 888 493 6165 Fax 1 888 493 6165 File Config Function Cfg s View Wizards Plugin Control Help Lock Program Run 2 um Auto Calculator Control OffLine Maintenance Hours Set Normal Condition Restore Settings Brain Control Brain Editor Check Config GCode Var Monitor File WoFietsaded Cs orielo File Loaded Load Load Wizards Last Wizard Wizards Edit G _ Edit G Code Rewind Ctrl W Ctrl Rewind Ctrl W Recent File nis Single BLK Att N lB Close G Code Reverse Run Im Rapi Load G Code ia 5 f Block Delete Nil __5 Next Line M1 Optional Stop Il tne d i cur m RPM Run From Here ESSE Sov 6001 Bapsed Spindle Speed ie G Codes M Codes 0 00 Units Rev Figure 14 After TTT Edit Button Script the Auto Tool Zero button will blink 5 Click on the Auto Tool Zero button to open VB editor see Figure 15 Ridge Coutrol Systems Email Contact ridqecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 __ CNC Demo HiddenScript m1s Mach3 VB Scipt DER Fie Edit Run Debug BreakPoints Ee P x Tool Zero Setting Macro Change the following three lines to PlateThickness 0 250 Thickness of RetractClearance 0 100 Clearance ProbeFeed 5 Feedrate to use f Define some constants ZDRO 2 Z Axis DRO AbsoluteModeLED Abso
6. 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 1 Make sure pin 15 is setup as per Figure 13 Click on Config gt Ports amp Pins gt Inputs Z touch plate and configure pin 15 as the Probe input making it Active Low Engine Configuration Ports amp Pins Enabled gt ctive Low Emulated Input 2 Input 3 Input 4 Limit Ovrd THC Down AFM Trin 1 MM ME OE S OE S A OE OE S K OE OE OE OE S S S S 4 e ar df ae ar Lf 0 O OTO Pins 10 13 and 15 inputs Only these 5 pin numbers may used on this screen Automated Setup Inputs Figure 13 Probe Z touch plate is hard wired to Pin 15 2 Verify the operation of the probe by touching the router bit with the Z touch plate When Z touch plate is plugged in the ZO LED on should turn ON When the plate touches the router bit the off 3 Click to the Offsets screen and in the top left corner thickness the front of case ZO LED should turn set the touch plate thickness to the exact thickness of your plate 0 250 or measure the plat 4 Click on Operator gt EditButtonScript At this time the Auto Tool Zero button start blinking see Figure 14 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1
7. 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 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 Gl 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
8. 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 5 x10 rack and pinion table Motor Tuning and Setup Axis Selection Y AXIS MOTOR MOVEMENT PROFILE yey 359 523 x Axis 323 57 287 618 Axis 251 656 215 714 Z Axis 179 761 IEEE 143 809 107 857 71 9045 35 9523 0 0 01 0 2 0 3 0 4 0 5 0 6 0 7 Time 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 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 peer 230 684 Y Axis 201 849 173 013 Z Axis 144 178 115 342 86 5065 57 671 28 8355 0 0 1 0 2 0 3 0 4 05 05 07 0 8 0 9 Time in Seconds ao o a e 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 acceler
9. 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 determined 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 old 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 s gt 02 03 04 05 056 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
10. of gantry JP1 must be jumpered Connectors Description Function ZCR Enable Zero Crossing Relay 12 VDC ES2 ESTOP pushbutton on controller case ES1 ESTOP pushbutton on gantry jumper if there is no pushbuttons on gantry 12V 12 VDC supply max 1A 5V 5 VDC supply max 1A 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 B ANS z es LIMIT SWITCHES ei RRA 3 2 AUX E Figure 6 Not all ribbon connectors are used with every system Connectors Description Function LIMIT SWITCHES Limit or home switch connector Header 8x2 1 Encoder header to DB15 encoder connector Header 8x2 LPT1 and LPT2 Parallel port one and two Header 13x2 1 and FPC2 Front panel LED connectors Header 8x2 Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Jumpers and Potentiometer ERN Ie Jl ce ts E DT p um Lm La oes MED min i B 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 adj
11. 1 888 493 6165 Fax 1 888 493 6165 Case Connectors gt ENCODERS SX Figure 31 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 24VDC 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 a
12. 165 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 Visit website Help Drive settings Step active high Step multiplier Encoder x Steps to move hoo 2 Max Error 2x mode PWM limit 4x mode Current lirnit Ap Ad Ai Li Sampling time SAVE TO EEPROM DOWNLOAD Drive type 0625 08020 Try to connect Data from drive loaded Figure 24 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 ridgecontrolsy
13. 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 LED s ESTOP etc ESTOP NIV iu a LLLE A Figure 32 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 fe
14. 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 Yellow Yellow Yellow ChA 3 Brown Brown 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 ChB 13 Green Green Blue Ridge Coutrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Motor power connector Figure 29 Motor power connector Pin Description 1 Black Power GND ARM2 2 Red Power 48 PWM ARM1 3 Magnetic brake GND 4 Magnetic brake 24 VDC Note Pin 3 and 4 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 30 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 Nn HR WIN Ridge Coatrol Systems Email Contact ridgecontrolsystems com Tel
15. 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 7 Document version 1 01 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 3 El ctrical Safety u 4 Quick 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 Puning u 13 aasma 16 Probe or Z touch Plat a a en eben hl pt 17 Magh 3 Software ee 22 Normal Operation of Controller 29 Drive Tuning Parameters PID Values 30 Wahle 3 Servo Drive Parameters 30 DG2S DG3S and DG4S Servo Drive Parameters 31 Wiring Information and Schemat
16. Setup of Inputs Apply Figure 19 Input 11 12 Ind 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 K X OE OE OE OE OE A K OE OE OE OE OE OE OE S OE S Lj r Dd df i f x ae r NFM Tria 1 tee Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated Setup of Inputs Figure 20 Input 15 is hard wired for probe Z touch plate 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 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 S NE Pins 2 3 1 14 16 and 17 are output pins other pin numbers should be used Figure 21 Output 1 is hard wired to spindle ON OFF output 2 to mister ON OFF Pin 17 generates the charge pump signal Ridge Coutrol Systems Email Contact ridgecontro
17. ated 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 dimension 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 RCSAAXIS v1 7 Slow Blow fuse for 110VAC controller 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 S 25 5 Power Supply 12VDC S 60 12 Power Supply Dual output 5VDC and 12VDC D
18. ation 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 Figure 11 12 and 20 The VFD control signal will be 0 10 VDC Set the maximum spindle speed by selecting Config gt Spindle pulleys In Figure 11 the maximum spindle speed is set for 18 000 RPM Pulley number is not relevant for VFD speed control Set the minimum speed to and Ratio to 1 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 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 VER 5 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 Sus 5 1500 49 998 10 0 025901 o 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 Coutrol Systems
19. de to original value AbsMode 0 Then Code G91 End If Else End If Exit Sub 7 Save the macro file wi Code Z touch plate is grounded check connection and try again th its default file name 8 To test the macro put the Z touch plate on the surface of the work right beneath the spindle Then c should slowley go down positon as Z0 it shou till ld re setup for the first time s anything is not done correctly lick on the it touches the Z touch plate After recording the tract to its Auto Tool Zero button The spindle original position When you do this tay close to ESTOP button to stop the machine if 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 Conf
20. edback 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 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 sy
21. er enabled left and middle pin or disabled right and middle pin The three other groups of connectors are defined in a similar way for use with Y Z and X2 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 AUX 1 0 2 TRS SS AUX 1 0 1 YFD MSTE MST4 zm L eL L Figure 4 AUX I O 1 is a 5 pin and AUX I O 2 is a 10 pin connector All others are 2 pin connectors Connectors Description Function Z0 Probe connector MST1 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 signal 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 1A Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Molex Connectors on the Right Edge H e e W IC POWER SUPPLY W 4127 2 208 a Figure 5 ES2 connects to controller case ESTOP ESTOP s on the side of gantry connect to 51 If there are no ESTOPS on the side
22. ew 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 risk of e
23. 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 AbsoluteModell D 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 Z 0 5 amp ProbeFeed Wait for it to complete i e moving down slowly till router biy touches the plate While Wend Delay for a little bit Code G4 P0 5 Get the Z position where probe input triggered ZProbePos GetVar ZTouchDRO Retract to touch position Code G0 Z 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 Retract Z to SafeZ if enabled else to RetractClearance above plat If IsSafeZ 1 Then SafeZ GetSafeZ If SafeZ gt PlateThickness Then Ridge Coutrol Systems Tel 1 888 493 6165 GotoSafeZ End If Else Email Contact ridgecontrolsystems com Fax 1 888 493 6165 RetractHeight PlateThickness RetractClearance Code GO Z amp RetractHeight End If Display the message Code Z axis is now zeroed Restore feedrate to original value Code F amp CurrentFeed Restore coordinate mo
24. hed ON both 5VDC and 12VDC should be available at the board UNREGULATED 48V DC POWER SUPPLY L HV q lt HV AC INPUT AS PER NAMEPLATE q FUSE RATING AS PER NAMEPLATE Figure 26 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 15 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 2 13 6 2 12 16 MISTER SOLENOID 17 10 PROBE Z TOUCH PLATE 23 Figure 27 LIMIT SWITCH connector signals Internal connections of LIMIT SWITCH receptacle TOOL 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 MST PROBE Z TOUCH PLATE 10 amp 23 70 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 28 AUX I O 1 connector Internal connections of AUX I O 1 Signal
25. hile 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 lt 0 004 The cost of a n
26. ics 33 Case ronis iro r NINH 39 Front Panel LED s ESTOP Fuse and ON OFF Switch 41 Crate Dimension and Weight essere 44 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 ear protection w
27. ig and select Ports and Pins see Figure9 Mach3 CNC Demo Function Cfg s View Wizards Operator PlugIn Control 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 Config Help File Loaded Figure 16 Main setttings of RCS4AXIS parameters with Mach3 software 1 Setup the Port 1 Port 2 address and Kernel speed as per Mach 3 manual user 2 Enable only those motors that are used on your machine The board supports up 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 Dir Active Low from checked to unchecked or vice versa The port pins are hard Ridge Control Systems Tel 1 888 493 6165 wired to RJ45 plugs on the board control one axis The controller Figure 16 Engine Configuration Ports amp Pins Email Contact ridgecontrolsystems com Fax 1 888 493 6165 Each pair of ports 2 amp 3 is built to use the 4 amp 5 6 amp 7 and 8 amp 9 suggested setup in Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Port 1 Port 2 Port Enab
28. lectrical 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 Tel 1 888 493 6165 Quick Setup Email Contact ridgecontrolsystems com Fax 1 888 493 6165 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 4 Replace the default Mach3Mill xml with one Save Link as 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
29. led 0x278 Port Address Entry in Hex 0 9 A F only Pins 2 9 as inputs Port Enabled 0378 Port Address Entry in 0 9 A F only MaxNC Mode Max CL Mode enabled Max NC 10 Wave Drive Program restart necessary Restart if changed Kernel Speed 25000Hz 35000Hz 45000Hz 60000hz 5500042 7500042 100khz Note Software must be restarted and motors retuned if kernel speed is changed Sherline 1 2 Pulse mode ModBus InputOutput Support TCP Modbus support Event Driven Serial Control _ ModBus Plugin Supported Figure 17 Enable port s MODBUS and select Kernel speed Apply 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 18 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 S 2 c oj ojojojojojojojo r df xr df x Lf df xr x Pins 10 13 and 15 are inputs Only these 5 pin numbers may be used on this screen Automated
30. lsystems 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 Clockwise M3 Output T PWM Control Closed Loop Spindle Control Step Dir Mot QOuput R 0251 ft 0 fos Output Signal s 1 6 Spindle Speed Averaging Flood Mist Control CN Me rur qo MinmumPwM x 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 CCW Delay Spin UP _ Seconds 7 Laser Mode freq ModBus Spindle Use Step Dir as well Delay Spind DOWN 1 Seconds Torch Volts Control Enabled 54 64 127 CCW Delay Spin DOWN 1 Seconds Torch Auto Off Max SDC Count 6380 Immediate Relay off before delay Figure 22 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
31. lute IncrementalModeLED 49 Incrementa FeedrateDRO 818 OEM code for fee ProbeLED 825 OEM code for pre Load Wizards _ Last Wizard j ZTouchDRO 2002 OEM code for DRO NFS Wizards Do nothing if probe is already grour If GetOemLed ProbeLED 0 Then Wait a few seconds for user to ge cage Code G4 P2 Auto Tool Zero Remember a Return Feedrate 6001 Bapsed EN UntsMn 0 00 Z Inhibit ON OFF Ctrl Att J _ M Codes _ 0 000 UnitsRev 0 00 g blinking b Figure 15 Copy and Paste the script for Auto Tool Zero in the editor and save the macro 6 When the VB editor opens delete the lines of code and paste in the macro explained below 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 Z Axis DRO 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 Ridge Coatrol Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 ZTouchDRO 2002 OEM code for DRO that holds Z touch position Do not do anything if the probe is already grounded GetOemLed ProbeLED 0 Then Wait a
32. re 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 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 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 Manual tool release by pressing the green button on the tool should be released AUX I O
33. stems 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 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 SERVO CONTROLLER 115 3 001 ON OFF Figure 33 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 r
34. stems 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 jepoou3 gt 2 12 V ZX NOLOW 5 ud NIV gt gt nsr Les 2 1 0 MOLOWM 9 ua n YAGOON pe AKT yoron z saua Es Asp gt l M3OOON3SM m ZN30OON3 2 LNIVIN _ ney LAGOONS AH jm ev 1 HLOOWS 3103 YIMOd qm 9 TEN NOLLNG 40153 357 SS Lon xnvy 11 01 xnv AYT3Y ONISSOND 0432 AV 133 2 0 jeusajul s qe 89uU O zgdnoiS eued 10 129uuoo BSED 912 35214 VION 9 jeued 3401 _ HOLIM E Ridge Control Systems Email Contact ridgecontrolsystems com Tel 1 888 493 6165 Fax 1 888 493 6165 Power Supplies 5VDC 5 _ POWER RED WIRE SUPPLY 12VDC 12V POWER YELLOW WIRE SUPPLY AC INPUT AS PER NAMEPLATE Figure 25 Turn ON the PC first then controller After the controller switc
35. ust this potentiometer in the field Jumper s Description JPl green Table ESTOP Jumper if no ESTOP pushbutton on gantry JP3 yellow Used with ATC Tool release should happen only when spindle has stopped Jumper if not used 1 red Enable 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
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