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BladeRunner Ether-Cut™ User Manual CandCNC

1. Torque Limit dC 36 3 24 000000 4100 Trimpot Dip Switch Access with Cover ON SW1 Not used SW2 Current or voltage mode select ON Current mode default OFF Voltage mode SW3 SW4 SW5 Current mode servo gain SW3 ON SW4 ON SW5 ON Low gain default SW3 SW4 OFF SW5 ON Medium low gain SW3 SW4 SW5 OFF Medium high gain SW3 OFF SW4 SW5 High gain SW6 SW7 Sets the G320X pulse multiplier SW6 and SW7 ON Step pulse times 1 default SW6 ON SW7 OFF Step pulse times 2 SW6 OFF SW7 ON Step pulse times 5 SW6 OFF SW7 OFF Step pulse times 10 SW8 SWO9 Sets the G320X following error limit SW8 ON SW9 ON 256 count following error limit default SW8 OFF SW9 512 count following error limit SW8 SW9 OFF 1024 count following error limit SW8 OFF and SW9 OFF 2048 count following error limit SW10 Sets the G320X current limit trimpot behavior CandCNC Page 96 Foleo EXAMPLES 50 oz in Servo motor 60 with 10 1 gearhead and 1 dia pinion gear amp direct drive T 1 F 9 4 Max possible IPM 4700rpm 10 X 3 142 1476 IPM linear force 100 servo motor continious torque X gear reduction
2. Enhanced Smart Power MOTOR DOWER DRIVE 5VDC TEMP POWER DRIVES TEST FAULT FAULT FAULT OFF BLADERUNNER AIO FRONT PANEL Enhanced System Power II Located on the Front Cover of the ESPII Enclosure the FRONT PANEL is the Operator Interface for the ESPII and provides tactile pushbuttons to turn the DC power to the Motors ON OFF The FRONT PANEL is a SMART CONTROL utilizing a powerful microprocessor that monitors and controls the power section of the BladeRunner AIO The ESPII monitors critical parameters controls ON OFF and will automatically shutdown in microseconds in the event of a fault The ESPII monitors controls 1 System DC status System Driver Status enable disable drives DC voltage level overvoltage shutdown DC current load level overload shutdown Internal Temperature overtemp shutdown oystem Fault Indicators LED s and Screen Text e gt os Te CandCNC Page 61 BladeRunner Mardware Normal Power up sequence 1 Operator turns on MAIN POWER SWITCH 5VDC LED comes on RED OFF LED comes on DRIVES OFF LED comes on All LEDS may sequence on once during processor turn on 2 Operator pushes ON Button ON LED turns Green OFF LED goes off Power comes up on DC bus Approx 2 sec later Drives OFF LED goes off and MOTORS LOCK ON Button OFF Button Sends Signal to Sends Signal to Processor to turn C an
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5. Connecting up the BladeRunner Control box Take look block diagram on th enext page that gives an overview of the control box Note that there are two cables that run from the PC and connect to the BladeRunner box One is the BLUE Cat 5 from the C2Bus 4 Port Hub not rewuired on ROUTER version The other is the Ethernet CAT 5 GREEN and it is REQUIRED on all Ether Cut systems 1 Install a Green CAT 5 drop cable All pins straight through between Ethernet network Port on the PC to the part marked Ethernet on the side of the BladeRunner controller unit 2 If you have the DTHC IV model you should have the C3BUS USB to RS485 installed and working and the cable should be connected BLUE 5 Note all of the 5 cables are the same pinout We designated provided cables in the colors indicated to help prevent plugging in the wrong device to the BladeRunner Getting the wrong device pluggin in and the unit powered up can result in possible damage to the module or the PORT on the C3BUS hub or the PC BE CAREFUL CandCNC Page 55 CABLE CONNECTIONS for DTHC IV BUS amp ETHER CUT PWM Module Y ETHER Connections Guide 5 09 E 0 CandCNC DTHC IV Digital Torch Height thernet Electronic Controls for CNC CP PWR UBOB III Technology Green Cat5 from Ethernet Jack on Ether Cut front panel TO Ethernet jack on
6. Xen yeus ez 3 OAJ9S cz Jouunsopelg Foleo ADDENDUM SERVO MOTOR SETUP AND TUNING The BladeRunner Servo systems ship with 4 or 5 servo motors and on the XY motors 3 there are 10 1 gearheads The following pages should be used to do the calculations for the calibration and to determine the best velocity and acceleration In addition to the normal motor tuning in MACH the Gecko G320X drives have a PID set of pots that can be used to do added response tuning of each motor The PID settings are done during final testing prior to shipping and seldom need to be adjusted We have included excerpts of the tuning process from Gecko but unless you are experiencing motion induced fault issues than doing adjustments just to see what it does will not fix anything While different loads can alter the response of the servo it will not effect the accuracy The servos are never at rest if they are powered up As a result they WILL make noise If you attempt to tune them for no noise or minimum noise you will have a sloppy system Even a poorly tuned system will not allow a lot of error in position to SERVO TUNING 101 Tuning by ear If you don t have a dual channel oscilloscope and the experience to use it the easiest way to tune a Gecko drive is by sound The following covers that method and will yield good results DO THIS ONLY IF YO
7. DRIVE RED 3 flash pause Z Drive Fault DRIVE RED 4 flash pause A Drive Fault DRIVE RED 5 flash pause 5th Drive Fault May indicate misconfigured Slave Axis Setup 5 VDC OK ON Steady 5 is ON OK Shows power on and logic supply OK TEMP FAULT 1 flash pause Case Temp Fault Internal Case Temp is too high Check fans and filters Fast Flash Power Overload DC POWER Too Much Current drawn Auto Shutdown Overload of power Module s Slow Flash Over Voltage DC Volts Exceed max for safe operation Line surge or back EMF Auto Shutdown DRIVES OFF ON Steady Drives Disabled Only on BladeRunner Shows drives are freewheeling disabled Normal condition during power up and faults shutdown ON Steady Test Mode Unit is in self test Flashing Config Error MODE Configuration error or unplugged module CandCNC Page 63 MACH SOFTWWARE Load and Testing MACH After you have installed MACH and run the BladeRunner INSTALL on the Support CD open MACH 3 using either the MACH Loader and the BladeRunner selection from the list OR using the BladeRunner Icon created in the desktop You should see the following screen or something very close If you are missing the Desktop icon or it s not in the selection list re run the INSTALL again If you have the Profile BladeRunner l
8. Processor to turn DC P OMIM ES OFF DC Power to the Motors Enhanced Smart Power the Motors ON LED OFF LED On Green On RED when DC whenDC power is power is OFF DRIVE 5VDC TEMP POWER DRIVES TEST FAULT FAULT FAULT OFF CandCNC Multi Axis Controller piay ee Chart on next page to decode FRONT PANEL indicators IMPORTANT INFORMATION The ESPII provides multiple levels of protection for the system and the motor drivers Electronic fusing will shutdown power in milliseconds as opposed to conventional fuses The Primary AC has two levels of control The MAIN POWER SWITCH and the in line SAFETY RELAY controlled by the FRONT PANEL The Safety RELAY controls AC power to the DC power supply section Besides Electronic fusing the system also provides failsafe conventional fuses breakers There are two levels of conventional fusing on the DC power side The locations and values of the conventional fuses are in the ESPII service Manual CandCNC Page 62 BladeRunner Mardware FRONT PANEL LED LEGEND Note LED s flash several times on intial power up Pushing recessed TEST button will test all LED s and show common patterns for comparison INDICATOR Color STATE MEANING NOTES DRIVE FAULT RED 1 flash pause X Drive Fault A Drive Fault indicates a shorted motor cable or a failed Motor Driver DRIVE RED 2 flash pause Y Drive Fault
9. Search Folders BE Stress Dj Contral Panel INSTALL 0 L Mame Control Panel accessibility Options 12408 Remove Programs Switch to Category view 1g Administrativa Tools S Dipy Add Hardware 5ee Also Fonts Windows Update Em iet wer Help and Support rots KA mee rk Connections Sprints an Fame DT Rega PPM 2 NOEL Acum pinus Slawi Ede Edit View Favorites Tools Advanced Help Search Folders Address MS Connections Fi LAN or High Speed Internet ai Network Ta Create new connection 2 Set up a home or small office network Change Windows Firewall sethings Local Area Connection 2 See Also Network Troubleshooter Make sure the Local Area Connector does not show itis disabled It may show it is not CONNECTED but if it is missing or disabled you will need to get the problem resolved before you can proceed with the install Other Places Control 1 Network Places Documents ij My Computer Details Network Connections System Folder CandCNC Page 14 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP Network Connections File Edit View Favorites Toole Adwanced Q Back a Searc
10. 9 5 LOE 70H eiqer gogn oi 59014 9091 NO suid uo y 3INOH X Ndu JNO 20 uonoeuuoo Jo Buyeo A6 Buneo 4 CandCNC op oseo d jsenboiJ jeu jo uonejueuunoop y si siu pue siu op UO y ui M Jeuunsepelg eui epiAoud JO 5 Sjonpoud JO sjueuoduuJoo u s d JOU SBOP 3 sJosues Jo ui MOY SC 3 1dlAVX3 se siu Jayo M dnjes y 100use qnoJ jueuudinboe s pue y sis y pue y puejsJepun pue peoJ ueo uondo siu zou oq S LMdNi IVO2OLLdo INISM E STOP and Safety Shutdown In the BladeRunner system there are two forms of E STOP software MACH3 based E STOP Hardware UACM Card E STOP SOFTWARE E STOP In MACH there is a manditory input for E STOP It is implemented as a normally closed input must be held low to come out of RESET That input is assigned in the BladeRunner AIO to input pin 10 With nothing attached to that pin it is pulled high by the parallal port IF MACH is in RESET all outputs are disabled and no inputs are acted on ignored There is a general misunderstanding about software E s
11. TE RKER T E Example of a Z with the Floating Torch Holder for doing the IHS for Plasma cutting CandCNC WHAT IS A FLOATING TORCH HOLDER and WHY DO I NEED ONE The Floating Torch holder is a torch holder mounted on a separate slide from the Z axis and allows the torch to move UP and DOWN independent of the Z motion In operation it uses the end of the torch torch tip as a Probe to find the Top of Material Because metal tends to warp and the slats may not be perfectly level the Z zero changes top of the material as you move around the table surface The DTHCII will track the rise and fall of the material as it cuts to hold a constant arc gap BUT the absolute value of Z as displayed by the Z DRO is based on the LAST REFERENCE DONE Where it started Each pierce needs to be done at exactly the right height above the material so a method if Initial Height Sensing IHS is needed The Floating Torch holder lets the Torch be the sensing probe for the IHS It is a mechanical way to do the probe and is more reliable than ohmic or capacitive sensing Using a Z homing sequence generated by the G Code from SheetCAM the 2 is lowered until the tip of the torch touches the metal and the floating mount allows the torch to be pushed UP and that trisp the swtich Z AXIS FLOATING HEAD SWITCH Close up of switch connections Use Normally Open Pair Precision Plasma HD Gantry and Z CONNECTED TOZ HOME in BLADER
12. When you open the Ether Cut Profile for the first time you should see the dialog box above MACH should recognize the ESS Ethernet device and ask you if you want to use it instead of the Parallel Port You DO If you DO NOT see the dialog box and MACH opens then it may have already been set If the ESS fails to load and you cannot get the screens in the Plug in Control menu then use the top menu bar and the Functions Cfg s menu and select the Reset Device Set option Stop and restart MACH If you get an error message like ESS_vi0pidie CT ftp WWakellpCliant Board does not reply Selact YES to retry te config Cancel ta quit MACH does not see the ESS Ethernet Device and you need to go back through the IP setup and the tests to make sure the card is communicating with the PC Ethernet port CandCNC Page 211 SOFTWARE INSTALL SETUP INSTALL lt BLADERUNNER AIO SUPPORT e Contains Master Installer Auto Install File to automatically load Drivers Plug ins Custom Screens and Custom Profiles for router and plasma e Contains This Complete Manual for BladeRunner and all associated Manuals for internal cards e Contains tested rev level of MACH3 software Unlicensed DEMO VERSION e Contains SheetCAM and Hyt Connect RS485 Licenses if purchased with the Bladerunner Auto installer allows any one or all to be automatically installed from the CD if they are on
13. BladeRunner Ether Cut User Manual CandCNC With BladeRunner AIO SERVO Addendums UPDATED 3 15 14 Covers BladeRuner Ether Cut Unit pictured is a Bladerunner 620 4 withe DTHC IV upgrade and C3 Bus 4 port hub CNC and motion control involves equipment that can cause serious injuries CandCNC assumes no liability for ANY damages to any person or property from the proper or improper use of any equipment CandCNC sells or from any advice verbal or written Use the equipment at your own risk Practice good safety precautions Be smarter than the machine Read full copyright notice on page 7 CandCNC Page 1 INTRODUCTION BladeRunner AIO INTRODUCTION The BladeRunner Ether Cut is a complete CNC motion controller in a single enclosure that consists of 1 Advanced logic Interface electronics to connect the signals from a PC and provide bi directional communication for controlling motion operator feedback and expanded Input ouput UBOBIII with Port Expansion for single Parallel Port operation 2 Safety monitoring and auto shutdown circuits controlled via embedded processors Monitors DC motor voltage DC load current and internal temperature Values displayed on screen Less than 1msec total shutdown to out of spec conditions Fault shutdown codes on Front Panel and on screen 3 Exclusive Driver Interface design monitors each axis independently and protects drives from shorts and overloads Reports faults with fl
14. BladeRunner Mardware 48V 12A MODULAR POWER CONTROL See next page Connections to Motors m 91991 Line SWITCHED POWER Multiple Inputs Switches probes sensors 70 gt c 2 Power Pak EH Expansion Module Option CandCNC Page 59 ppm EE TT c f 1 2 W N ge 1 4 _ a 7 m Aiei 1 E IGI UVV acii LJESL a oome modules may have changer appearance or position BladeRunner AIO Cover Removed Inside View EN UB B Breakout NT S LE J CrossFlow OPTION G251 4 Motor Driver 4 La Ta i f EE s dH 1 ZW am ET 4 94 R m 4 7717 DTHC EXPANSION 47 MODULE OPTION E re m E i il TABLE I O LE o M 2 2242 f 4 a ein E r m 8 d e T d ma G251 SOLO 5th Axis OPTION _ a END PLATE E 2 1 L j 5E i i 77 ml i CandCNC Page 60 MOTOR CONNECTIONS
15. CandCNC Page 4 BLADERUNNER AIO TABLE of CONTENTS PART 1 SETUP CALIBRATION E The BladeRunner Hardware Setup 1 C3Bus USB RS485 4 Port Hub Install 2 Making the External Connections a PC parallel amp Serial Ports b Power cables c Motor connections 3 Front panel Controls 4 Front Panel Dashboard F Configure and Testing BladeRunner with MACH3 1 The MACH3 CandCNC Screens a DTHC Screen Details Main Screen b Diagnostics Screens 2 Getting Motion from the BladeRunner AIO b Powering up the system c Keyboard Hot keys 3 Using the MACH Configuration interface Menu a Motor Axis Calibration and Tuning 1 Table Physics 2 Fine Tuning the calibration b Axis Slaving c Homing amp Limits G ADDENDUM BladeRunner SERVO system 1 Physical Differences between Stepper amp Servo 2 Servo motor and Gearhead Dimensions specs 3 Setup and Motor Tuning Servo 4 Gecko G320X default settings 5 Calculations amp Formulas 6 Recommended Settings Typically setup CandCNC 5 5 a 5 Detailed Install and Setup BladeRunner Hardware 1 Table card a Card location in the BladeRunner b Making the wiring connections 2 The Charge Pump CP 3 E STOP and it s variants jumper on Table I O b Power on Detection c Hardware E STOP Options 4 Setup and t
16. Page 89 CandCNC BladeRunner Mardware FORMULA FOR CALIBRATING steps per Unit on an axis Steps per unit in MACH Current Setting in Steps per UNIT lt Actual Distance Traveled Dt Commanded Distance you entered Dc New Steps per Unit value Sn Sc X Dc Dt Sn oh 15 in steps and will probably a decimal number oet the decimal amount to 3 decimal places CandCNC X Page 90 ADDENDUM SECTION ADDED 11 15 12 For BladeRunner AIO Dragon Cut SERVO products The following 6 pages are for the SERVO motor version of the BladeRunner Dragon Cut and cover the setup and tuning of a system with servo The Drive tuning is done at the factory and seldom needs to be changed but some mechanics may require some tweeks to the driver tuning Besides the change of the tuning in MACH calibration and recommended settings for the servo system the Dragon Cut will operate in the same manner The motor gearhead combinations were engineered for optimum performance for plasma cutting The wider torque range of the servo motors provides a better platform for mixed cutting applications router plasma but the typical issues of cross contamination and change over still remain The Servo system does offer higher performance with increase upper cutting speeds at high acceleration rates This does put larger stress on the mechanics so full out maximum settings are often counterproducti
17. SELECT NEXT Ready to Install Setup is now ready to begin installing Master Installer all Products on your computer Click Install to continue with the installation or dk Back f vou want to review or any Destination location Setup Custom installation Selected components BladePunner AIO EtherCut Install Install MACH license Start Menu Folder CandcNC C3 Select Install CandCNC Page 35 Setup Master Installer for all Products Information Please read the Following important information before continuing When you are ready bo continue with Setup click Next Sach of the MACH Profiles You have elected to install will appear in the selection list oF MACH Loader run equipment you need to start MATH using the Mach Loader or From the Associated CandCNC Icon on the Desktop is strongly suggested that you backup your entire MACH Folder on the drive te another drive or removable drive anytime you make a configuration change any profile You can recover lost setup by reloading MACH and simply copying in the ML and Screen Files you need 9 Setup Master Installer for all Products Completing the Master Installer for all Products Setup Wizard Setup has Finished installing Master Installer For all Product your computer The application rn
18. pinion Radius 50 Oz in X 10 5 1000 linear oz of force Same design but with 3 1 belt reduction from motor to pinion shaft in the above calculations the motor RPM and torque numbers of 10096 were used since servo motor torque does not drop off with RPM These are maximum numbers and NOT recommended for normal cutting and rapids High values of velocity and acceleration put maximum stress on components for little benefit Calculating the beginning Steps per Unit on an SERVO AXIS Use the following formula to get a ballpark steps per unit number in MACH Psr Pinion Speed increase ratio Pitch Dia in inches X PI 3 1416 Steps Per Rotation SPR of motor encoder line count X 4 250 line count 1000 Target Steps per Unit SPR X gearhead Reduction ratio PSR 1000 X 10 3 1416 3183 091 steps per inch Once you have the calculated the number of steps it takes to move the axis one inch then put that number into the STEPS per UNIT of the motor NOTE IF you have the Step Multiplier on the Gecko set to 2X than you must divide the Steps per Unit by 2 Based on the speed numbers you have calculated from the previous pages set you velocity to a value of 50 to 80 of that number NOTE MACH can only send the number of pulses per second as set in the Kernel opeed in Ports amp Pins The number of pulses per second you need is the target RPM max X the SPR 60 For a target RPM of 4000 and 250 line encoder you need 40000000 60 66 6
19. y Computer e Disk drives Display adapters DVD CD ROM drives ig Human Interface Devices Make sure the Network Adapter 2 IDE ATAJATAPI controllers does not show disabled or not working warning symbol x Pulseing Engine Mice and other pointing devices 7 Monitors Network adapters NVIDIA nForce Networking Controller NVIDIA Network Bus Enumerator Parts COM LPT Processors ig Sound video and game controllers h Dhar e ual Mew O me NVIDIA nForce Networking Controll 9 x General Advanced Driver Details Power Management This does not mean the 889 NVIDIA nForce Networking Contoler device is actually working and will talk to a network or the Ether Cut It simply Device type Network adapters means Windows sees the Manufacturer NVIDIA device and it appears the Location Location TEUS Id 00020000 000 right drivers are loaded goa problems T configuring or testing the port it can still be a bad IF you are having problems with this device click Troubleshoot to Ethernet card or the Wrong start the troublesheoter card drivers Device ATIC Page 12 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP NVIDIA nForce N
20. 3 PRO ess P2006 Net Page 17 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN 7 INSTALL m 0 L This connection uses the following items Ww Client for dl 005 Packet Scheduler wi IB and Printer Shaving for Microsoft Networks Intemat Protocol Version E Highlight Internet Intemet Protocol Version 4 14 Protocol Version 4 2 Link Layer Topology Discovery Mapper L O Driver 4 2 Link Layer Topology Discovery Responder Unna Click Properties Dee Button Trareniasion aniol Penkaeal Ainar Tie wide area network p aa aa across diversae interconnected networks amp oelect Use the Following Address Tau can get IP assigned automatically if your network eupports irs Thra you need to ask your network administrator for the appropriate settinge Enter the address exactly as shown 7 Obtain an IP address automatically 48 Use the following IP addrees 10 9 9 1 Subnet maski 355 265 255 0 Enter the Subnet Mask exactly as C3 Obtain DMS server address autamatical gt h 255 255 255 0 Preferred DHS server Alternate DNS server Leave all other settings blank no DNS servers 7 validate s
21. BladeRunnerAIO DTHC LBOE3 BladeRunnerAIO DTHC LIBOB3 Eom Delete Profile BladeRunnerAIO Router UBOB3 Your screen WILL look different depending on what you installed There are several things you can do at this point 1 You can highlight and delete unused profiles 2 You can highlight and RUN a specific profile by clicking OK after you highlight the file name in the list 3 You can Create a NEW profile see next page CandCNC Page 37 lt 5 INSTALL Working with MACH PROFILES Create Profile Hew Profile Mame MyNewProfile Default Profile Values Do put any extension an the new profile Session Profile Current Profiles Create Profile BladeRunnerAIO DTHC UBOB3 BladeRunnerAIO Router UBOB3 MyMewProfila BladeRunnerAIO DTHC LIBOB3 Eom Malaba Profile TO CREATE A NEW PROFILE 1 Select Create from the previous screen you will get a window similar to the one on the left 2 Type new name in the input box under New Profile Name Leave the Default Profile Values Box UNCHECKED 3 Find a Profile in the Clone From List you want to copy all of the settings from 4 Highlight the File you want to Clone From 5 Click OK 6 The new PROFILE will appear in the selection list It will have all of the settings of the PROFILE it was Cloned from It also sets up a folder under the MACROS folder w
22. Open CONFIG AXIS SLAVING Slave Axis Selection Y Slaved Axis Slaved Axis B Asis C DA Co CE Anis select the Axis you wish to slave the A to X or and click the A radio button on that axis If you have a 5 motor Ether Cut system The 5th axis is set by default to be controlled as a full 5th independent B axis Earlier Bladerunners with the parallel port could only directly control 4 axis and the 5th axis had to be HARDWARE slaved usign the jumpers on the UBOB It is recommended that you use A axis software slaved to either X or Y You then leave the settings in the Ether Cut Motor Ouputs mapped to have B as the fifth axis This will then correspond to the rotary posts for our system CandCNC Page 74 BladeRunner Mardware Set your table and control console up so you cut in the same orientation that you draw in where side to side is always X A X Typical rectangular table setup 4 motor setup dual drive on the gantry sixe sixe ssoJo SI X uoneoo J9UJOO YO SI Q 0 y uni eJeu puejs YOJO M SIXe 7 a GANTRY Master Motor 2 axis w torch holder alternate mounting X Y Homes J If you stand here to run the machine then 0
23. PC Up to 25ft length BLUE CAT5 cable for RS485 from UP TO 25ft C3BUS Jack on Ether Cut to Ethernet Jack CAUTION cables are CAT5 UTP 8 conductor and will plug into any CAT 5 RJ45 jack We have color coded the cables to help keep them from being mis connected If you use other CAT cables be sure to label them on each end Connecting cables wrong could damage modules UP TO 25ft CandCNC C3BUS RS485 4 Port Hub PWR Con ACT USB PORTS CandCNC RS485 4 PORT HUB mage ACTIVITY MONITOR KA TESE HUB is REQUIRED for DTHC IV CONTROLLER PC RUNNING CandCNC Page 56 BladeRunner Mardware NOTE For BladeRunner Servo system please see the end of the F section for the differences in the motor connections 1 2 1 B2 1 2 A1 A2 B1 B2 1 A2 B1 B2 A1 A2 B1 B2 A1 A2 0000 0000 0000 0000 0000 10000 0000 0000 10000 0000 IMPORTANT Screw Terminals It is important that the stepper motor wires are wired correctly When Face UP shipped from the factory the motors are wired right and each one is tested with the unit Because motors for other products we sell are wired differently it s possible a motor you order after the unit has been shipped could be wired differently DO NOT ASSUME THAT THE COLOR OF THE WIRES IS CONSISTENT We order wire from different sources and cannot always define the wire colors If you take the con
24. TT lt A c lt I 14 Plugging RS485 Hypertherm into RS485 PORT on back of Hypertherm 65 85 1405 See HyT Connect Manual for details on installing and using the RS485 remote control for the Hypertherm and the DCC Dynamic Cut Control CandCNC Page 47 INSTALLING RS48S5 4 PORT HUB 2 PN200 Hand Control The PN200 hand control uses normal high speed baud rates but the special dead man E Stop to the EPO of any CandCNC controller requires a special jack The PN200 MUST be plugged into the PN200 jack to be able to use the E STOP safety recommended PN200 has to be the last device group of devices The PN200 will worked plugged into other jacks on the 4 PORT HUB except JACK 1 but you cannot use the E STOP option You can also use the 2 jack on the hub for other RS485 devices if you do not have PN200 While the PN200 would work with other devices on the channel that have loop through pass through jacks the E STOP to DOES NOT PASS THROUGH OTHER DEVICES 3 DTHC IV High Speed Digital Torch Height Control The DTHC IV uses the RS485 C3BUS for the following Transfer of screen information to like Torch Volts Torch Amps and the status LED s for Torch UP Torch DOWN and ARC OKAY Unlike the DTHC II that uses defined parallel port inputs for the UP DOWN and ARC OK the DTHC IV sends the data across the RS485 The only hard input from the DTHC IV to MACH3 is the H
25. oetting up the Software Slaved Axis BladeRunner 300 4 and 620 4 are shipped with 4 motors but the A axis is NOT SLAVED in the default setup You will need to decide the axis naming convention you will be using for X amp Y There are several schools of thought here The old convention is to call the long axis X and the short axis Y This can make for some confusion as to how to layout files to be cut if the operator station is not facing perpendicular to the long axis Our approach has always been to use the computer screen layout where the vertical UP and Down on the screen is Y and the horizontal on the screen side to side is X That is the way the software will want to designate the axis on the computer by default In the following pages we show typical setups and operator position The goal is to have the toolpath oriented the same way as it shows on the computer drawing in relation to where the operator stands at the table The recommend placement of HOMES is based on the fact that normally the lower left corner of the drawing is defined as the 0 0 origin of the drawing and the resulting G code from the CAM if it follows the same convention NOTE IF YOU HAVE 4 MOTOR SYSTEM the A axis should be software slaved to the axis you have designed as the Gantry motion axis X or Y We do not have that setting as a default because we do not know which axis you will designate as the gantry motion axis To slave the axis in software
26. 0 is lower left corner from your location X is cross axis short axis X axis CandCNC Page 75 ala NOTE Bladeruner DTFIC IV and BladeRunner Ether Cut systems are shipped with the Il REV 15 card shown on the next two pages The default settings as shown are done prior to final testing and should not be changed IMPORTANT REG1 tab MUST be mounted tightly against the aluminum subplate The ESS uses a lot more 5V power and this regulator gets HOT and will shutdown if not on a good heatsink J3 TAB Q 6 e m im 5 out to 98 Ethernet Qu am EH BA do mm o pulse card 26 o m ol Flee la 4 Ol EB 4 E x OOOOOOMNOO z lt lt AX O Jt s Not Used wor 4 USED AF PTIONS SIP5 SIPA 2 R NORM T J3 26 25 475 UBOBIII 69s s DTHC IV Ethernet Port 10 pin header to ESS vi
27. 100 IPM Recommend DTHC Delay SheetCAM or Cut Profile 1 5 to 3 sec These settings may need to be adjusted depending on your mechanics to get smooth cuts Always adjust one parameter at a time Page 98 CandCNC SETTING and TESTING INPUTS HOMES The bulk of MACH3 and the Hardware has to do with Inputs and Outputs I O In the BladeRunner AlO system takes several forms Ultimately an INPUT is a signal coming INTO from an external source as a logic level either Active High or Active Low MACH is setup to watch certain Ports and Pins input points and then using a term called mapping it assigns an INPUT to an ACTION The BladeRunner is unique in that it has double the number of normal inputs to a single Parallel printer LPT port so you have more than the normal 5 inputs to work with It is important to understand how the input Port Expansion works and how the mappings are used The UBOB III REV15 is the hardware I O part of the BladeRunner Ether Cut It takes outside inputs from the Table I O card to sense physical switches and sets up the sharing of the inputs There are two PORTS defined in the setup PORT1 and PORT2 The physical inputs are individual and each one is opto isolated and noise filtered The Ethernet Pulse card has 1 0 for 2 ports of inputs and outputs There are two things to keep in mind The shared inputs do not work if you do not have both base TCP IP Ethernet and the MAC
28. 2 and Output 3 on the Buttons and they toggle ON OFF the AC Outlets A and B on the end of the BladeRunner Box These AC outlets are wired to the AUX AC line cord on the BladeRunner That cord must be plugged in before the outlets can be used CAUTION there is high voltage 120VAC at the Relays and the Outlets DO NOT OPERATE THE BLADERUNNER WITH THE AUX AC CORD PLUGGED IN AND THE TOP COVER REMOVED On a BladeRunner Plasma Profile with DTHC OUTPUT 1 is used for turn on the TORCH Relay located out on the THC SENSOR PWM Operation is covered in depth in the DTHCII User Manual but it is easy to simply plug in the THC SENSOR PWM module to the DTHCII module using the 25ft UTP Cable and test the TORCH ON by toggleing the TORCH button on the Diagnostics Screen and watching the TORCH LED on the front of the THC SENSOR PWM module You can test the other two AUX outputs by plugging in the AUX AC cable and plugging in an AC load table lamp 120VAC FAN etc and toggling the individual outputs on and off The AUX outlets can also be turned ON and OFF from G code using an command The M command that is used to turn on off an OUTPUT is a setting in MACH and comes defaulted so or M04 turns on OUTPUT Torch the Plasma Profile Spindle on the Router Profile MO5 turns OFF either CandCNC Page 121 n c gt gt c o o lI S 117 A scouners B
29. E y 15 10 Switched 4 mi Qutlet K3 Relay JAA Outlet Line Rela y Miain Power THIS OUTPUTS SECTION OF TABLE IS e EN Dangerous P High Voltage When AUX AC 4 CORD IS MEC PLUGGED IN 00 498 9o OO OO CandCNC Page 122 c gt gt v oO lI G Checking Outputs Using Diagnostics Page Once you have established that you are getting proper inputs See previous page then you can test the outputs With the BladeRunner connected and powered up and with the DC power on Front panel White Button pushed and GREEN Led is ON then open the Diagnostic tab Program Run ToolPath Settings BladeRunner Hardware Bring MACH out of RESET Indicator on steady GREEN If you cannot come out of RESET see previous page for Ethernet Connection to PC ESTOP input being OFF Must be plugged in and working Charge Pump LED Yellow As soon as MACH is out of RESET the CP Charge Pump LED on the side of the Bladerunner should come on steady Output Contr Torch Toggle No CP will inhibit ALL outputs including Motor motion signals Nothing will turn on or move Lack of CP shows the parallel port is not wo
30. File Misc About PN200 Pendant Rev 1 DTHC Hypertherm plasma Device Code Address b Firmware Version Select hub firmware file Lookin usb48Shub 1 2 ucecx 49 usb485hub 1 5 ucccx My Recent usb48Shub 1 6 ucccx Documents Select the highest release number New firmware can be found on the Candcnc website manuals page Network File name usb485hub 1 6 ucccx X Places Files of type CandCNC Hub Firmware Files x CandCNC Page 51 INSTALLING RS48S5 PORT HUB USING HUB UTILITY Application DEVICE TESTING PN200 48 Function Hand Control IF YOU DO NOT HAVE THE PN200 the device will not show up in your devices list and this screen will not appear 200 Test Joystick shows XY position when stick on the 2 is deflected Confirms operation or joystick ROTARY ENCODER 2 L1 L5 lamps TEST indicators You can 1 DTHC 1 click on the L numbers PRESET encoder ee to turn on an indicator Status Rotating the on the PN200 to test encoder will increase Checking the box under the count clockwise a M _ it will cause it to flash clockwise 2 14 Multicolor LEDS will a change colors if you Enc2 FeedRate click the L button again Goss Uie same cose J 2 LED Fast Flash menm amener changes 5 X 5 keypad reflects butto
31. OUTPUTS Output Toggle from DIAGNOSTICS Outputs Toggle SCREEN via the Toggle Buttons for each output NOTE Only 3 Outputs are availaible on a BladeRunner AIO Dragon Cut Large buttons above The Router setup only has 2 outputs available CandCNC Page 71 MACH SOFTWWARE Diagnostics Screen allows you to LOAD and G CODE files and to see the scrolling G CODE To load a G Code file move to the top tool bar and FILES Load GCode and select the file to load It will appear in the G Code window There is a small Toolpath display under the G CODE window and the dispaly can be turned ON OFF with the buttons under it To RUN Feedhold STOP Rewind of SINGLE STEP from the Diagnostics E mp 7 English Metric Screen use the Buttons shown Idle Run There are status LED s for UNITS and to False show running status and Dwell Tool Request Dwell Active USING SINGLE STEP TO TROUBLESHOOT Run CODE FeedHold Often a mistake in G Code or the setup is hard to Stop spot because it runs faster than you can watch the mee le machine and the code execute The SINGLE Single STEP can help with that It puts MACH in Single Block mode which means it will execute ONE LINE block of G Code at a time It does this by clicking the RUN button each time you want the next line of code to execute On a plasma we recommend you turnoff the plasma and disable the A
32. back up The objective is to have high gain but with enough dampening to keep the loop stable under all conditions Once you have established the highest gain P that you can support at a given D then back it off a little and leave the D where it is Do not set the motor so that it is silent or pulses After you have the P and D set raise the and that increases the dampening curve Once you have the motor tuned in a static non moving setup connect to load than set the tuning in MACH up to a high number 75 to 100 for acceleration and jog the motors at full speed and change direction several times If the motor driver faults that lower the P slightly raise the dampening slightly by increasing the setting Once you have one motor tuned correctly listen to the frequency of the sound Use that as a guide to tune the rest of the motors 6 Setting the Torque Limit Trimpot For 23 sized servo motors used on the BladeRunner Servo system set the Torque Limit Trimpot to 7 range centered between full CW and CCW rotation This limits current to 10 max Leave Dip Switch 10 set to OFF to prevent a 20A 1 sec peak cycle CandCNC Page 95 T 1 95 4 xotauon Clockwise increase G320X Top View T 1 F 9 4 P Accessed from rear using small flat blade screwdriver Do NOT D force is Sooo m mm T 1 ERE DEUS N SUL
33. be able to return to the same fixed spot Much like the address on your house versus the location of you RV at any given time If you establish a TABLE 0 and do all of your cutting in reference to the TABLE ZERO than you can always re establish your cut at anytime even after a power failure and E STOP event that can cause the loss of position TESTING HOMES at the TABLE If you have not yet mounted or wired your HOME switches yet it is easy to test to make sure of there operation 1 UNPLUG THE AUXILLARY AC CORD THAT PROVIDES POWER FOR THE AC SOCKETS BEFORE YOU RUN ANY TESTS You will need to power up the BladeRunner and the DC supply to run the INPUT tests but there is no AC high voltage in the top of the unit UNLESS YOU HAVE THE AUX AC CORD PLUGGED IN 2 Open the BladeRunner up remove the cover and place it gently off to one side leaving the cables to the Front Panel plugged in Expose the TABLE I O in the top of the case as shown in the illustration on page 73 Note the input terminal pairs side by side in two rows 3 Power up the BladeRunner AIO with and turn on the DC Front Panel You do not need the motors plugged in but if they are it is okay MACH will not come out of RESET if the DC power is off Inputs do not work right if MACH is in RESET 4 Make sure MACH3 is loaded and the BladeRunner Profile is selected Open the DIAGNOSTICS PAGE for the test 9 To test the inputs use a small screwdriver or metal object to
34. continue if the torch loses arc or there is a DTHC IV fault Limit Ovrd 0 Lj 1 10 bY a n 0 pd 0 D n a bP T E Stop Cannot be disabled The Active Low value is important Note THC related signals are on PORT 8 THC ON is the same as ARC OK NOTE with the DTHC IV the standard 3 THC inputs ARE NOT USED CandCNC Page 101 TABLE I O CARD LOCATION CHECKING INPUT SIGNALS The following sections detail how to use the hardware interface to use Inputs and Outputs Please review the section on the physical location of the internal cards and then the section on the Table I O card where Homes and Limits and other Inputs connected There are sections on using the E STOP either software or hardware or both Setting up HOMES and testing and optional LIMITS Even if you do not plan to use the XY or A homes it is important to at least test each input gt ees me 3e 8 Output E 0 o a a ar 0 a 1 Fa 2d a 2d g A 2d a E 1 Cuir a n n THE CHARGE PUMP The Charge Pump CP is an important safety signal in MACH and used by the BladeRunner It is a Keep Alive signal that is a waveform approx 12 KHZ and is generated by MACH and controlled by MACH and the RSS drivers If for any reason the power to the control system is turned on before the PC is powered up it is possible that as the PC boots the parallel port can have signa
35. exactly at table zero you can deal with the offsets in the CAM layout Having alignment stops on your table let you accurately remove then re load a piece of material Having a defined table 0 0 that can be referenced to makes the recovery of a loss of absolute position easy to recover from We have provided enough inputs to allow for up to 4 Homes The Z home setup is covered on the next page and depends on the type Floating Torch Holder you are using BladeRunner AIO enclosure is furnished with 2 access holes for routing switch wires into the box for connection to the tabs the TABLE I O card The holes are filled with two rubber knock out plugs that are easily removed HOME switch wires carry very small amounts of current lt 15ma and low voltage 3 5 volts DC so the wire size is not critical It is recommended it be stranded for flexibility on any moving part of the table and for longer runs twisted pair s are recommended Wire from 24Ga to 18Ga works best The smaller the conductor the more wire pairs will fit through the access holes Use the correct sized Crimp On connector for the size wire you use Switch Wire Access Plugs on End of BladeRUnner AIO BREAKER ON MAIN 5 H AC UINE Page 107 CandCNC c gt gt c o o lI AXIS Touch Off SWITCH X MOTOR 0 Precis om z axis w Floating IER SVVIIC P e WOME INPUT
36. holding torque Motor constants based on stepper motors provided by CandCNC Typical RPM of hybrid steppers moderate load with different DC power 24 VDC 300 RPM 48 VDC 600 RPM 65 VDC 800 RPM Number of steps for 1 motor REV 2000 this a fixed number based on Microstepping X10 CandCNC Page 871 BladeRunner Mardware EXAMPLES 620 oz in Stepper motor 48 VDC with 1 dia pinion gear amp direct drive Max possible IPM 600rpm X 3 142 1885 IPM 50 RPM linear force 50 Stepper motor torque pinion Radius Pinion Speed Ratio 8100z in 5in 3 206 66 linear oz of force Same design but with 3 1 belt reduction from motor to pinion shaft 3100Z in 5in 1 620 linear oz linear force in the above calculations the motor RPM and torque numbers of 50 were used to operate the motor the center part of 5 torque RPM curve Calculating the beginning Steps per UNit on an AXIS Use the following formala to get a ballpark steps per unit number in MACH Psr Pinion Speed increase ratio Pitch Dia in inches 3 1416 1 Target Steps per Unit Psr X 2000 Belt Reduction ratio This will give you the required number of steps it takes to move 1 Once you have the calcualted number of steps it takes to move the axis one inch then put that number into the STEPS per UNIT of the motor Based on the speed numbers you have calculated from the previous pages set you velocity to vlaue of 60 to
37. intact using the L3 Licenses steps below Each License file _ BXFTeal has a unique serial number issued MACH to CandCNC We keep a database of all licenses and in the 13 event you misplace your license E 1 MACH3Manual us n we can issue a 53 Sheetcan replacement 2 Open the Software Support Cd to the top folder root and click on the README FIRST txt file It will open in NOTEPAD It will explain the licenses and the way CandCNC can issue licenses If you already have a MACH license or have bought from another source the procedure is the same but the location of the license file will be different 3 Select the Licenses Folder and then the MACH folder under that 8 MachiLic dat DAT File If you purchased license or Software bundle from CandCNC then In that folder you will find a single file NOTE the new Master Installer V and later has an option dutin the process to auto install your licenses flF YOU BOUGHT THEM WITH YOUR BladeRunner To license Manually 1 Use File Explorer and RIGHT CLICK on the Mach lic dat file and select COPY this copies it to the Windows clipboard 2 Immediately Use File Explorer to navigate to the C MACHS folder on your system Hard drive C Right click the MACHS folder in File Explorer and select PASTE from the menu That will copy the file in the MACH3 main folder on your control PC Open the MACHS folder and display a l
38. it e Contains sample artwork for plasma and router CDR format Contains freeware drawing program Inkscape that will open and let you edit the CDR sample files e Contains Demo version of DXFTools for smooth arcs and curves from CorelDraw DXF export eContains Demo version of SheetCAM eContains Support Installer for SheetCAM Adds in custom POSTS and Tool Sets CandCNC Page 22 GENERAL CONCEPTS READ THESE NOTES It helps to have a basic understanding of how MACH operates what it does and how it combines with the BladeRunner Hardware to generate motion There 3 distinct parts legs of CNC CAD Drawing Toolpathing and CONTROL operation of the hardware and operator interface MACH is the third and last CONTROL It does not generate toolpaths from a file it cannot be used to draw or edit artwork It runs a specific dialect of G Code Specific software programs are used for the CAD drawing to generate the base artwork in vector format For simple shapes a pure CAD program can be used For artistic decorative or signage type cuts a drawing program that allows drawing in vector format lines will better fit the needs and is a lot faster than pure CAD It will allow import of several Vector type formats to allow you to use vector clipart like the files found at www VectorArt com The two most popular drawing programs are CorelDraw any version after 11 and Adobe Illustrator
39. motion it will not work with plasma Contains Sub folders of macros for EACH generated Profile In the specific sub folder that are macro files When you call a macro by number from code or internally it uses the specific macro in the folder of the same name as your running profile A folder of plugins installed The base plugins for CandCNC are the ccc comm and the ccc ubob Others are installed with options like the PN200 Every plugin the folder will be seen by MACH The Configuration of a plugin including enabled and disabled is stored in the specific XML profile so they can be differnt configurations in different profiles Backup copies of the Profiles XML s for your system Can be renamed and copied back to the MACH main folder to bring back a damaged XML You should STILL perform file backups onto another media source of your XML files anytime you change settings Page 28 MACH2 LICENSE INSTALL Mianual Method INSTALLING THE MACH 3 LICENSE SEE UPDATE NOTES 1 Locate your Software Support CD Itis separate CD from the Support CD Ifyou purchased either of the CandCNC Software bundles you should have the Software Support CD PlasmaSoftwareBundle Cp Artwork Samples CandcNCSamples LJ 2 INSTALL lt A NOTE ABOUT THE LICENSE FILE E3 DxfToolstd The Mach1Lic Dat is an Encrypted 3 inks file You CANNOT open it irn must be copied
40. motion more than 050 inches is about the same as a computer attached to a printer and no keyboard activity no user firing up and printing a perfect copy of the Magna Carta from random noise Since it REQUIRES concise control from the software to create motion the software can effectively control it going into RESET and E STOP The user can willfully disable Software E STOP by setting the E STOP input to read the wrong polarity and render the E STOP disabled but a hardware E stop can be disabled as well CandCNC Page 117 n c gt gt c o o lI E STOP and Safety Shutdown SOFTWARE E STOP Implementing a SOFTWARE ONLY E STOP BladeRunner AIO when properly setup will be put into RESET if the E STOP EPO string is broken EPO CONTACTS ON TABLE I O CARD lt lt Wired Jumper Isolated LED Power ESPII Supply Supply Bypass DANGER ZONE WHEN AUX AC CORD IS gt PLUGGED IN ESPII Control relay NC when ON oystem is ACTIVE ON All connections voltages and components MUST be intact and working OR the system will ooftware E STOP Anytime power is off MACH cannot come out of reset Jumper at EPO can be a string of N switches NC in series that can be wired at any point on the equipment any switch or connection in the string that open will trigger an E stop Once closed condition is restored the operator must inititate a RESET to bring the sy
41. short across a pair of inputs Start with X Home and go down through A home 6 Note on the TABLE I O Card there are small LED s next to each pair When you short across a pair you should see the associated LED turn on That indicates the circuit is complete between the Input on the Table and the UBOBIII It also confirms the 25 pin cable is working n BladeRunner SETTING and TESTING INPUTS HOMES 55 5 2 S FEES DANGER ZONE WHEN AUX AC CORD IS gt PLUGGED IN CONNECTED TABLE I O HEADER ON UBOB CARD K3 QUAD RELAY o oocom mac 756 _ OMO Ou es euloHg D ux 9uloHZ SWOHV S INPUTS TO TEST SHORT ACROSS INPUT PAIRs Example of testing X HOME input and indications on the DIAGNOSTICS SCREEN Test each input at a time and match up the INPUT STATUS The RAW PORT BITS shows the signal AT THE PORT 1 input on the PC as MACH sees it NOTE You cannot test the LIMIT input The AUX 0 is NOT and input for the BladeRunner CandCNC Page 105 TABLE I O CARD PINOUT If you have a BladeRunner with the DTHC IV option your MACH profile maps the signals to the physical INPUTS listed below P24 DC volts TABLE I O REV 12 fo
42. system with 620 oz in motor running a 5 TPI leadscrew Your settings will vary but you should be able to hit about double the velocity and acceleration of the Z motor tuning in MACH IT IS IMPORTANT THAT THESE SETTINGS BE OPTIMIZED for best response under DTHC control They will effect the Gain and Tracking settings for the DTHC THIS IS THE ONLY PLACE TO SET THE Z TUNING FOR DTHC IV A MINIMUM INSTALL REQUIRES YOU PREFORM THIS ONE FUNCTION IN THE HUB UTILITY MB DTHC Settings 19 DTHC Information File Misc About Arc votsh Current from DCP EPROM Read EPROM Write Devices Device Details DTHC Enabled Hypertherm plasma Arc OK MM PN200 Pendant Rev 1 Torch ON DTHC HOLD Tip Save ON DTHC WD Good Tip Save Active DTHC pet Test Mode Device Code E 2 Motor Settings for DTHC Address 2 Steps per unit 10000 Units Full Speed Jog Max Velocity units minute 250 mm Device Status indes gt has inch Iv Step Active Low Device ready for use cceleration units second 2 Down This setting MUST be exactly the same as the Steps Per Unit in Z Motor Tuning in MACH3 Note Max Velocity and Acceleration may be higher than the Z axis settings in MACH Thase values will vary widely based on the type 2 motor slide friction torch weight and linear drive ratios Send Motor Config Use this Hub Utility to test and set these values using the Z scroll buttons and the ac
43. the Profile i e motor tuning axis slaving etc for your specific table machine TO START THE INSTALL FROM THE CD OPEN THE CD TO THE STRUCTURE in the ROOT folder of the drive and double click the Masterlnstaller V exe file The install will start with a series of windows most screens you will just hit NEXT 2 Setup Master Installer for all Products Welcome to the Master Installer for all Products Setup Wizard This will install Update MasterInstall an your computer It is recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup CandCNC Page 32 lt 5 INSTALL CandCNc SUPPORT FILES Install Setup Master Installer for all Products Information Please read the Following important information before continuing When you are ready to combine with Setup click IMPORTANT MAKE SURE 15 MOT RUNNING WHEN THIS INSTALL IS RUM support Files on this CD are protected by copyright grants owners of CandCNC products the right fo use these Files in the operation of their products These files Including screens profiles C amp ML s macros and plug ins are intend for the use by CandCNC product Owners ONLY and MAY NOT be used with products Some files are the property of other copyright holders and are used with
44. under it you should see the CandCNC USB to RS485 hub device IF YOU DO NOT then unplug the USB connector either end and wait 5 seconds and plug it back in You should NOT get the Hardware Install or Update Wizard The Device Manager should update and show you the screen below The CandCNC USB to 5485 hub device will only show up when it is plugged in Device E m x File Action View Help B DP m gt Keyboards x Macha Pulseing Engine and other pointing devices Monitors 88 Network adapters x NVIDIA Network Bus Enumerator Ports amp LPT f Processors Sound video and game controllers Storage volumes 4 System devices amp Universal Serial Bus controllers amp Universal Serial Bus devices gt Canach USB to RS435 CandCNC Page 45 INSTALLING RS48S5 4 PORT HUB RS485 4 PORT HUB DEVICE CONNECT The USB Active ACT LED only comes on when there is a valid USB connection to the PC Drivers have to be loaded and active BR HARDWARE INSTALL USB ACTIVE LED PWR Con ACT USB B plug to PC USB CandCNC ACTIVITY MONITOR To Hypertherm C amp C 1 C amp C 2 PN200 RS485 PORT L INSTALLING RS485 Devices to the 058 5485 4 PORT HUB The USB RS485 4 PORT HUB has an advanced processor that can communicate with several RS485 devices RS485 is a robust and noise immune communications stan
45. you have running Loaded Running G code screen shows g code as it is executed Stopped code can be scrolled and new start points selected The code can be Edited using the Edit G Code Button Function Buttons allow control of the G code Loading and Closing G code and a rewind to the start button REF XY Button Function Buttons allow control of the G code Loading and performs a REF move Closing G code and a rewind to on XY at the same time the start button but not on Z Useful on plasma after the first REF has been done to locate 0 0 LOAD MATERIAL button JOG ENABLE Button initiates a to preset Turns keyboard jog on off s postion should stay on normall Eu sirra pm 4 OUTPUTS ON OFF Buttons overnive 9 00 Turns on off the two AUX relays FRO Feedrate Override reconate 6 00 ese OUTPUT 3 table i o Card Bladerunner AIO changes feedrate on all has two wired AC sockets that are Axis at the same time 100 0 0 AUX OUTPUTS controlled from these buttons CandCNC Page 66 MACH SOFTWWARE DTHCII SCREEN SECTION A detailed breakdown of all the buttons functions and readouts on the DTHCII section are covered in the DTHCII User Manual separate manual Only general descriptions are covered here UP DWN and Send to DTHC Button Any value typed into the PRESET VOLTS and ENTER is used to lock the value inthe DRO is instantly tr
46. 0VAC in 5V DC out USBA to USB B interface cable 6ft Installer driver CD User Manual PDF May be on Master Support CD in RS 485Hub4 Folder Any trademark or logo used in this manualis the property of the trademark owner CandCNC Page 39 INSTALLING RS485 4 PORT HUB INSTALL C3BUS USB to RS485 PORT HUB Handles all secondary backside communications to and from the DTHC IV to All screen readouts and all settings to the DTHC IV are handle by the C3BUS The HUB UTILITY uses the same C3BUS to communicate with all the RS485 BR HARDWARE modules including the DTHC IV It is essential the C3BUS be installed and running BEFORE you attempt to setup the DTHCIV RS48S5 4 PORT HUB TOP VIEW PWR Con ACT RS485 4 PORT HUB CandCNC USB END VIEW ACTIVITY MONITOR To Hyperth RS485 ig 9401 amp 2 200 RS485 4 PORT HUB FRONT VIEW C amp C amp 200 HyT Connect CandCNC Page 40 INSTALLING RS48S5 4 PORT HUB LLI 5 o Universal AC Power Plug lt 100VAC to 240 50 60 2 USB ACT LED shows x 2 Regulated 5 1 out valid connection to PC vim on USB channel PWR Con ACT CandCNC ACTIVITY MONITOR To Hypertherm C amp C 1 C amp C 2 PN200 RS485 PORT ONLY To EPO on ESP front panel EPO on Table I O Standard 5 UTP up to 50ft 4 ACTIVITY MONI
47. 66 0 steps per second 66 thousand if your Kernel speed is set to 45 000 default than you cannot achieve 4000 RPM The step multiplier in the G320X multiples the steps from the PC so a 2X setting makes the steps per second required from the PC to be 33 333 The trade off is that it drops the resolution by 72 as well Set your Beginning Acceleration to a low number like 10 CandCNC Page 97 Foleo Calculating the max IPM you can travel limited by max motor RPM 4500 RPM 75 RPS Kernel Speed SPR RPS 45000 1000 45 RPS Final Speed is limited by the smaller of the above two numbers Pinion RPM RPS gearratio X 60 IPM Pinion RPM X Psr T F 9 4 For 45 000 250 line encoder 45000 1000 45 RPS Pinion RPM RPS 10 X 60 2 4 5 X 60 270 RPM IPM 270 X 3 1416 848 23 RECOMMENDED SETTINGS FOR BladeRunner Dragon Cut with 23 Frame servo motors and 10 1 Gearhead reductions Recommened pinion DIAMETER 1 25mm Recommended belt reduction to pinion NONE Maximum belt reduction to pinion 2 1 Velocity XY and slave 500 IPM 12700 mm min Acceleration XY and Slave 35 to 50 IPS sec 7 Steps per unit XYA 3183 091 1 pinion Velocity Z 5 turn Leadscrew 300 IPM 7620 mm min Acceleration Z 20 IPS Sec Steps per unit Z 1000 X leadscrew TPI THC Rate Mach setting 20 Recommended Span Voltage Cut Proffile 4 to 8 Recommended plunge rate SheetCAM 50
48. 80 of that number Set your Beginning Acceleartion to a low number like 10 To fine tune the calibration see the next pages CandCNC Page 82 Setting the initial Steps per Unit in motor tuning Every table will have different Steps Per Unit Velocity max speed and Acceleration settings To do testing on the table you must determine the correct settings for your table Use the following method For Steppers 1 Determine the number of steps your motors need to make one full revolution Normally 200 for most steppers 2 Multiply by the Motor Driver microstepping rate 10 for BladeRunner Gecko drivers 2000 steps for one motor revolution 3 Determine the drive ratio of your mechanical drive how far does the leadscrew or pinion move the load with one revolution of the motor 4 Convert everything to you Units inches millimeters and same time measurements seconds or minutes Using 1 and 2 above we know we have to send 2000 pulses step pulses from MACH to rotate the motor one complete revolution 360 Degs The rest of the math is based on the transmisson ratio s between the motor and the final drive element If it s Rack amp Pinion you need to know the DP diametric pitch or the tooth count of the pinion gear and the TPU of the Rack Teeth per unit If it s a direct drive leadscrew you need to know the treads per unit TPI for inch units We have to
49. A FREE alternative is Inkscape and is included on our Software CD You can download it from http inkscape org download lang en CAM process takes a drawing file and allows the user to import it in line format define the objects to cut and in what order with which tool and what type of cut Better CAM programs have automatic lead ins outs essential for plasma and cut type settings The most essential piece is the POST processor that translates the CAM program s native toolpath data to standard G Code in a form that matches your control program The best value and most flexible CAM for 2 D or 2 5D cutting is SheetCAM It is available at www SheetCAM com SheetCAM is a part of our Software Bundles Some programs combine CAD and CAM or CAM and CONTROL but they typically are a compromise and one or more section will not be as robust as the other To maintain maximum flexibility and not be placed in a position where you have to change out an expensive tool or quit using a section itis recommended you run separate applications for each leg of the CNC Triad You can then pick and choose the features from each one that best suit the type cutting you do e MACH uses setup Profiles stored in the main Folder as an XML file It stores all of the settings about the hardware and interface input pins output signals and pins motor tuning and travel directions We use a term called mapping It refers to
50. AIO TABLE of CONTENTS PART 1 SETUP CALIBRATION CONT A Introduction Table of Contents B Detailed Install amp Setup PC Hardware 1 PC Requirements amp Prep a Not Supported List b Limitations c Profile Copies d PC hardware requirements e Windows Optimization f Unused NIC Disable 2 PC Hardware LPT printer Port Motherboard a Install and Setup Printer Port Motherboard b Using Windows Device Manager to display Ports c Check Hex Address 3 PC Hardware COM serial PORT a Using Windows Device Manager COM setup b Setup details 4 PC Hardware LPT printer Port Expansion Card a Using Mfg s disk to setup expansion card b Using Windows Device Manager to display Port Address C Detailed Install amp Setup Software 1 General Concepts a The 3 C s CAD CAM CONTROL b Definitions c MACH concepts Profiles and Screen SETS d G Code Definition 2 Installing from the Support CD a CD file structure b Running the INSTALL FILE for MACH 3 After the MACH Install a Sample Folder Structure b Folder Contents Defined 4 License Install 5 CandCNC Support Files a General Info b BladeRunnerAIO UBOBIII Install Defined 6 Installing CandCNC files from the Support CD a CD file structure b Running the INSTALL FILE Screen shots 7 Working with MACH3 PROFILES a Starting the Profile from the Desktop ICON b Starting the Profile from the MACH LOADER c CREATE a new PROFILE
51. CH3 Manual on the CD Do not use it as you primary manual for the setup and realize there are settings in the BladeRunner that should not be changed or it may cease to operate In most cases you will not need to referernce that manual For plasma cutting most of the information is not needed and if there is a conflict between a plasma specific setup or procedures this Bladerunner manual should prevail The following pages will take you through the install and setup of you CONTROL PC First you will install MACH3 then run the Master installer to do a custom setup for MACH for the BladeRunner and the DTHCII or DTHCIV Detailed setup and testing of the DTHCII is separate manual on the CD titled DTHCII Manual Detailed setup and testing of the DTHC IV is a separate manual on the CD titled DTHC IV Setup and Config Manual NOTE THE MP3000 products use the same interface electronics and DTHC as the BladeRunner CandCNC Page 24 lt o INSTALL INSTALLING MACHS INSTALLING FROM THE SUPPORT CD TO YOUR CONTROL INSTALL 1 Locate the Support CD same one this manual is on and open the Main Folder Root of the CD drive Use Windows File Explorer or My Computer and navigate to the CD Drive onthe PC 2 Open the CD and the folling structure should be displayed lt 5 SDEFTool File Folder FreeArtwork File Folder MACH Pragram File Folder Manuals File Fol
52. Folder 1 30 2014 9 11 38heetCAM CandCNC Support File Falder 1 30 2014 9 11 4M Bonus File Folder 1 30 2014 9 11 Master Installerv install exe 10 722 KB Application 1 28 2014 1 23 PM 2 WHAT TO tst Text Document 1 27 2014 11 44 Version of Master Installer is a Roman Numeral in this case 5 decimal and will increment with each release Check the website Manuals Page for the latest release NOTE THE WHAT TO DO FIRST READ txt open that file with Notepad and it will give you the latest basic instructions or changes CandCNC Page 31 lt INSTALL CandCNic SUPPORT FILES Install Master Installer What it DOES 1 Copies two PROFILES 5 to the MAIN MACH Folder for each product selected 2 Copies several Screen SET files to the MAIN MACH Folder depening on the Menu selection 3 Creates a folder under MACH3 Bitmaps named CandCNC 4 Copies all of the bitmaps for the MACH screens to that folder 5 Copies the custom drivers PLUGINS to the MACH3 Plug in folder 6 Opens the MACH3 macros folder and creates a folder for each Mach Profile added in step 1 7 Removes default MACH profile links Icons from the Desktop 8 Installs any specail drivers like the C3BUS Hub and the Hub Utility for products that need that WHAT IT DOES NOT DO Load or install MACH3 Load or install any other software setup
53. H driver for the ESS interface loaded and it has communication with the actual ESS module The process is controlled through a special DRIVER plug in for the UBOBIII It has to be installed and enabled and set correctly for the shared inputs to work It is added during an auto install from the CD or the Master Installer Install file Unlike the conventional Parallel Port versions the Ether Cut version handles all of the Input and output signals from No port pin to MACH function The Ethernet Signal System ESS reads the signal FROM TO the UBOB sends them back to MACHS via the high speed EtherNet port on the PC In order to get the INPUTS to work properly BOTH processes have to work properly When you load the Bladerrunner Ether Cut selection on the Master Installer Menu earlier in this manual it loads the right Drivers plug ins enables them and sets their parameters It also provides a default configuration for all of the INPUTS and OUTPUTS that are common on the BladeRunner IT DOES NOT automatically setup MACH to use the ESS THE MOST COMMON SUPPORT CALL ON THE ETHER CUT IS BECAUSE THE ESS MODULE IS NOT ACTIVATED IN MACH3 SEE PAGE 21 in this Manual You must be able to see the ESS configuration Menu under the MACH Menu PLUGIN CONTROL If it is missing the ESS is not in communication with E55 10pidie Ethernet IP ESS v1 pidle Contig ES5 v1 pldle Backlash Config ESS vi pidle Data Monitoring E55 10p1dile
54. HOME THC DOWN INPUT1 HOLD CHOME ARCOK LIMITS LIMITS LIMITS ESTOP EPO EPO AUX1 NC AUX2 AUX3 AUX4 AUX5 AUX6 OUTPUTS XSTEP AxislO 2 XDIR AxislO 3 YSTEP AxislO 4 YDIR AxislO 5 ZSTEP AxislO 6 ZDIR AxislO 7 ASTEP AxislO 8 ADIR AxislO 9 BSTEP AxislO 18 BDIR AxislO 19 CSTEP AxislO 24 CDIR AxislO 25 OUT1 TORCH RELA OUT2 10 K4 RELAY OUT3 11 K3 RELAY Charge Pump Page 1 CandCNC Page 78 AXIS I O TO G251 4 or MTA 150 Card UBOB III REV 15 Standard Cables used on ALL configurations TO TABLE I O CARD Table Card located inside BladeRunner and Plazpak products o c T ur e O E 1 E 3m BB a RI E ooooNM rn 6 1 E S 1 12 system bia m supply m 017 UBOBIII ce CO 69 5 S PO See previous pages for Jumper settings and cables for different configurations On MP3100 and MP3500 systems the Axis ties to the 150 card either internally or via a DB25 cable connection depending on the model CandCNC Page 79 BladeRunner Mardware INITIAL
55. Homing Config CandCNC Page 99 I c gt gt c o o lI SETTING and TESTING INPUTS HOMES Each axis as a and which are the FAR and NEAR LIMITS Each axis has a HOME Each axis has an Enabled Column Do not use Emulated ON Red X for normal setups 5 12 am 5 12 O amp Engine Configuration Ports amp Pins Input Signa m Signal Enabled Port Pin Number Active Low mulated Hotkey ar 2 2 a i we ae 2 2 ar ar X Home 7 1 11 7 er D Y e a 1 1 uf ar D m d D 1 7 ar 7 YHome f 1 12 zi d D Z 27 D D uf a D E ar 10 f BP D DO NOT USE THIS BUTTON Note A home is enabled by default This may need to be changed if you do not software slave Ato another axis with a Home See the setup of Homes amp Limits section for details Pot 12 E 1 4 a o ef 21 0 Y 4 ef 1 15 uf 0 af n 57 BY ar 0 0 ar 2d 0 gt 4 f ay ar oO 0 ar a 0 CandCNC L3 5 100 n ee Pin Number Active Low 9 Emulated Hotkey 58 c gt c o oO L oOo oO u rm m uU 47 oA o uw ce m INPUT 1 handles the HOLD motion signal FROM the DTHC IV and MUST be setup as shown or the motion XY will
56. ING WIN 7 with MACH3 You must use 32 bit version of Windows 7 l 4 1 2 Tammy Documents E Pictu Started i Musi Lomiputer Connect te a Projector Devices and Panel Default Programs and Support s bk Control Panel c L 8 E Contro Manege wireless networks Chang e adapter settings Change advanced sherning settings k E A h Local Area Connection Make sure the Local Area Connector does not show it is disabled It may show it is not CONNECTED but if it is missing or disabled you will need to get the problem resolved before you can proceed with the install CandCNC Cut You cannot use WIN 7 64 bit running in 32 bit emulation Network unplugged Breedeem 44 00 100 htegrated Right click and select Properties m 0 Select Control Panel from Start Menu Select Network and sharing Center from the Control Panel Full Menu You will get a graphical representation of your network and installed links On the left you will see the Change Adapter Settings menu choice END t All Control Panel Items Network and Sharing Center 4 k Metworkandintemet Network Connections k Wireless Network Connection hcuse I tel
57. IV ETHER ETHER CUT or Plazpak RouberPak ETHER CLIT Install 3 8 MB 1 BladeRunner AIO DTHCH Install 42 80 7 BladeRunner AO DTHCIV Install 3 8 MB 4 BladeRunner AIO ETHER CUT Install 3 8 MB 055485 4 Port Hub Installer Update ONLY 66 _ Install SheetCAM Support Filles POSTS amp Toolsets 0 3MB _ Install MACH license Q LMB instal wa a vast Starting with Master Installer the same installer is used for all CandCNC products and a MENU selection system is used version IV and higher the menu has been expanded and the options to load licenses if you purhcsed them is included You will see a much expanded list of products reflecting recent additions to our product line Components Exist 3 Setup has detected that the following components are already installed on your computer MP3200 DTHCIV or Plazpak RouterPak DTHCIV Install Deselecting these components will not uninstall them Would you like to continue anyway You may see this dialog if you have previously installed any components Select YES CandCNC Page SUPPORT FILES airtel Setup Master Installer for all Products INSTALL Select Start Menu Folder Where should Setup place the program s shortcuts lt 5 PF Setup will create the program s shortcuts in the following Start Menu folder Ta continue click Next IF you would like to select a different Folder click Browse lt
58. IVE Anti Dive ON OFF Bl HT ONLINE HT ONLINE indicates RS485 connectio between Hypertherm and is val DTHC IV Ether Cut Screen Set with DCC TAP fly out using TAB key CandCNC Page 10 INSTAL SETTING UP THE ETHERNET PORT Windows XP System Properties g Remote Advanced Sustem Restore General System Microsoft Windows Professional Version 2002 Pack 3 Registered TOMC Computer AMD 54 42 D ual Core Processor 5800 301 GHz 2 00 GB of RAM Physical Address Extension System Properties System Automatic Updates General Computer Mame Fr M OK Device Manager The Device Manager lists all the hardware devices installed your computer Use the Device Manager to change the properties of any Driers Driver Signing sure that installed divers are compatible with Windows Windows Update lets you set up how Miedo connects to Windows Update for drivers i Driver Signing Windows Update Hardware Frobiles Hardware profiles provide wap you to set up and store different hardware configurations Hardware Profiles CandCNC INSTALL m 0 L FOR ETHER CUT WIN XP Device Manager 34 File Action View Help E Py Blain Radios
59. LY Space available on selected drive 92 79 GB ea 36 Mach3 Setup Several Features will be Select Packages a m selected by default Flease select the program features that veu want to install pai 4t checked Turn off 7 7 Wizards LazyCam You can turn off Screen sets Program Features unless you want to use B 11 Port Driver Installs the Parallel Port Driver This is not the Default MACH wizards needed for extemal motion control devices screens to build your 328 OWh Screens LazyCam experienced MACH users ONLY If you are installing the Ether Cut Make sure you Turn off the Parallel Port Driver Hitthe NEXT Total space required 33 7 MB button CandCNC Page 26 INSTALLING MACHS Mach3 Setup Create Profiles and Desktop Icons Custom profiles will help to ensure that your settings do nat get accidentally overwritten future updates Ibis highly recommend that you create Create a custom Mill Fiouter profile at this time Tan at this time Create a custom UN at this time CandCNC Do not create any profiles in this screen All of the Profiles you will need for the BladeRunner oystem will be automatically created in the next section of the software install section Page 27 lt 5 INSTALL IVIACH 3 SOFTWA
60. MOTION CHECK After you have powered up the BladeRunner and checked the power on sequence and checked the motors on each axis the next step is to plugin all motors and run an intial motion check You can wait to do this after you get the motors mounted on your CNC table if you want or you can set the motors on the table oriented like they will be mounted to check inital motion and direction 1 Make sure the PC connections have been made and the PC Hardware ports setup as per previous sections 2 Plug in all the motors Orient them like they are going to be mounted Label them if they are not on the table 3 Turn on the main power switch on the end of the BladeRunner ESPII box 4 Turn on Motor DC using the Front Panel ON White button 5 Check to make sure the motors lock and that you have a Green ON LED 6 Start MACH3 with the plasma or router profile desktop Icon 7 Switch to the DIAGNOSTICS TAB in MACH 7 Jog the axis in turn using the keyboard Jog keys a Left and Right Arrow gt and lt should jog X axis b Up and Down Arrow should jog Y axis c PageUP and PageDown should Jog Z axis 8 STOP If you cannot get an axis to move or or it only moves in one direction a Check to make sure the associated DRO is changing on the screen b If it is then check all of your cables from the parallel port c If you have DRO action and still fail to get motion in both directions turn to the Service Manual Section See the section on tr
61. N commands even when the THC Button is OFF in MACH The manual UP and DOWN is like a Z JOG command but DURING running code You cannot JOG Z with the same inputs when it is NOT running code and the Torch is fired Output 1 active The buttons you use either from a pendant table I O inputs or from an EMULATED input will ONLY move the Z WHILE YOU HAVE THE TORCH ON AND ARE MACH has ARC OK not typically used with the DTHCIV You will have to assign an input to the THC ON Arc OK and set the input so it is on with no signal because even though the DTHC IV reads and handles the ARC OK directly you have to make the MACH3 internal THC code THINK it has ARC OK for it to release Z motion To do the same thing using the keyboard you must setup the INPUT Pins in MACH so THC UP and THC DOWN use EMULATED enabled green check You can then click on the HOT KEY for each and use the Set Hotkey to select two keyboard keys Do not use keys assigned to any other function While you can use both hardware swtiches and the keyboard hot keys it could get confusing We present both as options but recommend you use one of the other 2 15 a af 65 2 uf ef as 2 df ef 5E CandCNC Page 114 5 12 am USING TABLE INPUTS FOR REMOTE CONTROL OF UP and DOWN ON OFF ON Center off Single toogle Normally Open Momentary Switches used for external control of UP and DOWN manual for OXY FUEL
62. OLD signal mapped to INPUT 1 on Ports amp Pins Communication to the plug in in MACH to update Z position when DTHC is active tells where the DTHC has moved the Z while under THC mode Pass parameters and settings in MACH to the memory of the DTHC IV This includes all of the DTHC Cut Profile Settings either from the screen or from the G code when using DCC C3BUS MANAGING THE HUB During the install the CandCNC Hub Utility was added and an ICON was placed on your desktop Click on the icon to open the Hub Utility IMPORTANT The purpose of the HUB UTILITY is primarily to confirm proper communication with each device and to be able to do some base level testing You cannot run the Hub Utility at the same time as MACH is running The following screens show the CandCNC Hub Utility displaying information about different devices connected to it The Hub is smart and automatically detects any compatible device connected to it Review the screens that follow and understand what each section of the screen is used for CandCNC Page 48 BR HARDWARE INSTALL INSTALLING RS48S5 PORT HUB USING HUB UTILITY Application LLI lt _ lil CandCNC Hub Utility im DEVICE DETAILS Fila About 7 Device Details Provides the 5 2 Rev 1 Device Y DEVICES E Device Code Each e CLASS type of device Shows a list of De
63. RE Basic Structure gt MACH FILE STRUCTURE a L3 Macha lt lt 7 Addons __ Bitmaps SAMPLE FOLDER STRUCTURE 5 5 Brains 0o _ Flash Some folders are added for GCade specific options so your folder view __ Help will not have all of the ones shown 1 3 BladeRunner AIO DTHC UBOB3 BladeRunnerAIO Router UBOB3 W DTHCI HyT Connect E3 5 3 ETHER CUT TAP EtherCutRouter 9 00 18063 W MPSODO DTHC UBOB3 2 MP3000Ro0uter W MPS1D RDuter 19 MP3100 Router 1 3 MPa1B0 Rauter xml 22 OlderScreens Plugins 2 Subroutines TurnAddans Uninstall xmlbackups From time to time if you add features or certain upgrades are installed there can be added folders and or changes to files We make available specific files that upgrade files in this structure In some cases the user must open the specific folder and copy the new file into or overwrite an existing file in a folder Being familiar with the structure makes this process easier CandCNC on an initial install The important ones are listed below This is located on the C drive of your Control PC FOLDER Bitmaps xmlBackups CONTAINS Contains Bitmaps custom backgrounds and Buttons for the custom screens CandCNC has a Folder under Bitmaps for the specific bitmaps for our screens Sample G code for ROUTER Do not use except for testing
64. STALL Hardware Update Wizard Next Screen of Hardware Install Update Wizard This wizard helps vou install software for Leave the radio button USBrs485hub set on the Install the software 9 M your hardware came with an installation CD 122 ur floppy disk insert it now driver has already been installed in the earlier steps so you do not need try to find the Install the sn tware automatically Recommended driver manually Install from a list or specific location Advanced What da you want the wizard bo do Click Nest to continue Cancel Hardware Update Wizard Completing the Hardware Update Wizard The wizard has finished installing the software for This screen indicates the software and driver install for the USB to USE ta H5485 hub RS485 4 port Hub has been successful oee the following pages for checking the install and to use the CandCNC Hub Utility Admin Click Finish to clase the wizard t Bac Finish CandCNC Page 44 INSTALLING RS48S5 4 PORT HUB lt N BR HARDWARE 4 To confirm that your USB RS485 4 PORT HUB drivers have been installed open the System Application in Control Panel in Windows and then the Hardware Tab and the Device Manager You will see a Tree Structure of hardware devices Scroll to the bottom and Find the UNIVERSAL SERIAL BUS DEVICES and
65. TOR LEDS When a device is plugged into a port on the hub the LED will light if it has proper communications It does not mean the device is operating correctly see later pages for using the Hub Utility The Activity Monitor shows send and receive activity on the port CandCNC Electronic Controls for CNC 2 sdais NO DTHC IV Digital Torch Height Port1 INPUT TS DEI CandCNC DTHC IV parallel port system shown Page 41 CandCNC INSTALLING RS485 4 PORT HUB A 10 tino 0 n gt 0 Los CandCNC CONNECTION EXAMPLES The CandCNC C3BUS USB to RS485 4 Port Hub CONTROLLER PC Mount close to PC oft Port Hub S B T5 SLV9 UP to 506 a oe 475 48 function gt UBOB B Mark IV gt CandCNC RS485 CandCNC 4X4 Driver C 65485 5 Cards Spindle SSpeed Mark IV NOTE Example ONLY some of the examples are not available yet Only ones in Yellow are currently available Names may change and release dates are not yet scheduled Page 42 BR HARDWARE INSTALL Hand Controller INSTALLING RS48S5 4 PORT HUB 1 Plug the USB RS485 4 Port Hub wall plug power supply into an AC outlet NOTE While the wall plug power supply has pins for standard US AC 120VAC sockets the power
66. U ARE CONFIDENT THAT THE MOTORS ARE EXHIBITING SYMPTOMS OF IMPROPER TUNING Most problems are mechanical backlash loose gears pulleys or settings in MACH and cannot be helped with driver tuning This should be done ONLY if you experience any of the following 1 Any motor that pulses slowly is completely quiet qhen powered and not moving 2 An axis that faults often when you are accelerating the motion NOTE it is normal for a servo to fault and the ESPII to throw a fault when you do an emergency STOP in MACH The motor cannot stop instantly without causing a fault Faults from other issues like overloads and noise cannot be fixed with motor tuning The motors need to be mounted and under load to do tuning by ear 1 Power up the motors It may be easier to disconnect all but one motor and encoder apir at a time so you can hear just that motor if you accidently try to jog a motor that is not connected the Gecko drive WILL fault 2 Make sure the motor under test locks If it starts to move than make sure the encoder is plugged in for that motor If the motor losses encoder pulses either channel it will start to run away spin at full speed huntting for a line on the encoder 3 The motor should hum The frequency is typically below 220 hz octive 3 A on the music scale The important thing is that the motor does not sit and pulse indicating it is way over dampened The higher the frequency of the hun the tighter the tuning There are tw
67. UNNER on the TABLE Page 108 c gt gt Y o oO lI SETTING and TESTING INPUTS HOMES Using an Optional Salve Side Home Switch It is advantageous to use a HOME on the slaved axis in this case A There is an input for an A HOME If you set your inputs to have an A HOME in INPUT SIGNALS then slave the A axis the gantry will move towards the switches and stop the motor on the first one to make contact The other axis will continue to run uniti it contacts it s swtich If the two sides have gotten out of sync the XY REF will let the gantry Auto square itself If you make the bracket on one side or the other adjustable you and fine tune the position and square the gantry with the table If you elect NOT to use a slave axis HOME in case you need the input for something else You must still enable A home in the MACH Profile but map the A home to the same Port and PIN as the Master Home Y in this example CandCNC Y Home we SWITCH BladeRunner Typical rectangular table setup 4 motor setup dual drive on the gantry GANTRY 2 axis SS holder Z HOME A Home SWITCH X axis Make this If you stand here to run the machine Switch Bracket then 0 0 is lower left corner from your Adjustable location X is cross axis short axis Page 109 G Hardware SETTING and TESTING INP
68. UTO THC ON Cut Profile before using the SINGLE button With the SINGLE Button on LED ON you can run a line watch the moves take a measurement if needed and see if the motion is correct CandCNC Page 72 MACH SOFTWWARE Other things you can control from the Diagnostics Screen 1 JOG ON OFF unusually left ON 2 Set the SINGLE STEP Jog Increment Cycle Jog Step 3 Change the JOG MODE from CONTINIOUS to STEP STEP MODE only moves the axis the JOG INCREMENT each time you hit the Jog button 4 Change the SLOW JOG rate no SHIFT with a JOG KEY Slow You can use the UP DOWN buttons or type in the value in the DRO hit enter to SET the value 5 Turn the THC Logic in MACH ON OFF 6 Enter a new TIP VOLTS PRESET VOLTS value Enter Key to Set and then SEND to DTHC change the running value in the current DTHC configurations OMOFF CuLAlt J _ Cycle Jog Step AIt 0 0100 St While most of the controls are on the Program Run Screen of MACH the DIAGNOSTICS SCREEN lets you monitor inputs outputs and position while running manually or via code While there is a lot of information and buttons it offers the feedback you need when doing the intital setup or troubleshooting of a system Earlier in the PC Hardware Section you see how the RAW PORT INPUT BITS shows if the Parallel Port is properly configured and respondiing CandCNC Page 73
69. UTS HOMES SETTING HOME SWITCH SEEK DIRECTION Each HOME Switch in the system has an associated set of parameters to define how it is used To access the Configuration Menu open the CONFIG Homing amp Limits window shown below Most of the defaults will be correct The HOME NEG setting tells MACH which way to move to find a home switch After you setup your home switches you should test each one and setup the seek direction 5 2 c gt gt c o o lI 1 Make sure the HOME switch shows up in the Diagnostics Window when you manually activate the switch On the Z home for a plasma setup using the floating Torch holder manually raise the torch by hand and test the switch 2 Do one axis at a time In the Program Run and the Diagnostics Tab you will find a REF button next to each axis DRO Move jog each axis out several inches away from it s home switch Click the REF button on the X axis and if it starts to move AWAY from the HOME Switch stop the motion and open the Home amp Limits window and click the Home NEG indicator for that axis Each time you click it will change the setting from a Green Check to a RED X and back Set it to the opposite value and click OK Re Test the REF on the axis you changed and make sure it moves to its Home Switch 3 Test and set each axis Home that you have When Homing the Z axis on a Plasma setup should move down to the material It will move until it trips the Z home swi
70. a special ribbon cable Provides Independant 5th axis B with J63 and J65 set as shown Page 76 CandCNC Connections UBOB III REV 15 to ESS Ethernet Other standard connections not shown PORT2 Header To ESS PWR SIP3 m O OS SIP1 1 TEENE lt D oooooooootm OO OO OO AXIS 10 m 855005059 LO Qo Me S Q Z O E C n x AXIS J11 1 222 9 3 1 2 5 TUUM d T 6818 DIROPTION 4 c te PTIONS UBOBIII OF oO 695 me E WO po LLIYOd OL Page 77 CandCNC BladeRunner Mardware 25Pin TABLE IO PORT PIN OLD SIGNAL ZHOME AHOME BHOME XHOME YHOME ZHOME AHOME BHOME XHOME YHOME ZHOME AHOME THCUP C
71. ansferred to the DTHCII memory when the Send to DTHC button is hit The User operator can quickly change the PRESET VOLTS before or DURING a cut and change the ARC GAP in the process TORCH AMPS Displays the action Cutting AMPS IF the CandCNC DCP01 Digital Current Probe b JH E ri has been installed Otherwise it reads zero IT 15 1 2 f 2 FOR THE CUT CURRENT PRESET THC ON OFF turns the THC function In MACH ON or off The DTHCII can turn this on automatically when the torch fires setting in the Cut Profile Operator can turn the THC on off manually When THC is off MACH ignores any commands from the DTHCII to move the Z EAD TORCH ON OFF toggles the torch OUTPUT1 on off manually from the screen The torch can be turned on or off at any time MACH is out of INDICATOR LED s RESET even during a run STORED SETTINGS CUT PROFILES This TIP SAVER turns on when TIP button opens a window that displays a range of saver is active TIP SAVER is a values and settings for the DTHC to use The dynamic anti dive that keeps the initial display is of the CURRENT SETTINGS in torch from diving on corners or when the DTHCII memory Profiles by material can be crossing a void or existing kerf recalled selected and added Detailed use of the CUT PROFILES is covered in the DTHCII User Manual UP DOWN ARC OK shows the statues of those inputs from the DTHCII These are the IMPORTANT There are Self Test
72. are FINE TUNING the calibration using the tape measure method Once you have a ballpark of the number of steps it takes to move your machine 1 inch then you can fine tune that using a simple tape measure and a calculator 1 Establish a zero spot you can precisely mark on your table On a plasma table you need to remove the torch and either mount a laser pointer at tool center or use a sharp pointed tool in a holder You can also tape a small drill bit or pointer to the torch nozzle if your mount has enough room You want something small enough you can see errors of 032 on the marks of the tape 2 Setup up the axis you want to calibrate with the pointer sitting at the zero point and zero that axis DRO 3 Write down the Steps per Unit value you have for that axis 4 Open MACH to the Diagnostics Page and find the MDI window 5 Type in a distance to send that axis out using the following G Code example is for moving X out 30 inches HIT THE ENTER Key to execute the line 500 X30 000 6 Measure the ACTUAL distance you went with your tape measure from zero to where it stopped and write down the distance to as close a decimal value as you can estimate the distance if its less than a 1 16 063 7 BEFORE YOU make ANY changes move the axis back to the start point by using the MDI and typing G00 X0 000 for the example above 8 Use the formula On the next page and calculate the new Steps per UNIT Then open the motor tuning i
73. ash code and on screen in text Driver interface card has input high speed opto isolation step amp dir 4 High quality Gecko stepper drivers with X10 microstepping and tuned anti resonance for smooth motion 5 High capacity toroid linear power supply provides low noise DC power with large surge capability AC input has two levels of ON OFF AC side fusing breaker DC side Electronic fusing and conventional fusing Operation on most AC power grids in the world 6 Wired and tested motors are specially designed to match Gecko Drivers for optimized performance 7 Unit is expandable for up to 5 motors and drives full 5 axis independent 8 Warranty covers labor and parts returned to factory for a full 2 years All components including motors and drivers 9 No Parallel port or serial port needed Uses one Ethernet network port and one USB port for 5485 C3 Bus hub IN ADDITION to the Above the BladeRunner AIO DRAGON CUT offers 1 Fully integrated Digital Torch Height Control with Dynamic Fault and anti dive detection On screen display and setting of all Torch Height Parameters Full high speed digital response Total electrical isolation for safety and noise rejection Advanced PWM digital pickup at the plasma via a single cable Exclusive HyT Connect SINGLE CABLE plug n go interface for all Hypertherm 45 65 85 105 125 Direct Connection kits for most other brands Industry first DCP 01 digital current probe opt
74. ay be launched by selecting the installed icons Click Finish to exit Setup Another screen of information we think you should know so humor me and please read it FINISHED Once you have installed the Master Install file then you can start the final setup calibration and basic motion tests of your BladeRunner You can always get back to the basic default values for a BladeRunner if you simply rerun the install again BUT BE AWARE that any configuration changes including motor tuning etc will go back to the install defaults The following page will cover how you can start the specific PROFILE CandCNC Page 36 lt 5 INSTALL Starting The MACH PROFILE STARTING THE BLADERUNNER PROFILE From the the Desktop on the computer Look for the C3 Icon and select the Plasma or C Router Profile to run If the C3 icons are not Ed present you may find it installed them with a generic icon like this it will run from either Icon HOW TO RUN FROM THE MACH LOADER The MACH LOADER ICON should still be on the desktop It gives you access to a MENU of installed profiles that exist on your setup Session Profile a Your display may have more or less profiles than the screen here You need to see at the products you have selected in the install menu The DTHCIV will have it s own profiles and screens Current Profiles 1
75. be counted on to actually position the motor shaft at a fraction of a motor pole between poles It can be off and the faster the motor spins the less effect microstepping has The only true resolution will be the 200 steps per rev of the motor In practice it will be somewhat better especially at slower RPM but it varies CandCNC Page 83 For proper tuning of please refer to the MACH manual The exact tuning of the software is beyond the scope of this document Motor Tuning Screen in Testing the BladeRunner for motor control In order to get motion and you need to have running with it out of E stop and the CP LED on the front panel active ON Without CP active you will not get motion e Make sure all of the cables are connected Power up the BladeRunner Load Mach3 with the proper profile BladeRunner and Screen e Turn on DC Motor power using the ON button on the Front Panel e Motors should lock when power comes on to the motors e Hit the Reset button The LED over the Reset in MACH will turn solid Green he CP LED on the front panel of the BladeRunner will turn solid Yellow Use the keyboard arrow keys to jog your machine Don t worry if they jog the wrong way with the keys or the wrong axis jogs We will fix that later e The Optional test Step and Direction Monitor will confirm that the signals are getting out to t
76. dard used in industrial electronics for years Because of its differential signal methods it is unaffected by external or ground based noise and reliable communications of several hundred feet are common RS485 is a multi drop topology meaning there can be multiple devices on the same pair of wires as long as all of the devices operate at the same speed BAUD RATE and have a unique address Since USB is a common port on most PC s it is a logical choice for communications that do not depend on precise timing You will note that the USB RS485 4 Port Hub has four independent channels and each channel can talk to multiple devices Because of different Baud Rates or special signals the 4 port hub has two special jacks 1 Hypertherm RS485 Port This channel runs at a much slower speed and can only talk to Hypertherm Plasma Cutter equipped with an RS485 port optional and through our HyT Connect 5485 interface If you already have the HyT Connect RS485 SIM Kit installed and have the older single port dual jacks RS485 module you need to unplug the existing setup and plug the RJ45 Cat5 cable FROM the port on the rear of the Hypertherm into the jack 1 marked To Hypertherm Rs485 PORT CandCNC Page 46 This page shows connection of the optional EY T Connect RS485 SIM Kit More lt detail can be found in the Fly T Connect 85485 SIM Manual The 85485 option to control plasma cut current is part of the TAP product
77. defining a specific function to a specific port and pin setting in MACH The BladeRunner Install copies the profiles needed to the MACH folder to run the Bladerunner Hardware Certain settings that are specific to you machine motor tuning travel directions etc have to be entered during setup The settings get stored in the current running PROFILE eThe screen presentation for the BladeRunner is in the form of a custom screen set The file is stored in the Folder and has a set extension It controls what buttons readouts DRO s and bitmaps pictures are on the screen The visual look is controlled using custom bitmaps Bitmaps used with CandCNC screens are all stored in a folder located in the Bitmaps Folder under MACH3 and in a sub folder named CandCNC With the exception of certain custom objects in a screen there is no setup information Certain operations on the Bladerunner parameter feedback and DTHC or Spindle Speed functions MUST use the associated screen set to operate properly eT he G code runs in MACH and gives it moves in absolute measured from a beginning zero point XY and Z coordinates It s up to MACH to process the file do the math and based on the settings in the Profile issue the proper number of pulses steps and proper direction dir to the motor drive modules hardware There is no positional feedback between MACH software and the table position Hardware MACH is not closed loop It issues the signa
78. der yotherInstalls File Folder j Sheet CAM File Folder 15 aladsRunnerATO spindls UBO amp 3Update Inst 3 043KB Application jSleladeRunnerATO UIBOBITI Install exe 3 607 Application ReadmeFirst txt gt ZKE Text Document 3 Navigate to the MACH Program Folder MachsVtersion3 042 029 6xe 26 456 Application 7 Screens exe 1 880 Application 4 Double Click the Mach3Version3 042 029 exe line The sutomated install of MACH Will start E Mach3 Setup Welcome Welcome to the installer for Macha Version 3 042 029 1 strongly recommended that you exit all Windows programe before continuing with this installation Ifyou have any other programs running please click Cancel the programe and run this setup again Otherwise click Next to continue CandCNC Page 25 INSTALLING MACHS 86 Mach3 Setup E 35 o Installation Folder Where would you like Mach to be installed The software will be installed in tke folder listed below it iz recomended that you use the listed MACH will ask you for folder but you are welcome to a different location either type new path er click Change the default installaion folder V for folder Disk and folder to use DS SELECT THE Install Mach ta STUCTURE IT SHOWS OR OTHER INSTALLA MAY NOT WORK Space required 38 8 MB CORRECT
79. detail in the DTHCII User Manual Added controls can be accessed with TAB flyout Use TAS Fhis gane Mete Using DOC tha G Coda gets mosralirass paranmeters 0 Cul Curent AUPS is 45 2 Set Hi 1001 5 ur COLNE HE QNLIME inficalaa 694595 BladeRunner DTHC IV PLASMA PROFILE SCREEN Page 65 CandCNC MACH SOFTWWARE Screen Sections e TOP MENU POPS up windows on top of the screen to access various settings Three most used are 1 Files 2 Config 3 View This menu row is visible and can be accessed from all screens MENU SCREEN SELECTION Consists of tabs to select different screens In normal run mode the PROGRAM RUN screen is the most used The DIAGNOSTICS screen is used to confirm proper settings and functions and will be covered later E EL ibi h A i CH rli Boj i IS TET Program Run DRO Digital Readouts for axis position and for manual referencing and zeroing the DRO s REF buttons move an axis towards an associated HOME switch When the axis hits the switch It will stop and backup slightly If it moves the wrong way or does not move at all see the section on CONFIG HOMING amp LIMITS Current G Code File Loaded or running RUNNING PROFILE Box Shows the current MACH PROFILE
80. determine how far the load moves in units for each REV of the motor Lets do a direct drive leadscrew of 5 TPI It takes 5 turns to move the load one inch of linear movement so the steps per inch unit of the axis is simple 2000 number of steps for one rev X 5 number of Rev to move one inch 10 000 steps per inch 0001 resolution About 6 to 7 times the torque 1 5 the motor Speed Now let s do a R amp P direct drive and an R amp P with a belt reduction transmisson Fora R amp P the distance traveled per rev of the pinion is given by the DP of the pinion X PI 3 1416 use a 1 DP pinion the distance traveled is 3 1416 per rev of the pinion Soa direct coupled motor gives us over of travel per To get it back to a Unit 1 it would be the number of steps 2000 from above 3 1416 or 636 6183 as you can see the resolution at 00157 per step is MUCH courser than the 5 TPI leadscrew The max velocity speed would be over 8 times the leadscrew but with 1 3 the torque of the motor specs is over 2000 IPM To gain back the lost resolution and torque you should belt reduce between the motor and pinion With a 5 1 ratio you would see the numbers change 10 2000 3 14165 X 5 or 3183 1 steps per inch 000314 inch Torque would be 1 66 times greater than motor rated torque NOTE DO NOT use the microstepping in a true resolution calculation for accuracy Microstepping is for motion smoothness and cannot
81. epper just stalls starts slipping and loses steps Because if this they are safe from overload and will simply stop turning Simple mechanical stops on an axis will keep motors from running to far and no damage to motor or drive is inflicted It sounds bad because the motor vibrates as it attempts to turn but no harm is done The motor will not overheat and the electronics will not see it as an overload unless all 4 motors are stalled at the same time LIMITS are more for decoration than function on a stepper system Some users like to have them If that describes you then by all means install and set them up you will feel much better Page 112 CandCNC c gt gt c o o lI SPECIAL SECTION Hooking up a remote control for doing Oxy Fuel cutting Disregard this section if you do not have an oxy fuel setup on you table IF YOU DO WANT TO SETUP AN OXY FUEL SYSTEM PLEASE NOTE THE FOLLOWING 1 Setup and copy your working Plasma Profile using the MACH LOADER covered inPage 34 of this manual 2 Make the changes listed on the next pages to THAT NEW PROFILE 3 You can control the Z UP and DOWN manually during flame cutting using either a set of switches OR the PC keyboard but not BOTH 4 There may be some reconfiguration of outputs needed for oxy fuel if you want automated control of the Oxygen valve and or an automatic striker 5 The THC cannot sense the height of the tip since there is no cutting
82. er Cut products the outputs are direct mapped and are as shown Output 1 is always tied to the Torch relay while output2 and output3 are tied to the AUX relays on the Table 1 card and in all Bladerunner and Plazpaks the two AUX relays are wired to the AC sockets on the end of the ESPII enclosure and ready to control AC loads up to 15A and 10A respectively max 15A TOTAL on both at the same time 5 2 c gt gt c o o lI Signal Enabled Port Pin Number Active Low Output 1 zd 1 14 a Output 2 zd 1 1 a Output 3 ef 1 16 ur Output 4 ar 0 fi er Output 5 ar 0 0 ar Output 6 a r ChargaPump f 1 17 ur Charge Pumpe a 1 17 a CiwrentHiAnu a n n p DO MAKE CHANGES THE Charge Pump SETTINGS Note the Output SIGNAL name above is mapped to a PORT PIN pair and that defines which physical device is activated by the UBOB output section While there are 3 signals one of them is used with the DTHC internally SETUP amp TESTING OUTPUTS OUTPUTS Ola JN9292 oo He HO OO amp 9 C OO 2 OO On oul ioc E ott OO TABLE 1 Xhome Nice E LIMITS B DOWN s BEER UP OUTPUT Status Cont There are two AUXILLARY OUTPUT Relays on a BladeRunner EtherCut PlasmaAlO unit They are designed as Output
83. ersion 3 43 067 off this CD installed and running first THEN run the appropriate selections off the Menu The installers will load both the Router and Plasma profiles and both ICONs will show up on your Desktop Each profile for MACH XML stands alone so if you want to use both you must setup both profiles with the Motor Tuning and any other parameters that are exclusive to your machine For reference the full MACH3 Manual is in the Manuals Folder You will also find the BladeRunner AlO Manual there as well We also post the latest manuals on our website http www CandCNC com Manuals htm Expansion Cards DTHC II DTHCIV have their own manuals for install setup and use lf you have purchased the BladeRunner Dragon Cut for plasma cutting you will also need to refer to the Setup Config pdf All Manuals are in PDF format You will need to have the Adobe PDF Reader Or something like Foxit installed Free to view or print the manuals IF YOU DO NOT HAVE THE SUPPORT CD or it is more than 30 days since you received your BladeRunner you should check http www CandCNC com Manuals htm for the Master Installer ZIP at the bottom of the page You can download unzip and run that installer STRUCTURE OF THE SUPPORT CD Name Type Date Modified Machinstaller File Folder 1 30 2014 8 11 4M Manuals File Folder 1 30 2014 9 11 AM SPN200 Macras File Falder 1 30 2014 8 11 AM j amp heatCAM TNG Program Install File
84. esting INPUTS HOMES a Z axis setup and testing required for DTHC b Optional XY amp A homes c Other inputs 5 Setup and Testing INPUTS LIMITS 6 Setup and Testing OUTPUTS a How Outputs work in the BladeRunner b Things that trigger an output b Testing OUTPUTS Final system checkout 1 Bringing it all together a Final Motion Test b Doing an Air Cut CandCNC Page 6 PC Requirements amp Preparation THE FOLLOWING CONFIGURATIONS ARE NOT SUPPORTED a Any Windows 64 bit install WIN 8 or 8 1 not yet tested Laptops usable but discouraged for the harsh environment of a plasma shop Other Limitations We have included a version of MACH3 on the Support CD that has been tested and certified to work with our plug ins and screens If you have already installed a LATER version then it MAY work f you experience problems with a version newer than our version on the CD then SEE THE BEFORE YOU UNINSTALL MACH BELOW 1 Uninstall the newer version of MACH using Windows Software Install remove program 2 Open the Hardware Manager on the PC and uninstall the MACH PULSING ENGINE device in the hardware list Do a fresh install of and re install the CandCNC files INSTALL off the CD BEFORE YOU UNINSTALL MACH OR DO A REINSTALL OF THE CandCNC INSTALL OFF OF THE CD If you have settings you would like to preserve from the earlier install make a copy of the MACH folder on your drive usi
85. ettings upon exit Click OK to save CandCNC Page 18 CABLE CONNECTIONS for DTHC IV BUS amp ETHER CUT PWM Module Y ETHER Connections Guide INSTALL m 0 L CandCNC DTHC IV Digital Torch Height thernet Electronic Controls for CNC CP PWR UBOB III Technology Green Cat5 from Ethernet Jack on Ether Cut front panel TO Ethernet jack on PC Up to 25ft length BLUE CAT5 cable for RS485 from UP TO 25ft C3BUS Jack on Ether Cut to Ethernet Jack CAUTION cables are CAT5 UTP 8 conductor and will plug into any CAT 5 RJ45 jack We have color coded the cables to help keep them from being mis connected If you use other CAT cables be sure to label them on each end Connecting cables wrong could damage modules UP TO 25ft CandCNC C3BUS RS485 4 Port Hub PWR Con ACT USB PORTS 9485 4 PORT HUB ACTIVITY MONITOR KA TESE HUB is REQUIRED for DTHC IV CONTROLLER PC RUNNING CandCNC Page 19 SETTING UP THE ETHERNET PORT FOR ETHER CUT OP TIONAL TESTING OF THE ETHERNET PORT TESTING Your IP address INSTALL m 0 To do this test you must the Ether Cut connected to the Ethernet jack on the PC You should see the yellow LED on the JACK RJ45 of the Ether Cut come on steady as soon as the two a
86. etworking Controll General Advanced Advanced Diiver Details Power Management NOTE the screens shown The following properties are available for this network adapter Click are for an NVIDIA Network the property you want to change on the left and then select its value card and may have an the tight different option screens and Property Valuer settings Most cards have default settings that are IEEE S02 TP Support correct and do not need to i Lew Power State Link Speed Network Address be changed 5 Speed duplex settings VM Support patter Pe akelnLAN Fron When running MACH3 A on a computer you General Advanced Driver Details Power Management 2 MUST turn off all Power Saving options in Windows and make sure the communications device is not set to turn off to save power This option may not appear on all Ethernet Cards NVIDIA nForce Networking Controller TT devra nm al stand Property Value Flow Full autonegotiation EEES02 1F Support Low Power State Link Speed Address W alkkelnL AN From Power TE wakeDnLAN From CandCNC Page 13 ETHER CUT INSTALL SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP Control Panel File Edit View Favorites Tools Help Back 7 3
87. g code commands to the machine make specific moves You don t need to have a deep knowledge of g code to use it for testing Your may look different e When you type in g code command it is not case sensitve but be sure to use zeros s and not O s for the numbers At this point do not worry about which hotkeys are assigned to a direction e With the machine out of e stop and power on type the following into the MDI Frame o Move the screen cursor to the MDI frame and click on it The frame background color should change to yellow meaning it is ready for input No other movement keys work when the MDI frame is selected G00 X3 0 o Enter key activates command e The X axis should move 3 inches in some direction It should have moved away from your established X zero and the DRO numbers should have increased If it did not then you need to reverse the direction of axis travel reverse the direction of any axis open the Ports and Pins Motor Outputs and change the polarity of the Dir LowActive setting for that axis Clicking the Green Checkmark or the Red X will swap the definition Red X is posiive and Green Check is negative polarity e Work with each axis to establish that the movement direction is correct Use the MDI frame and change the axis letter from X to Y then Z Do NOT change the polarity of the step signal Should always be Red X for BladeRunner CandCNC Page 87 BladeRunner Mardw
88. ges are information and critical messages from the MACH system Diagnostics Tab Used to test and diagnose general Input and output problems and to do test runs Config Function Cfgs view Wizards Operator Plugin Control Help SempTest Setings Pause Tool Request Dwell Active G CODE CONTROL Run FeedHold Rewind n Jog OWOFF cukAR Cycle Jog Step AN Stop Single Step m EJ E Buffer Load pt itp Time Scale FAULT de Blended Time in Int CPU Speed 0 00 0 0 100000 0000 OverRide 100 FeedRate _ M Codes G Codes 0 of 0 _ 600 Fault Code CandCNC Page 69 MACH SOFTWWARE AXIS CONTROL Diagnostics Has the same DRO s the same Axis ZERO buttons and manual REF buttons as the Program Run Screen so the User can see the numbers without have to flip back and forth When troubleshooting you can see activity on an axis and do setup if needed INPUT STATUS BOX Shows the Inputs as they are mapped in MACH The Inputs are YELLOW when ON active The inputs should all be OFF grey when the system is first turned on and MACH is out of RESET There MAY be an Emergency E STOP on if the DC power to the motors is off on the BladeRunner The Limits will seldom light because as soon as a LIMIT goes active to puts MACH in RESET and the INPUTS are no longer displayed correct
89. h Folders Find the Local Area tid ass Network Connections diane d Mad be _ _ wireless 5 SS shown too Ether Cut Eg rectum spes needs DEDICATED network connection Disable from the ethernet port office network Status on the PC directly to Repair the Cut this network Bridge Connections Repair this connection Create Shortcut Right click and select mi Rename this elei PROPERTIES from the creat ni Rename List Box The incertam Properties window will 2 Change settings of this display connecFian Local Area Connection 2 Pro E x Other Places General Advanced gt Control Panel J Network Places Connect wng Rare EB NVIDIA nForce Networking Controller 4 My Computer This connection uses the following items 095 Packet Scheduler Internet AEGIS Sted a 802 14 37 50 Protocol device al T and hit the PROPERTIES button pu P Description Transmission Control Protocal Intemet Protocol The default wide area probocol that provides communication actoss diverse interconnected networks Show icon in notification area when connected me when this connection has limi
90. he EzPlug G251 4 Driver card If the LED s flash and you are not getting movement the problem at and the motor drivers Check your cables and connections carefully The DB connectors need to be seated and the holding screws tightened for each cable Sporadic motor movement or direction changes without changes at the Step amp Direction Monitor indicates one winding on a motor may not be making good Ot _ aa m or Tuning and Set AXIS MOTOR MOVEMENT PROFILE Velocity DTE 0 01 02 03 04 05 06 07 08 09 1 Time Seconds Accel gt Velocity Acceleration Step Pulse Pulse WE y Steps per In s or mm s per in sormm s sec sec 1 5us 0 5 so ho WE Cancel Page CandCNC SETTING MOTOR DIRECTION At this point you should have motion on all axis using the Keyboard keys to scroll with In this section we will set the direction of motion for each axis and match the keyboard keys to that motion IF YOU HAVE THE MOTORS ON THE BENCH AND LABELED YOU WILL NEED TO ORIENT THEM LIKE THEY WILL BE MOUNTED ON THE TABLE AND WATCH THE DIRECTION OF TURN OF THE SHAFTS IF YOU DECIDE TO MOUNT THE MOTORS ON THE TABLE YOU SHOULD DISENGAGE THEM FORM THE TRAVEL MECHANISM UNTIL YOU GET ROTATON DIRECTION RESOLVED THIS IS ESPECIALLY TRUE FOR THE SLAVED MOTOR ON THE GANTY AXIS 1 Load MACH and the BladeR
91. hine and so certain parameters have to be set based on your specific machine Engine Configuration Ports amp Pins Pot Setup and Axis Selection Motor Qutputs Input Signals Output Signals Encader MFG s Spindle Setup Mill Options Sonal Enabled Step Pina Dir Pint D laActe Step Low Ac Shep Port Dir Port Axis i 2 8 1 Y Axis Axis uf d ef 1 1 1 1 1 1 1 0 0 Spindle x ___ NOTE 5Axis systems use the B axis as an independent axis Set ENABLE to Green Check mark if it is a Red X Disabled Each axis has a Step and Direction pin At this point do not worry if the axis moves in the wrong direction simply that you have the axis as you define them correct The next step is to make the axis movement agree with the DRO and g code commands for that axis The DRO Digital Read Out for each axis is at the top of the screen You will need to take out of E stop by pressing the Reset button Jog your machine so the cutting head is away from the Homes approx center of the table is good Don t worry if the jog keys aren t correct or that the DRO s are running in the wrong direction e f your machine is setup so that one corner is X0 YO lower left corner then all moves from 0 0 should be a positive number CandCNC Page 86 MDI is line to allow you type in direct
92. ion shows actual cut current on any plasma cutter Instant recall Stored Settings Library A Cut Profile that is a dynamic Cut chart stored by material type thickness More precise control than any other THC ATHC AVHC AVC THO on the market Only THC with and for storing and adjusting plasma cut parameters while cutting 2 High quality electronics and same 2 year warranty CandCNC Page 2 INTRODUCTION BladeRunner AIO The setup of the BladeRunner AIO Series Interface involves the installation of MACH3 software and some support files on the PC to be used for the machine controller UPDATED MANUALS CAN BE FOUND AT http www CandCNC com manuals htm Always check that location Familiarize yourself with the controls on the BladeRunner Front Panel and with the loading and operation of MACH3 with the proper profile The SOFTWARE part of this manual is devoted to getting MACH3 properly installed with the right CandCNC support files and profile to run the BladeRunner AIO Plasma and Router After you have the software installed and the cables and satellite cards hooked up you will be guided through a series of tests to determine if everything is working We ask that you go through the setup and manual in the order presented If at some point you cannot get the expected results and check your connections and setup with no success then call our tech support person at 903 364 2740 during normal business ho
93. ist of the files in the righthand portion of the Screen Make sure the Mach1Lic Dat was copied NOTE MACH will load and run in DEMO mode without a license It is fully functional with the exception it will only run about 500 lines of code and advanced features like the THC logic are not functional You MUST have a valid license loaded before you can use the DTHC IV in MACH The Ethernet Pulse card ESS may not load and run on an unlicensed MACH install CandCNC Page ege MACH2 LICENSE INSTALL AUTO Method This method of install covers customers that have purchased a Software Bundle at the same time as their equipment The MACH3 license and SheetCAM license can be installed automatically using the MASTER INSTALLER As part of the install you can select to install either or both licenses You can come back later and use the Master Installer to install other options including the software licenses INSTALL lt 5 Install 5 Support Files POSTS amp Toolsets 0 3 Install MACH license 0 1 Install 5 License Install Hyt Conmect License CandCNC Page CandCNc SUPPORT FILES Install THE FOLLOWING PAGES COVER THE INSTALL OF THE BLADERUNNER CONFIGURATION FILES FROM A MASTER INSTALL EXE FILE The Master Installer Auto Installer Files will automatically load all of the CandCNC support files for MACH3 You must have MACH 3 v
94. isted in the MACH LOADER and the screen does not display go to the top menu bar and select VIEW Load Screens and navigate to the folder and select BladeRunner Router set If it is missing any of the Bitmaps picture buttons and or backgrounds then confirm the Installer created the CandCNC folder under the MACH3 Bitmaps Folder and there are files in that folder We have included a Zip file on the CD of all the bitmaps and the ZIP file is on the CandCNCSupport Forum site in the FILES BladeRunner Support Files Folder You can UNZIP the files in the Bitmaps ZIP file directly to the MACH3 Bitmaps CandCNC folder Along with bitmaps and other features the BladeRunner screens contain several custom functions embedded as code behind certain buttons If you elect to use another screen SET file with the BladeRunner be aware some functions will not work The DTHC screens have specific functions and the DTHC functions will not work on other screen sets Fie Conky Funchonclys wars vata Operakr Flan onTub Hep Use TAB io LE E DISPLAY DE G mE op ree pe Bet Sein i AE oo Fors iT apa ona TAB OPTIONS Typical Router Screen with TAB Flyout CandCNC Page 64 MACH SOFTWWARE CUSTOM CandCNC Screen SET provided with BladeRunnerAlO UBOB3 Profile from the Master Installer file Some features may change over time DTHCII specific functions are covered in
95. ith all of the same macros the original had To make new profiles or to change the Profile Name DO NOT simply rename the PROFILE XML in the MACH folder It will show up the list as a new name but there will be no corresponding MACROS folder so you may encounter problems trying the run form that profile IF YOUR RESTORE A PROFILE FROM A BACKUP or ANOTHER SOURCE of the same name it will overwrite the exiting PROFILE and chagne all of the settings to those of the backup NOTE While a profile of another name contains all of the settings you may need to run MACH it lacks the matching Macro Folder created during a Clone You should first create a Clone of an existing profile using the same name as the file CandCNC you wish to transfer and THEN overwrite it with the imported file Page 38 lt 5 INSTALL USER MANUAL RS485 4 PORT HUB USE THIS SECTION TO INSTALL THE C3BUS RS485 3 PORT Hub if you have the DTHC IV Hypertherm Advanced Connection Kit Hyt Connect 5485 SIM kit the 200 48 function Hand Controller The C3BUS will be the universal BUS for CandCNC equipment New products from CandCNC will utilize the C3BUS YOU ONLY NEED ONE HUB PER SYSTEM It is sold bundled or separate It is REQUIRED for the above listed products BR HARDWARE INSTALL C3BUS INCLUDED IN THIS KIT USB to RS485 4 Port Hub Module Universal WallPlug Power Supply 100VAC to 24
96. its in the BladeRunner CandCNC A Page 102 n c gt gt c o o lI TABLE I O CARD LOCATION n BladeRunner Ether Cut Systems are not shipped with the older REV9 and TABLE IO cards or with the REV 14 or sooner UBOBIII cards If you find any reference in this manual with regards to those earlier devices disregard those references F c J o Y o 6 REV 10 and later To B Socket HOT terminal To Socket HOT terminal ot Feed To AUX line INPUT Hot side SUNT dn OaOo 00 QQ 080 TABLE I O or TABLE I O CARD 4 n m m 33883338 This area open fo E Ion DTHC or ISS 02 amp mun Expansion tm CARDS nae q 4 UBOB III Universal Breakout Board Page 103 CandCNC SETTING and TESTING INPUTS HOMES Setting up HOMES Homes are used for establishing a known POSITION Most often to define the TABLE ZERO locations and
97. l changes during POST that would might cause an output to go active Stepper motors require very specific signals to move making them inherently immune to random port signals The circuits in the BladeRunner do not allow any signal to pass to any of the drives unless MACH is fully started and is functional and the operator has brought the system out of reset NO CP NO OUTPUTS HOW IT WORKS MACH is programmed to turn on the CP only when MACH is loaded and has control of the PC and the parallel port and MACH is out of RESET The CP going active is detected by the ESS Moduels via the Ethernet channel is generates the 12HHZ signal out to the UBOB card in the BladeRunner THIS 15 IMPORTANT Whereas in previous Parallel Port versions a loss od CP if MACH was active and out of reset shows a lack of communication through the parallel port in the case of the Ether Cut it can be from lack of communiation to the Ethernet Port or the ESS driver plug in in MACH is not activated and talking to the ESS module In the UBOB III based system the CP signal MUST be present not just a logic level on the CP line from the PC or the internal buffers will be disabled No outputs will function Without CP no Step signal will be sent to any motor drive No MOTION Without CP no relay will fire If you start MACH and the BladeRunner and you get no motion the first thing is to check the CP LED on the side of the BladeRunner It detects and turns on the buffer circu
98. ls at the rate set by the motor tuning rules and it s up to the hardware to move to that location CandCNC Page 23 lt INSTALL SOFTWARE INSTALL OVERVIEW Installing MACH3 and the custom BladeRunner files The actual installation of MACH3 software is straight forward since the file is downloaded from CandCNC support CD and the file when clicked on will take you through an install of the software on your machine We have included an unlicensed version demo of MACH 3 that is needed to use with the BladeRunner series of devices DO NOT TRY TO USE AN OLDER EARLIER VERSION THAN WHAT IS INCLUDED ON THE SUPPORT CD While we can answer questions about the proper interface of our BladeRunner with MACH3 the actual setup and use of MACH3 on a specific PC may better be handled through the actual software provider or the support list Our custom files provided on our install disk should setup the PC to work correctly with the BladeRunner but be aware that changes you make to setup parameters after the install make changes to the profile Make a copy of the BladeRunner XML files in the MACH folder backups when you have finished setting up the unit It will save you a lot of time and frustration if you ever need to recover from PC hardware problems Any time you make setup changes to a profile then refresh the backup Store it and your MACH license file on an external device We have included a version of the MA
99. ly It turns the LIMITS OFF as soon as the LIMIT goes active The indication a LIMIT is working is if when hit it puts MACH into RESET The setup or HOMEs and LIMITS will be covered in later in this manual Use the INPUT Status to test the individual inputs Please note that Inputs FIRST hit specific pins on the parallel port and the MACH PROFILE determines what each one does so if you have inputs that are not correct the first thing to check is the RAW PAORT INPUT BITS on the following pages Jh 5 1 T1 F 1 1 i E E OUTPUT STATUS Displays the status of the OUTPUTS Active outputs FLASH RED not on steady It uses the mappings in MACH to activate a specific out NAME The physical output that is matched to is set in the PROFILE Ports amp Pins Ouput Signals When you activate an output like the TORCH Output or Outputs 1 and 2 you should see them start and flash in the OUTPUT STATUS BOX It does not mean the actual output signal name is active only that the signal is active and if mapped properly should activate the specific output on the BladeRunner See the section on setting the OUTPUTS CandCNC Page 70 MACH SOFTWWARE OUTPUT Status Cont There are two AUXILLARY OUTPUT Relays on a BladeRunner AIO unit They are designed as Output 1 and Output 2 on the Buttons and they toggle ON OFF the AC Outlets A and B on the end of the BladeRunner Box These AC outlets are wired to the AUX AC line cord on the BladeRu
100. n MACH and make the change Run the same test again you should be MUCH closer Once you are as close as you can see by eye at 30 inches do one final test at the longest point on that axis Typically if you are within 032 at the end of the move you will be within 4 decimal points at 1 inch Page 88 CandCNC 0 G 5 I 0 C C 5 x 0 5 amp m Ze g esf SUOISUBWIG 4eddo1s 029 J uuny pejg uN 20 17729 31 14 99 0 N9IS3Q T z y Q 9099720 ON ava 3AWN SONVH JOVI ou SO Had 9 0790 4 TAI 0091 9 9 52 72 NOLLV TSNI WN Ley WN 0 370901 NOLO3NNOO 93 439 NOLO3NNOO NIYIM 15913 0 c Qv 993 NYO NY Sd LMM 39 57 INIYYNI 4 ge 4 V A A18 21970 9319 1999 3791319 o LJ 15 0 A 29 0 3999 101231402 9095 ONAM 1698 SNOMVOLIOJdS ud IND 70 8 SIYM 073730540100 _ 6 y r 880 2 1 JC Q9 LN e E 9 Z1 e LY co ee LGE C 696 s y uj ui SUOISUBWIG SNOISNINIG
101. n pushes on the PN200 keyboard and displays key number in the Last Key IF YOU DO NOT HAVE THE HyT Connect RS485 options the device 221 will not show up in afe C ade vd tw rear your devices list _ wO and this screen will E A ernie tent not appear Te Bae nerd 917 Tire Die Thi Male Kj OO NS _ sc uncle 200 m amp A CR aa Z e Piana trm aun EI ZL IL IIR ILI CL Uli an He Paks quos be Ta i Lei sl 2 rite ibi 7 1 k be bish EIL ered X 17 qn 1 PP igi in AAL N ot Ben ur DEH C E nive nalis res 26 Pact aed Bi anes fede dmg Wu in quin ul Foliis d ingma ca lada 1 uirgo arg CandCNC Page 52 BR HARDWARE INSTALL BLADERUNNER AIO RIGHT SIDE VIEW INPUTS FOR UBOB III AND EXPANSION OPTIONS CLOSE UP VIEW UBOB MODULE RIGHT SIDE CandCNC Page
102. ndCNC Page 111 Status Y m cmm The X Home should light up when you manually activate X Home switch It should be off when the switch is not active If it is reversed i e goes OFF when you activate the switch but stays on otherwise you will need to reverse the polarity of the switch in Ports amp Pins Input Signals We recommend using normally open NO contacts on Homes and Normally Closed NC contacts on the far limits if used The far limits are wired in series external to the Table I O card and it is setup so breaking the string at any point activates a hard limit The hard limits are safety switches located at points on the table to prevent the machine from going past the table travel limits You can have far limits opposite the 0 0 location of the table AND near limits at points where the machine would crash on the other side of the Home switches Limits are optional and on stepper based systems you could elect to have just hard stops since the motors can be stalled without damage A NOTE ABOUT LIMITS on the BladeRunner A stepper motor driver is a torque limited system meaning that the drives limit the amount of torque a stepper motor can apply to a load It does that by limiting the current on each pulse While most AC and DC motors will quickly exceed their ratings if presented with a large overload the st
103. nectors off for any reason either mark the wires by position or use an ohmmeter to test for coil pairs see Bladerunner Manual Partll Service Manual If you use any other motor rewire for any reason CHECK TO MAKE SURE THE COILS ARE COLOR CODE MAY VARY MOTOR SIDE BladeRunner ESPII box CandCNC Page 57 BladeRunner Mardware BLADERUNNER G251 4 MODULE FRONT PANEL FUNCTIONS A1 A2 B1 B2 A1 A2 B1 4 A1 A2 B1 4 A1 A2 B1 B2 A1 A2 B1 B2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 IMPORTANT It is important that the stepper motor wires are wired correctly When shipped from the factory the motors are wired right and each one is tested with the unit Because motors for other products we sell are wired differently it s possible a motor you order after the unit has been shipped could be wired differently DO NOT ASSUME THAT THE COLOR OF THE WIRES IS CONSISTENT We order wire from different sources and cannot always define the wire colors lf you take the connectors off for any reason either mark the wires by position or use an ohmmeter to test for coil pairs see below If you use any other motor or rewire for any reason CHECK TO MAKE SURE THE CONNECTIONS ARE CORRECT USING THE METHOD BELOW COLOR CODE MAY VARY TESTING FOR PROPER MOTOR HOOKUP Motor DC resistance per coil is less than 50 ohms On OPEN most DVM s show OV CandCNC Page 58
104. ng another name or roll it over to a memory stick The important files will be the specific PROFILES all have XML extensions on the file name You can copy the older XML profile over to the new install BUT if there is a bad setting it will transfer that too One way around this it to open MACH Loader and CREATE a new Profile with a New Name and CLONE it from the profile you are using You can then copy the Cloned profile back to the install from your COPY of the MACH folder and run it in place of the default profiles created during and install Even if it does not work right you can move the motor tuning and other setup values from the cloned profile CandCNC Page 7 LLI lt 5 c PC Requirements amp Preparation TO run MACH3 with the Bladerunner Ether Cut Systems 1 Pentium 4 PC or later 2 4 to 3 4 GHz Processor 512M to 1G RAM 20G Harddrive 1280 X 1024 SVGA no shared system RAM RJ45 8 pin Ethernet Port 1ea USB port Windows XP SP2 or SP3 Windows 7 32 bit Keyboard Mouse 2 Optimized Windows setup No automatic updates running Disable Remote Assistance No Virus Checker or background file checkers Turn off all non essential background processes in Windows 5 Disable Power Management 1 Right click on your desktop and then click Properties 2 Click on the Screen Saver tab 3 Set Screensaver to None 4 Press the Power button near the bottom 5 Set all options to NEVER shut down au
105. nner That cord must be plugged in before the outlets can be used CAUTION there is high voltage 120 at the Relays and the Outlets DO NOT OPERATE THE BLADERUNNER WITH THE AUX AC CORD PLUGGED IN AND THE TOP COVER REMOVED NOTE The number of output relays can be expanded by adding in a Quad Relay Expansion card but is seldom used so connections and setup are not covered here On a BladeRunner Dragon Cut with DTHC OUTPUT 1 in MACH is used to turn on the TORCH Relay located out in the THC SENSOR PWM Operation is covered in depth in the DTHCII User Manual but it is easy to simply plug in the THC SENSOR PWM module to the DTHCII module using the 25ft UTP Cable and test the TORCH ON by toggling the TORCH button on the Diagnostics Screen and watching the TORCH LED on the front of the THC SENSOR PWM module You can test the other two AUX outputs by plugging in the AUX AC cable and plugging in an AC load table lamp 120 FAN etc and toggling the individual outputs on and off The AUX outlets can also be turned ON and OFF from G code using an M command What M command is used to turn on off an OUTPUT is a setting in MACH and comes defaulted so or M04 turns on OUTPUT1 Torch on the Plasma Profile Spindle on the Router Profile 05 turns OFF either In a full Spindle Speed System the M04 turns ON the REVERSE RELAY The two AUX Relays See Setting Outputs Section are located the TABLE I O Torch Toggle Control
106. o main controls The P and the D pots The P is the gain and as you increase it the hum frequency will go up CandCNC Page 94 1 F 95 4 Foleo 4 Start with the D pot turned all of the way counterclockwise minumum slowly advance the P pot until you either hit a point it gets unstable and the motor starts to twitch oscillate or you have it turned all of the way up Make a note of the pot position and back it off until the oscillation stops and then advance it to a position below that point Now increase the D dampening and listen to the frequency it will drop Stop the D at about 1 4 turn and then advance the P past where it became unstable before If it starts to become unstable note the position and back it back down then advance the D some 5 Start with the D and pot turned all of the way counterclockwise minumum and slowly advance the P pot until you either hit a point it gets unstable and the motor starts to twitch oscillate or you have it turned all of the way up Make a note of the pot position and back it off until the oscillation stops and then advance it to a position below that point Now increase the D dampening and listen to the frequency it will drop Stop the D at about 1 4 turn and then advance the P past where it became unstable before If it starts to become unstable note the position and back it back down then advance the D some more and turn the P
107. oubleshooting port problems 9 f you have motion on all attached motors then proceed to the next section A Axis JOG unslaved DEFAULT HOTKEYS BladeRunner Profiles Z JOG KEYS na N ofo v 9 p m m 3 LINEAR MOTION WITH RACK 4 PINION 5 Pitch Diameter ressure Angle 2 TYPICAL SPUR gears Psr Pinion Speed increase ratio Pitch Dia in inches PI 3 1416 1 Pitch Dia in mm PI 3 1416 25 4 Example 1 Pitch Dia pinion will have a step up ratio speed increase of 3 14 approx 3 Belt reduction decreases speed by Raw Speed Belt Reduction Ratio Belt reduction increases linear force by normal force X Belt Reduction Ratio Raw Motor Resolution 1 200 005 linear 127 mm Final linear resolution 005 Belt Reduction Ratio Belt Reduction Ratio R2 R1 Numbers for direct pinion drive are simply Psr Motor RPM speed e Torque oz T1 R3 Y 554042 XED Forces T1 Rated motor holding torque Oz in R1 T2 Shaft holding torque of P2 motor holding torque Belt Reduction Ratio T3 Torque oz in at pinion teeth T2 R3 Note Motor torque decreases with Motor RPM so a number of about 50 of the
108. r FT 01Input PRW O 5 01 PWR 25 RELAY I 3 lt D 5 EE 10 13 ZHome touch off 0 p ONG OQ P5 x3 gt D CandCNC Table 1 0 KEV 12 1 TO DW D LIMITS LIMITS D5 P18 EP Jumpered for normal operation Page 106 CandCNC n 58 c gt gt c o o lI SETTING and TESTING INPUTS HOMES Home Switch Connections At least one Home Z is required if you are using the BladeRunner Dragon Cut for plasma tables Itis recommended you mount and connect up HOMES for the X amp Y but it is not required EXAMPLE of HOME SWITCH MicroSwitch Type switch with roller lever actuator Switch has 250 quik connects and a NO and NC set of contacts Mouting in this case is drilled and tapped AL block with High Strength 3M double sided tape holding it to the table frame Switch trips on bottom of gantry frame but allows it to roll past if needed Mount your HOME Switches so they define the X and Y zeros on your table Mount some clips or brackets stops on the cutting surface or edges to let you index a sheet of material in relation to the table zero Even if the STOPS are not
109. re plugged in together and both powered up This LED indicates there is a physical connection the cable is good and both ends are connected and have power It DOES NOT indicate the two are actually talking sending data The Green LED does indicate activity both send and receive so while it may confirm there are packets going one way it does not indicate there is full bi directional communications Type of a program Folder document or Internet resource and Windows will open ik Far vou Cia Microsoft Windows Version 5 1 2608 1 CC Copyright 1985 20801 Microsoft Corp C Documents and Settings tonmmy gt ping 18 9 9 9 Pinging 10 0 0 1 with 32 bytes of data teply From 18 999 bytes 32 time 28ms ITTL 249 ply From 18 999 bytes 32 time 30ms I ITL 24 ply from 999 bytes 32 time Z6ms ULL Y iply From 108 9 9 9 bytes 32 time Z3 ns IIL 247 ring statistics for 10 9 9 9 Packets Sent 4 Keceived 4 Lost Mx loss Approximate round trip times in milli seconds Minimum Zoms Maximum 36ms Average 28ms C Documents and Settings tonmmy gt CandCNC Page eo SETTING UP THE ETHERNET PORT FOR ETHER CUT Motion Control Hardware Plugin sensed x Your system is showing more than one control device Flease pick the one you would like this profile to use Normal Printer port Operation ESS vl pldle C No Device Mo Device Device 7 Dont ask me this again
110. rking or at the wrong port address in MACH You can also get no CP if you are not running the correct profile or the ccc Ubob and ccc comm plug in s are not active ll digitize Output Toggle Outputs N Once you have the CP on you can trip an output and it will start to flash in the OUTPUT STATUS Plasma systems will have 3 ouputs Torch is output1 Routers only have two outputs If you want to test the physical outputs on a Blade runner plug an AC device lamp fan etc into the A or B outlet on the end and toggle Output 2 or 3 to turn it on CandCNC Page 123 END of BladeRunner Ether Cut MVMianual Once you have setup and tested you BladeRunner EtherCut system you are ready to proceed with setting up and tuning the DTHC IV Digital Torch Height Control if you have the Plasma version of the BladeRunner Use the DTHC IV Setup and Config Manual provided to add this feature
111. s that can be COMMANDS from the DTHCII to preformed on the DTHCII modules and other MACH modules in the setup They establish that the modules are functional and sending data to DTHC ONLINE shows the both the parallel port inputs and the PC serial communication status of the DTHCII input If you do not have proper display of module to MACH3 It MUST be on values while cutting or the DTHC ONLINE is to allow MACH to displ reen not ON you are missing critical signals See values and to allow to the DTHCII User Manual to run the tests transfer to the DTHCII CandCNC Page 67 MACH SOFTWWARE RUN Cycle Start runs g code that is loaded Will restart g code if in PAUSE or STOP NOTE To stop gracefully no lost position use the FEEDHOLD and after machine motion has ceased use the STOP CandCNC STOP Stops G FEEDHOLD Pauses code execution G Code at end of instantly dumps buffer Leaves outputs buffer Turns off active ouputs STOF G CODE DISPLAY RESET Toggle ON OFF Stops all code Turns off all ouputs Stops any macro Turns off Charge Pump Toggle turns Page 68 MACH SOFTWWARE FAULT ERROR Message box Scrolls FAULT messages from CandCNC ESPII and other smart devices Shows drive faults Power Faults and Hypertherm Fault messages for units equipted with otions 5485 port and optional HyT Connect RS485 SIM Kit ERROR messa
112. sor and the control software there is no possibility of motion from the system even if the Hardware E STOP is pulled out of tripped condition c gt gt c 09 o lI Switch must be Normally Closed and OPEN when pushed or pulled on some types If switch is mounted more than 6 ft from Front Panel card use twisted pair wire 24 to 20 ga wire is okay REMOTE SWITCHES NOT INCLUDED Serial 019 SL EN sw on MTA Side Plate cl Interface G251 4 2 1 DB9 Serial nem FRONT PANEL CARD ami mM 1 4 1 M 9 50 2 Jumpered gt Rear of Programing MODE 50 60 HZ ELE Jumpers 3 4 BladeRunner FRONT PANEL STOP NI 2 Jumpered 650 1504 1 Grey jumper CA I E U N 2 1 ALL versions Jumpers 3 update Temp 2 jumper see Teal i on all units shipped after 4 2 11 YIL TEMP 2 m m Sensor Mil UACM 2 ON for FRONTPANEL BladeRunner H REV3 Lamps amp Switches on Backside of card Ew in Test zd emp 50K riv CandCNC Page 119 SETUP amp TESTING OUTPUTS Starting with ehr REV15 UBOBIII used all DTHCIV and Eth
113. stem back out of Software E Stop ONO n 58 c gt gt c o o lI O wr 3woHs E Oo TABLE I O HEADER ON UBOB CARD INPUTS CandCNC EPO MUST BE JUMPERED Closed Jumper can be replaced by one or more Normally Closed Switches in series for Software E STOP Page 118 E STOP and Safety Shutdown HARDWARE E STOP n HARDWARE E STOP an option there are USE Dotted wiring for single connections provided for a Normally Closed switch You can wire multiple Hardware E stop that removes current flow from the switches in series as long as Control relay The Control relay is a small electro they all are Normally Closed mechanical DPDT relay that DIRECTLY provides when inactive Pushing any power to the Main Safety Relay AC INPUT RELAY swtich in the string will OPEN This is a direct shutoff with no semiconductor failure points When the HARDWARE E STOP is tripped the DC power is removed from the motors dynamic m EN braking is applied Load Dump a software e stop is EE sent via the second set of realy contacts on the BEEN Control Relay and the processor that controls all of the power monitor and functions is signaled As long as the Hardware E STOP is OPEN tripped than the AC is removed from the main power supply Barring failure of both the proces
114. supply will work and run from any AC power source from 100 to 240VAC 50 60HZ You can purchase plug adapters from several on line merchants including Amazon com for less than 2 00 No voltage conversion is necessary 2 Using the included USB A to B adapter cable plug the B pay 7 matching jack at the end of the hub and the other end into USB jack on the control PC BR HARDWARE INSTALL Note For testing you can load the drivers and CandCNC Hub Utility on any PC or Laptop but for operation you need to have the hub installed and working in the PC that runs MACH and controls you machine 3 Windows will see the new hardware and will launch the Hardware Install Wizard Use the following screens to finish the hardware install Hardware Update Wizard Welcome to the Hardware Update Wizard First Screen of Hardware Windows will search for current and updated software by looking on your computer the hardware installation CO er on Install U pdate rs MI gt site with your permission Wizard Leave the radio button set on the ei connect te windows Update to search No Not this time Oru are T option and hit the CO Yes this time only Next Button C5 Yes now and every time connect a device gt not this tima Click to continue CandCNC Page 43 INSTALLING RS485 4 PORT HUB BR HARDWARE IN
115. tch then stop IT WILL NOT AUTOMATICALLY PICK UP THE Z above the material Motor Home Softl imits Entries are in setup units Reversed softMin Slow zone Home Off Neg Auto zero Speed 100 0 dw 99 00 1 00 0000 20 6 00 0 00 0 50 0 0000 20 99 00 0 00 1 00 0 0000 20 100 00 100 00 1 00 0 0000 20 ar 100 00 100 00 1 00 0 DOO 20 G28 home location coordinates yr amp 2 CandCNC Page 110 HOME amp LIMIT WIRING n Hardware Home and limit switch hook ups 12 9 Normally closed contacts For far limits Wired in series of the inputs are opto isolated and map to a specific pin on the parallel port s In reality you can use any input for any signal Inputs are not fast enough for Encoder feedback faster than a few pulses per second The inputs use a floating ground 12 return If you need more inputs than the 8 9 with EPO then a PORT 2 card can be hooked to the UBOB and the added Aux and BHome inputs will work with a second parallel port START of STRING JUMPER EPO to be able to bring MACH out of RESET See FT 01 manual for installing Feather Touch ES pi CONNECTED TABLE I O HEADER ON UBOB CARD AVTH YNO Ca
116. ted er no connectivity CandCNC Page 15 m 0 L INSTALL SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN XP Internet Protocol TCP IP Properties 2 Properties window will appear ou ean gel acuoned auremahc ally your network supports Make the following changes this capability Otherwise you need bo ask your network administrator the appropriate settings Select Use the following IP Address 54 04 m nir C2 Oban an IP addiess autoragtic ally gt Use the follevung IP address Type in the IP address I addrest 3 4 exactly as shown 10 9 9 1 pe mh 2 25 in the Subnet mask Default gateway exactly as shown 255 255 255 0 Use the following DNS server adcteccas Do not assign a Default J Gateway blank Fretenad DNS server Altesniate DHS cee assign any DNS servers blank Do not use the Advanced button A NOTE ABOUT THE TCP IP Address and the Ether Cut The Ether Cut uses a modified version of the ESS Smooth Stepper and the manual for that product should NOT be used for this installation We have all of the settings including the IP address of the ESS card preset and tested at the factory as part of the final system tests we do on all our products The address of the ESS is 10 9 9 9 It is STRONGLY advised that you DO NOT run this
117. the permisson to support products made by CandCNC other rights are granted or implied and user agrees to copy decomple reverse engineer any File or program From Cand Files programsimaruals may be copied to the hard disk of anny Select Destination Location Where should Master Installer Far all Products be installed LJ Setup will install Master Installer for all Products into the Following Folder continue click TF you mould like to select a different folder click Browse At least 9 5 MB of free disk space required CandCNC Basic information about the CandCNC software and programs Take a couple of minutes to read the text as boring as it is so you will know the details about your CandCNC products We have made the custom drivers and our software as non restrictive as possible It does not limit the resale or use by a legal owner If you installed your in the C drive on your Control PC as we suggest in the MACH Install Then just hit the NEXT button on this screen Page 33 lt 5 INSTALL CandCNc SUPPORT FILES Install Master Installer Menu System INSTALL lt 5 Select Components Which components should be instalad Select the components you want bo instal clear the components you da mot want to install Click Next when you ready to continue MP3SOD DTHC
118. through a hub or have it on a network with other devices If you need network or wireless connectivity you need to install another device and set that up separately with it s own address and settings You can run multiple Ethernet cards in the same computer For the Ether Cut setup there is NOTHING you need to change or setup other than the Ethernet port on your control PC If you cannot get the proper indications or the ping response on the tests and have done all of the CandCNC Ether Cut installation than it is most likely a PC related hardware problem Alot of PC s Dells in particular from refurbishers or that have been used with the parallel port version may have the Ethernet disabled or the proper drivers not loaded We have found that if you load the wrong driver you may get an indication in the Device Manager the Ethernet card is OK but it still won t communicate Windows does no testing for functionality of ANY device It just confirms it is there If you cannot get your Ethernet port to function properly then you should check and see if there are driver updates for your PC and the Ethernet Card you have CandCNC Page 16 SETTING UP THE ETHERNET PORT FOR ETHER CUT WIN 7 The procedure for setting up the Ethenet address and settings on Windows 7 for the Ether Cut are very similar to those for Windows XP shown in the previous pages The process of getting to the Network Connections is a little different A NOTE ABOUT US
119. tomatically No Sleep options 6 Disable Wallpaper 1 Right click on your desktop and then click Properties 2 Click on the Desktop tab 3 Where it says Background scroll all the way up and choose None 4 Click OK NOTE The Ether Cut system moves the pulse engine from part of Windows and the PC hardware parallel port to a dedicated pulse card that give clean even pulses to the motor drivers The overhead to the PC processor goes way down so MACH then becomes a typical program Windows is not a true multi tasking OS so we still do not recommend running another active program will MACH is running code but having other applications on the control PC is now okay CandCNC Page 8 LLI lt 5 c Setting Up EtherCut Systems with Ethernet and IP Address CandCNC page 9 MACH SCREENS FOR amp ETHERCUT DTHC IV Screen Set with DCC TAP flyout using TAB key NOTE Screens change as we upgrade certain features and your screen may not look exactly like this one but it should be similar Mach3 CNC Licensed To CandCNC Serial 11011006 File Config Function Cfg s View Wizards Operator Plugin Consol PAUSE G CODE r J 9 f Or STOP C CODE DISPLAY J MODE Use to OPEN CLOSE this panel Note Using DCC the G Code sets most of these parameters mabcally 9 Cut Current AMPS Set Value Hit ENTER B ACT
120. top and if it is safe if the motors are still under power The answer lays in the fact that a stepper based system like the BladeRunner HAS TO HAVE PRECISE TIMED SIGNALS to special drivers to initiate motion It cannot simply run away It is virtually impossible to make a stepper motor turn without the operating software MACH and the electronics providing a valid pulse stream In any failure scenario of the hardware drive malfunction shorted open signals disconnected wires loss of power etc motor rotation is not possible Since the software MUST be in control to issue pulses and the Charge Pump will turn off if the software is frozen in a loop or malfunctioning putting the software into RESET for any reason will stop motion It is actually harder to get motion when you SHOULD have it than to have a stopped system One of the added benefits to a stepper based control is IF IT DOES NOT HAVE VALID STEP COMMANDS IT LOCKS THE MOTORS if power is still on the drives Any consequence of applying DC or a short to any motor winding will cease rotation and typically lock the motor The only argument is that the input device for E STOP might fail but that is no more likely than a failure of a HARDWARE based e stop So a failed drive will not cause a motor to Run Away A failed computer or communications interface will not result in random or uncontrolled motion Coupled with the Charge Pump see section on the Charge Pump function the probability of any
121. tual Z setup you will be using Values set here cannot be changed in Cut Profile tabs NTH amp affinace Setup Test Device Are Volt Preset 31 DTHC Enable Tip Save ON i Tip Saver 4 01 Vi Fault it 2 Update Device Firmware DTHC Delay see Upper Volts Fault Lim 00 Arc OK Current fi 0 Lower Volts Fault Limit 50 Volt Tracking Tolerance Slowest Z Velocity 0 DTHC Sensitivity e DTHC Tracking o These settings are for testing and reflect the actual values stored in the DTHC IV local memory They may be ovenwritten during MACH Cut Profile changes or from 9 Code settings during run time Send THC Config DTHC SETTINGS These settings are covered in the DTHC IV Setup and config Manual CandCNC Page 5O canacNc Hub connected Firmware version 1 6 INSTALLING RS48S5 PORT HUB USING HUB UTILITY Application CandCNC Hub Utility Misc MISC Update Hub Firmware Device Details Only the 5 lt Opens choice to PN200 Pendant Rev 1 devices you lt update firmware deni qu have purchased gt This is the first and have t DeweCode b Address Firmware Version b Device Status step in updating the HUB FIRMWARE connected will show up in this List Box CandCNC Hub connected Firmware version 1 6 Current Firmware Version a gt
122. unner Plasma or Router Profile 2 Load the Diagnostics Tab 3 Power up the BladeRunner AIO and the DC to the motors 4 Move Each axis several inches away from the Table 0 home switch positions5 Zero each DRO with Zero Button next to each axis 5 Jog the Z first Note the Z DRO as it moves UP a If the numbers are INCREASING in value then the direction is correct b If the numbers are DECREASING then the DIR is wrong See the next page to change the DIR of a motor c key not match the direction of jog do not worry it will be redefined 7 JOG the non slaved axis next and do the same DRO check and change if it is scrolling the wrong direction 8 The Slaved Axis is a little different You must FIRST setup the slaving See Page earlier in this section using the 4 axis or 5 axis instructions 9 The DIR setting on the SOFTWARE Slave A is slaved to Master axis is opposite the Master axis motor faces the other and spins opposite to move the same direction Hardware Slaving is set via jumper on UBOB III 10 If in the setup you need to change the Master Axis DIR to make it move correclty you will also need to change the Slave Axis on a 4 axis Software Slave setup CandCNC Page 85 Setting up the proper axis direction and motor tuning While the Profile file BladeRunner XML provided with the unit sets up all of the pins there are several things we don t know about your mac
123. urs posted on the CandCNC website Often an email to Tom CandCNC com will get a response after hours or on weekends Another valuable source of help is the CandCNCSupport Group at http www candcnc net supportforum You must have a yahoo membership and you must request to join the CandCNC forum The Group is open to all persons interested in CNC cutting and or CandCNC products Installation and setup of your BladeRunner AIO ETHER CUT OVERVIEW There are a series of steps you must complete to setup and interface the BladeRunner Ether Cut AIO with your PC Install and setup the Ethernet Port in your Install MACH3 software proper version Install MACH3 license into the MACH3 main folder Run menu driven CandCNC Master Installer program from the CandCNC Support disk to load selected custom screens and setup files and Plug ins Open MACH3 and check screens and configurations Setup and configure the C3 BIS USB to RS485 serial connection Connect the 2 PC port cables 5 to the side of the BladeRunner Run a quick series of tests to confirm the ports are working and that is configured correctly Tune and Calibrate the motors on each axis Setup and Test Inputs and Outputs for Homes and Limits Check for proper motion Proceed to the DTHC IV Setup amp Config Manual CandCNC Page 3 a 5 BLADERUNNER
124. ve Page 91 CandCNC Servo Addendum SERVO SETUP CALIBRATION HARDWARE DIFFERENCES for BladeRunbner SERVO Servo Addendum ae 8 5 DM IN E lins f Xn EZPlugll reum Drive Assembly NOTE Servo Motors use the same 4 wide motor plug as the BladeRunner Stepper systems but the pinout is different Do NOT plug a stepper into a servo unit or vive versa SERVO systems use a rotary encoder mounted on the motor Each encoder is supplied with a differential driver pigtail that allows a standard CAT 5 cable to be ONE AXIS plugged in and transmit the encoder information back to CONNECTED the servo interface sub assembly you MUST HAVE THE ENCODER CABLES CONNECTED when motor is n powered With no feedback to the electronics of Fx 4 where the motor is it will Run Away We have color CH coded the label and the cables to make it easier to identify each motor encoder pair Do not get the pairs mismatched The Inputs from the PC parallel and serial port are connected the same way as the stepper version as is the DTHCII connections see DTHCII User Manual 1 a 2 Plugs for Motors TIE Dual Switched AC HomeiLimit Outlets from wiring knockout OPTIONAL Sth Axis Module Right Side View Left Side View CandCNC Page 92
125. vice Code has a different Device connected Address p CODE Codes can be devices As a Firmware version h from 1 to 99 device is Device Status Device Address The connected and unique address of a device sensed by the within a class values from hub it will appear 1 to 8 Devices of the in the list If you same type must have a connect a device different Device Address and it does not Future cards will have show up address jumpers to allow immediately multiple cards of the same stop close the ice Firmware type to work on the same application and hub restart jCandCNe Hub connected Firmware version Firmware Version This displays the current Hub Connected TEST DEVICE to USB on PC Action button that Displays current opens a new Update Device Firmware firmware of the HUB dialog window This allows you to update This MUST show You must have a each module with new connected status device firmware New firmware before any other of the highlighted in the will be designated by a functions will display Devices List to REV number Firmware use the updates will be available Setup Test for down load in a special Device download section of the CandCNC website and on the Yahoo CandCNCSupport Forum The Hub Utility is an application provided to manage the C3BUS USB to RS485 4 Port Hub and the devices attached to it With the utility you can Update the Hub Firmware Firmware is the program that runs the hub Update Firm
126. volts or current to read Typically oxy fuel is done on thicker material and at much slower feedrates than plasma so manual height operation is possible Access Plugs for Wires From Homes MAIN BREAKER SWITCH MAIN LAC CORD Page 113 CandCNC n 5 2 c gt gt c o o lI 5 12 O xS Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Dutputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Inhibit Compensation 541 342 T 2 Inhibit Cin 7 MaxDepth 00 Unis Advanced Compensation Analysis Persistant Digitizing Loop Control 4 Axis Point Claude Allow Serve Hold an 1 T Add Axis Letters to Coordinates CL Closed Loop Emulation THE Options General Options Allow THE UP DOWN Centrol Homed true when home swithes even net in THC 373 Fullback 01 828 1 No Initial Mowe Set OUTPUTS when in THC x e If you want to use the manual UP DoWN inputs on the Table I O card for controlling the Z while code is running you can use one of the switch setups on the previous page into inputs You must then open the COFIG in MACH and select PORTS 7 PINS and the MILL OPTIONS TAB as shown Check the Allow THC UP DOWN Control even if not in THC Mode Checkbox and then APPLY button This sets up MACH so it will listen to the UP and DOW
127. ware in the Devises attached like the DTHC IV Test basic communications Test device functions Device level diagnostics oet some device settings What you CANNOT DO CandCNC Page 49 INSTALLING RS48S5 PORT HUB USING HUB UTILITY Application IMPORTANT This section covers some setup and testing of the DTHCIV module While the DTHC IV Setup and Config Manual should be used to do the actaul DTHC IV part of the install you should do the minumum tuning listed to setup the Z motion BR HARDWARE INSTALL DTHC INFORMATION is direct feedback from the DTHC IV module and indicates the current status of the unit You cannot make changes or do inputs from this section Since you cannot run MACH and the Hub Utility at the same time these settings are primarily used for off line diagnostics at the factory 2 MOTOR SETTINGS This section is the most important because it sets the base motor settings for the Z motor under DTHC control You will find that the Max Velocity and Acceleration will be much higher than your settings in MACH for the Z motor tuning This is normal because of the DTHC IV controlling the motion directly under THC You should set this as high as possible Move the settings up and test the Z motion using the Full Speed Jog buttons on the screen The motor should move smoothly and rapidly both up and down Lose steps or faults a servo system back the numbers off by 25 The settings here are for stepper

BladeRunner Ether-Cut™ User Manual CandCNC

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BladeRunner Ether-Cut&trade; User Manual CandCNC

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BladeRunner Ether-Cut™ User Manual CandCNC