MaxStepper - KellyWare
Contents
1. 5 GE GOMMON COMMON D a o OSC YLMIT 1 Q UF ASTEP N YLIMIT 2 MPER DIRECTION N S wu gr BIEN COMMON AENABLE 10uF D ALIMIT1 6 3 5 E NJ ZSTEP u a AUMIT2 LN 2 DIRECTION INPUT 1 9 CQ ZENABLE 5 1Kohm E STOP en zuMm 1 12VDC S MMON 0 bag S RX TX COMMON ZLIMIT 2 COMMON COMMON 2007 Kellyware 4 MAX STEPPER Installation WWW KELLYWARE COM 1 Connect the cable to a 9 pin serial port at the rear of the PC If only 25 pin serial port is available use an adaptor to convert to a 9 pin port 2 Plug the AC power adapter to a wall outlet 3 Connect the stepper motor drivers to the X Y Z and A axis Setup 1 Start the KCam software 2 From the Setup menu select Port Setup 3 Select Serial Port MaxStepper OCX Figure 1 sf Port Setup Port Controls MaxStepper Port Type LPT Parallel Port dll Ze b Apply Cancel Figure 1 4 Select the MaxStepper tab Figure 2 Let Port Setup Port Controls MaxStepper up Port Status Max Inputs and Outputs MaxStepper 1 7 Aux 1 0 Z Invert Step X Limits Invert Step Dun nvert X Direction V 21 Invert A Direction M nvertX Enable Invert Enable xmi OuT2 puma nication invert Limit Invert Limit DUT3 Comms 00000000 Invert Y Step Y Limits2. 2 Direction nvert 2 Enable nvert Z Limit Ramo Rate ulput RampRate 5 el Hz step Maximum Spindle v XLimis Invert A Step Invert Direction B Invert A Enable Invert A Limit Y Limis iv HH Z Limits NM PWM 0 gt ex IX 29 LG Le H 10000 Value WWW KELLYWARE COM MCode Outputs Output In 2 Spindle CW Spindle CCW Coolant Mist ER Coolant Flood 4 M high f 5 Figure 3 9 Close the Port Setup window 10 From the View menu select CNC Controls and test the motors with the jog buttons The motors should move as the jog buttons are pressed Zero CH Zero Zero Feed Overide Spindle CW Spindle CCW 4 e Coolant Mist Tune Coolant Flood Auxillary 1 Manual automatic Timing Process Status TH gt gt Y F Yl inge Step Keboard 5 0 001 e Jog Jog X G01 0 25 v0 25 20 25 Move to Move to ReTool Home MOTORS ENABLED Goto Figure 4 Setup is complete and you are now ready to use KCam 2007 Kellyware MAX STEPPER Troubleshooting WWW KELLYWARE COM Problem Solution just installed MaxStepper The Status bar shows MaxStepper Failure and the Port Setup Window shows an increasing number in the Erro
3. I Li DUT4 nvert Y Direction V gt Len Er 00000000 Invert Enable v went Ens 10075 Buffer 00000000 Invert Limit Rev 00000000 We ESSI Date 00 00 0000 nvert Z Step Z Limits inven 00000000 Z Direction v v Kx E lt E E I IN 1 OUT E STOP CByte1 00000000 CByte2 00000000 Invert Z Enable Status Msg nvert Z Limit Ramp Rate PWM Output Clear Ramp Rate 5 ei Hz step Maximum Spindle 10000 Value MCode Outputs Output Spindle CW BR Spindeccw 2 Coolant Mist ER Coolant Flood 4 Apply Cancel Figure 2 2007 Kellyware MAX STEPPER 5 Under Port Status select the MaxStepper Comm Port to which you connected the serial cable during installation 6 Make appropriate adjustments to the Max Inputs and Outputs to suit your stepper motor driver requirements 7 Click Apply to save your parameters 8 You should see the MaxStepper firmware Rev and Date information in the Port Status group sf Port Setup Port UO Controls MaxStepper Port Status MaxStepper Comm Port Communication Present Comms 191 Errors 0 cS 0 0 Butter N Rev 402 Date 01 03 2007 0 CByte1 0 CByte2 0 1 v Max Inputs and Outputs nvert X Step nvert X Direction nvert X Enable nvert X Limit nvert Y Step nvert Y Direction nvert Y Enable nvert Y Limit Z Step
4. MH END OF TRAVEL SWITCH 1 COMMON 24 TUM 20 8 END OF TRAVEL SWITCH 2 COMMON Ki Motor Driver MOTOR POWER SUPPLY STEP iin DIR ENABLE COMMON END OF TRAVEL SWITCH 1 END OF TRAVEL SWITCH 2 E STOP SWITCH NORMALY CLOSED Diagram 1 Typical Motor Connection 2007 Kellyware 8 AP X ST EP PER WWW KELLYWARE COM Note If your motor drivers do not have an enable input leave the MaxStepper Enable outputs unused to PROPORTIONAL CONTROLLER MAX STEPPER VERSION 1 0 COPYRIGHT 2001 KELLYWARE AuF zur PC SERIAL PORT 2 9 PIN DSUB Z aw PIN 2 White SERIAE TX G ut 9 PIN 3 Red SERIA RX CO 2 m 2 PIN 5 JUMPER MAXSTEPPER PROCESSOR 10uF 508 12VDC e 2 C POWER RX TX SUPPLY Diagram 2 Serial Port and Power Supply Connection Note If you require a longer serial cable than the one supplied you may extend its length Add a length of 22 gauge 3 conductor shielded cable to the terminal end of the existing cable Be sure to connect the shields of the two cables 2007 Kellyware 9 ELL WARE B LIII MANX STEPPER Circuit Board Mounting Pattern MAX STEPPER VERSION 1 0 COPYRIGHT 2001 KELLYWARE 3 9900 WWW KELLYWARE COM D N 2 m D JUMPER MAXSTEPPER PROCESSOR WYO L s D
5. MaxStepper Serial Step and Direction Pulse Generator User Manual O 2007 Kellyware AP X ST EP PER WWW KELLYWARE COM Table of Contents Table OF CBRNE TRETEN EET 2 cM ML 3 Sada 3 duse JUN 4 RETIRER TORTE 5 5 EU ER 7 EAS DILE 8 Circuit Board Mounting 10 2007 Kellyware 2 MiK ST EP PER WWW KELLYWARE COM WARNING Improper operation of CNC equipment can result MaxStepper board in severe injury Keep RS232 Serial Cable with a 9 Pin D Sub connector hands fingers loose 9 VDC 200mA AC Power Adaptor Parts List clothing long hair and all other body partsa Key Features safe distance away Serial commands at 115 200 baud rate from moving parts e 24 bit motion commands up to 16 777 215 steps per motion D 77 Hz to 16 KHz adjustable step rate with 1 Hz resolution single axis motion 77 Hz to 14 KHz adjustable step rate with 1 Hz resolution dual axis motion 77 Hz to 13 KHz adjustable step rate with 1 Hz resolution triple axis motion 77 Hz to 14 KHz adjustable step rate with 1 Hz resolution quadruple axis motion Four axis linear interpolation Hardware linear ramping in 1 to 10 Hz increments user adjustable User adjustable ramp up down for fast sequences 39 motion command buffer for fast sequences of motion Dual limit switch inputs per axis TTL or pull up E stop input TTL or pull up for instant stop Spindl
6. capacitor will convert the PWM signal on Output 6 to a variable 110 VAC power source for a spindle motor or Dremel tool 2007 Kellyware ME OO Mik STEPPER WWW KELLYWARE COM Wiring Diagrams Hot Neutral Ground SSR for Coolant ie N Mist SSR for Coolant w Flood 1K ohm f 10 uF to 12 VDC Spindle S Proportional Controller 1225 S Motor Driver S MAX STEPPER M oes STEP STEP MOTOR POWER SUPPLY VERSION 1 0 J gt gt COPYRIGHT 2001 KELLYW RE NO XDRECTON S ENABLE ENABLE e Sy COMMON S N IME O END OF TRAVEL SWITCH 1 MIST OUT e FOU O O END OF TRAVEL SWITCH 2 Ks lle EM lt S OMMON a AUX OUT 1 Motor Driver gt lt gt lyser ma 2 7 MOTOR POWER SUPPLY SPINDLE PWM v KON CX Y DIRECTION AUX OUT 2 Y gt Dn Ze SO ENABLE c c SOMMON Ny COMMON H OSC C HHMH OC END OF TRAVEL SWITCH 1 0 ASTEP N e Y LIMIT 2 END OF TRAVEL SWITCH 2 9 9 A DIRECTION LQ 6 El S T COMMON AENABLE Motor Driver 9 ALIMIT 1 5 S amp LLzsTER SE MOTOR POWER SUPPLY 8 2 K N SZ DIRECTION INPUT1 ENABI 5 1Kohm E STOP COMMON AO
7. e clockwise and counter clockwise digital outputs for solid state relays Flood and mist coolant digital outputs for solid state relays Two user configured digital output for solid state relays One pulse width modulated spindle speed output for solid state motor control One auxiliary digital input TTL 5 VDC for monitoring OCX control for Visual Basic VB and other software use KCam 4 compatible X Y Z A Axis outputs Step Direction Enable X Y Z A Axis inputs Forward Limit Switch Reverse Limit Switch Stable motion with any operating system including Win95 98 Output frequency is smooth and consistent regardless of PC operating system load 2007 Kellyware 3 AP X 7 P PER WWW KELLYWARE COM Introduction MaxStepper is a PC controlled serial step and direction pulse generator that provides exceptionally smooth operation at a reasonable price It interfaces a PC running Microsoft Windows and a set of four stepper motor drivers and uses a microcontroller to convert serial commands to pulses MaxStepper can control auxiliary devices such as relays and has inputs for monitoring devices or auxiliary switches 4 MAX STEPPER X STEP 2 VERSION 1 0 COPYRIGHT 2001 KELLYWARE X DIRECTION t X ENABLE CW OUT e X LIMIT 1 CCWOUT lt lt MISTOUT XLIMIT 2 FLOOD OUT one uF Jup AUXOUT1 SPINDLE PWM SERIALTX 9 XQ uF S AUXOUT2 Q Y DIRECTION SERIAL RX ES
8. iagram 3 Mounting Pattern 2007 Kellyware 10
9. r status Make sure MaxStepper is connected properly to a working serial port on the PC Verify and correct the KCam communication port configuration When press the jog buttons the position displays show change but the motors to not move e Check and correct any mistakes with the wiring to the stepper motor drivers ls the enable wire connected Drivers may need this to operate the motors e The enable output may be inverted If so reverse the setting in the Port Setup window e Make sure power is applied to the stepper motor drivers e lf the axis limit switches are displayed as set and limits are not engaged reverse the Invert Axis Limit as needed e Check the E Stop switch circuit It should be closed during normal operation The stepper motors move but one or more are running backwards Reverse the Invert Axis Direction in the Port Setup window as needed The stepper motors move but one or more do not stop with limit switches Reverse the Limit Switches Disabled in the Table Setup window The stepper motors move but one axis occasionally goes in the wrong direction Swap the step and direction wires to the stepper motor driver for that axis The spindle speed output does not work with my Solid State Relay SSR A special type of SSR is required for spindle speed control A Crydom MCPC1225A Proportional Controller SSR or similar model along with a 1K ohm resistor and a 10uF
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