BR-AIO-Master_Sectio..
Contents
1. OK Cancel Testing We will test the functionality of the com port after we hook up the BladeRunner to the computer CandCNC Page 20 0 SOFTWARE INSTALL SETUP 4 Sa Eb LL of 2 BLADERUNNER AIO SUPPORT CD e Contains Auto Install File to automatically load Drivers Plug ins Custom Screens and Custom Profiles for router and plasma eContains Complete Manual and all associated Manuals for internal cards eContains tested version of MACH3 software DEMO VERSION eContains sample artwork for plasma and router eContains Demo version of DXFTools for smooth arcs and curves from CorelDraw DXF export eContains Demo version of SheetCAM eContains Demo version of nesting tool for SheetCAM eContains Basic TubeSlicer Plug in CandCNC Page 21 be NN AN a a M a E 0 READ THESE NOTES SOFTWARE INSTALL 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 e There are 3 distinct parts legs of CNC CAD Drawing CAM 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 e Specific software programs are used for the CAD drawing to generate the base artwork in vector format For simple shapes2. Click OK Exit MSCONFIG NOORWN 4 Disable Indexing on all NTFS drives 1 Double click My Computer 2 Right click on hard drive and choose Properties 3 On bottom uncheck Allow Indexing Service to index this file for faster searching 4 Hit OK 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 automatically 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 CandCNC Page15 PC Requirements amp Preparation Disable any unused network cards 1 Open Control Panel System Hardware Device Manager 2 Scroll list to Network Adapters 3 Click to show list of adapters 4 Right click unused Network Adapter 5 Select DISABLE 6 Select Yes System Properties i z System Restore Automatic Updates Remote a General Computer Name Hardware Advanced Action View Help m R Device Manager J TCAUDLE2 The Device Manager lists all the hardware devices installed a on your computer Use the Device Manager to change the d Computer properties of any device S Disk drives Display adapters _4 DYD CD ROM drives E5 Human Interface Devices 3 TEH ees yon Driver Signing let
3. Slave Axis Selection x Axis Y Axis Z Axis Slaved Axis Slaved Axis Slaved Axis C A Axis C A Axis C A Axis C B Axis C B Axis B Axis C C sis C C Axis C Axis None None X None Restart Mach3 after resetting these selections Select the Axis you wish to slave the A to X or Y and click the A radio button on that IMPORTANT NOTE IF you have the 5 axis 620 5 system shipped with 5 motors The slaving is done differently When setup at the factory the 5th axis is HARDWARE slaved to Y If you are setting up a 5 axis system EVEN IF YOU DO NOT INTEND TO USE THE 4th independent axis at this time you should use the 5th axis as the slave axis and disregard the SOFTWARE SLAVE above END OF QUIK START Proceed to Advanced Setup Page13 CandCNC PC Requirements amp Preparation A NOTE ABOUT RUNNING A PC WITH MACH3 There is a tendency to treat the PC used for the CNC machine as a general purpose workstation and use it for other purposes when it is not cutting We strongly urge you to resist the tempation to use the PC on the CNC table for ANY other purpose than as a DEDICATED CONTROLLER running MACH3 With the requirements of the PC being modest an older or refurbished PC makes a nice machine to dedicate to the task You will NOT get better performance from a new super duper quad processor PC with 8G of RAM and a 500G HD Optimize and treat the PC with MACH as a CNC controller and you will have fewer issues and a better
4. 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 A FREE alternative is Inkscape and is included on our Software CD You can download it from http inkscape org download lang en e The 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 MACH3 The best value and most flexible CAM for 2 D or 2 5D cutting is SheetCAM It is available at www SheetCAM com SheetCAM TNG is a part of our Software Bundles e 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 it is recommended you
5. brands Industry first DCP 01 digital current probe option 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 THC on the market 2 Same 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 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 MACHS3 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 hours posted on the CandCNC website Often an email to Tom CandCNC com will get a response after hours or on weekends Another valuable sour
6. if you don t know how e Use the Support CD and run the BladeRunnerAlO UBOB3 Install exe in the AUTO INSTALL FILES folder on the CD some early units had the MP3000E install name e Plug in the DB25 cable supplied to the PC parallel port and the other end to PORT1 input on the side of the BladeRunner AIO box e Plug in the MAIN Power to the BladeRunner AIO box e NO MOTORS Plugged in YET e Turn on Main Power Switch on end of enclosure Red LED over OFF switch should come on and the PWR light on the UBOB panel and the PWR LED on the FRONT PANEL should light up CandCNC Page 8 Flo f a al a i Oei aola a ere al BLADERUNNER AIO RIGHT SIDE VIEW INPUTS FOR UBOB III AND EXPANSION OPTIONS CLOSE UP VIEW UBOB MODULE RIGHT SIDE CandCNC Page 9 Flo f alal oe t oe eola al eire a Connecting up the BladeRunner Control box Take a look at the block diagram 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 These are labeled Port 1 and Serial It s important that you connect the first parallel port in the computer normally the existing printer port or LPT1 port to Port 1 on the BladeRunner Controller box There are also other cables that connect three satellite cards Table I O and THC Sensor Module VFD Interface Card to the BladeRunner DTHCIl or Spindle Speed as well The Table I O is connected I
7. 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 MACH3 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 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 MACHS3 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 ina 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 eThe G code runs in
8. see Bladerunner Manual Partll Service Manual If you use any other motor or rewire for any reason CHECK TO MAKE SURE THE COILS ARE COLOR CODE MAY VARY MOTOR SIDE BladeRunner ESPII box See Section F Addendum for views of BladeRunner Servo Systems CandCNC Page 11 BladeRunner AIO QUIK START e Push the ON White Button RUN LED green should light You should hear a faint click inside the unit Main fan end of enclosure should turn on on later models the fan may come on as soon as the Main Power switch is activated QUIK START y e If for any reason the unit fails to power up unplug it from the AC and open the front cover 4 screws and carefully set the front cover aside and check all of the cables and wires to make sure none have come loose in shipping Refer to the manual detail pages to confirm cable connections e Once you have the power on sequence operational TURN THE DC OFF USING THE RED OFF BUTTON ON THE FRONT PANEL RED LED SHOULD BE ON e Plug a motor into the X motor connector on the side of the BladeRunner AIO case requires match encoder connection for servo motor systems e Turn on the Motor DC Power using the FRONT Panel ON Button Motor will lockup after about a 1 sec delay Lock up is defined as the motor becomes difficult or impossible to turn e Turn off Motor DC Power you can leave the Main power Switch on e Plug in the other motors and make sure they lock up when you
9. 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 MACH3 Manual on the CD For plasma cutting most of the manual 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 BladeRunner Auto installer to do a custom setup on MACH for the BladeRunner and the DTHCII Detailed setup and testing of the DTHCll is a separate manual on the CD titled DTHCII Manual NOTE THE MP3000 products use the same electronics and interface as the BladeRunner CandCNC Page 2 INSTALLING MACHS 0 INSTALLING MACH3 FROM THE SUPPORT CD TO YOUR CONTROL PC 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 SOFTWARE INSTALL DXF Tool File Folder Freeartwork File Folder MACH Program File Fol
10. turn on the Motor DC using the front pushbutton e Start MACH and select the BladeRunner_Router OR BladeRunner Plasma Icon e With motor power ON and MACH running the profile hit the RESET button If you cannot bring MACH out of reset 1 Open MACH3 Diagnostics Tab If External E stop Request error is flashing then the EPO Jumper on the table I O is not in place OR the Table I O card is not connected 2 E Stop input is OPEN or E Stop polarity is wrong Open CONFIG Ports amp Pins Input Signals and make sure E STOP input Active Low is set to RED X If you CAN come out of reset The Charge Pump LED on the UBOB Panel should come on IF it does not d 1 You may not have communications to the parallel port on your PC 2 The EPO jumper may not be in place on the Table I O card inside If you still cannot get MACH out of RESET then go to the UBOB section in this manual and check the cables MAKE SURE YOU ARE RUNNING THE RIGHT PROFILE IN MACH CandCNC Page 12 BladeRunner AIO QUIK START e Once you have the power lights and CP light on and out of RESET you are ready to do a preliminary motion test NOTE IF YOU HAVE A 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 Open MACH3 CONFIG AXIS SLAVING
11. use of your equipment Use you hot new PC Laptop to Draw and do the CAM work Take it to the Controller PC and us it to cut the job THE FOLLOWING CONFIGURATIONS ARE NOT SUPPORTED zsAny Windows 64 bit install lt Any non parallel port pulse card or control e g Smooth Stepper USB drivers etc zLaptops even with a parallel port In addition While WIN7 is supported by MACH we do not currently support WIN7 running the BladeRunner The problem with WIN 7 is usually the drivers for the hardware on the PC and not something we can help troubleshoot In other words You can try to use WIN 7 and it MAY work but if it does not please don t call us for support 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 3 Do a fresh install of MACH3 and re install the CandCNC files INSTALL off the CD BEFORE YOU UNINSTALL MACH OR DOA 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 o
12. ACH 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 you wish to transfer in and THEN overwrite it with the imported file CandCNC Page 34
13. BladeRunner AIO User Manual CandCNC With BladeRunner AIO SERVO Addendums Release 2 11 17 2012 CandCNC DISIE ALL IN ONE CNC CONTROLLER 5 fF e x S d gt V4 oa a id J y s y gt All Content Copyrighted 2008 2013 any reproduction in printed or electronic formats is prohibited without the express written permission of CandCNC 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 CandCNC Page INTRODUCTION BladeRunner AIO INTRODUCTION The BladeRunner AIO 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 I O 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
14. Driver Interface design monitors each axis independently and protects drives from shorts and overloads Reports faults with flash 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 4 5 axis configuration one axis hardware slaved for adding double Z motion or rotary axis 8 Warranty covers labor and parts returned to factory for a full 2 years All components including motors and drivers 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 Connection kits for most other
15. II amp ISS 02 have their own manuals for install setup and use If you have purchased the BladeRunner AIO Dragon Cut for plasma cutting you will also need to refer to the DTHCII _Setup Config or DTHCll setup_install full pdf All Manuals are in PDF format You will need to have the Adobe PDF Reader installed Free to view or print the manuals IF YOU DO NOT HAVE THE SUPPORT CD or it is more than 90 days since you received your BladeRunner you should check http Awww CandCNC com Manuals htm for the BladeRunner Installer ZIP at the bottom of the page You can download unzip and run that installer STRUCTURE OF THE SUPPORT CD DXF Tool File Folder Freeartwork File Folder MACH Program File Folder Manuals File Folder O CtherInstalls File Folder 3Sheetcam File Folder jf BladeRunnerAlO Spindle UBOB3Update_Inst ai 3 043 KB Application jf BladeRunnerAlO UBOBIII_Install exe 3 607 KB Application ReadmeFirst txt N 2KB Text Document CandCNC Page 2S CandCnic SUPPORT FILES acit 0 BladeRunnerAlO UBOBIII Install What it DOES SOFTWARE INSTALL Copies two PROFILES XML s to the MAIN MACH Folder Copies several Screen SET files to the MAIN MACH Folder Creates a folder under MACH3 Bitmaps named CandCNC Copies all of the bitmaps for the MACH screens to that folder Copies the custom drivers PLUGINS to the MACH3 Plug in folder Opens the MACH3 macros folder and creates a folder for each Mach Profile add
16. 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 signals at the rate set by the motor tuning rules and it s up to the hardware to move to that location CandCNC Page 2 SOFTWARE INSTALL OVERVIEW 0 SOFTWARE INSTALL 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 MACHS3 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
17. OWS Version 2002 Service Pack 3 1 Go to START lower left CONTROL PANEL Registered tor and select SYSTEM from the list You will see a screen simialr to the one on the left Th774 840 95 23345 2 Select HARDWARE Tab TERNA 3 You will see a window like the one below ANO Athloritnd 642 Dual 4 Select DEVICE MANAGER Core Piocessoe 5800 5 A list of all the hardware devices on your PC 3 01 GHz 200 GB of RAM will appear Physical Address Extension see next page to continue System Properties System Restore Autoenatic Updates I Remote Gereral Computes Name Hardware Advanced File Action View Help Device Manager The Device Manager lists all the hardware devices mstalled on yout computer Use the Device Manager to change the properties of ary device F Display adapters na S DWD CD RONM dives Osiver Signing lets you make sure thal installed divers are Og Human Interface Devices compatble with Windows Windows Updale lels you set up E IDE ATAJATAPI corkrofers how Windows connects to Windows Update for divers H 5 Keyboards i Matna Puceing Egre Widac Up 5 Mice and other painting devices H Monitors Hardware Profiles fies Maturi adaptare Hardware piofles provide a way fot you to set up and store E3 NVIDIA Network Bus Enumerator different hardware configurations 4 Y Ports COM amp LPT SP Processors H P Sound video and game controllers Hardware Profiles See Storage volumes m T System
18. a H CandCNcSamples M 3 i 4 DXFToolSamples DxfToolstd The Mach1Lic Dat is an Encrypted file You CANNOT open it It Inkscape must be copied intact using the Licenses steps below Each License file DXFTool has a unique serial number issued mach lt to CandCNC We keep a B SheetCAp database of all licenses and in the MACH event you misplace your license E MACH3Manual contact us and we can issue a replacement O Sheetcam 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 Mach1Lic dat DAT File If you have purchased a MACH3 license or Software bundle from CandCNC then In that folder you will find a single file To license MACHS3 1 Use File Explorer and RIGHT CLICK on the Machilic dat file and select COPY this copies it to the Windows clipboard 2 Immediately Use File Explorer to navigate to the C MACH3 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 3 Open the MACHS folder and display a list of the files in the right
19. ade by CandCNC No othe tights are granted or implied and user agrees not to copy decomple or reverse engineer any file or program from CandCNC Files programs manuals may be copied to the hard disk of any computer that belongs to the owner of CandCNC products Resale of any CandCNC product is no as the person in legal possessi t restricted and owner is defined on of any CandCNC product related to ie Setup Install BladeRunnerAlO UBOBIII Select Destination Location Where should Install BladeRunner4 O UBOBIII be installed D Setup will install Install BladeRunner4 O UBOBIII into the following folder To continue click Next If you would like to select a different folder click Browse IC MACH3 Browse At least 8 7 MB of free disk space is required CandCNC 0 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 SOFTWARE INSTALL If you installed your MACH3 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 311 CandCnNnic SUPPORT FILES aite 0 ie Setup Install BladeRunnerAlO UBOBIII Information Please read the follow
20. are Please shy carey eee on some computers this may take a minute Adee shoei e and is used to generate the high speed outputs and inputs needed for proper operation of the BladeRunner and the Cancel CandCNC Page 26 MACHS3 SOFTWARE Basic Structure 0 MACH FILE STRUCTURE lt Eb _ of 2 ORE SAMPLE FOLDER STRUCTURE g Bitmaps 3 Candcnc Some folders are added for Icons specific options so your folder view MillBitmaps will not have all of the ones shown Brains on an initial install The important Documentation ones are listed below Flash E GCode This is located on the C drive of Help your Control PC H HT_connect Icons 5 macros BladeRunnerAlO DTHC UIBOB3 FOLDER CONTAINS BladeRunnerAlO Router UBOB3 Mach3mill Bitmaps Contains Bitmaps custom backgrounds O THP3000 BASIC UBOBIII p and Buttons for the custom screens E MP3000 Basis UBOB3 CandCNC has a Folder under Bitmaps E MP3000 DTHC ROTARY3 for the specific bitmaps for our screens 3 MP3000 DTHC UBOB3 MP3000 Spindle UBOB3 Sample G code for ROUTER Do not use except for testing motion it will not ml THCON OFFMacros zip work with plasma Manual Browser Contains Sub folders of macros for HyT Connect EACH generated Profile In the specific PNz200 Macros sub folder that are macro files When you call a macro by number from 1 Plugins code or internally it uses the specific Bonument
21. ation macro in the folder of the same name Subroutines as your running profile Uninstall xmlbackups A folder of plugins installed The base 7 plugins for CandCNC are the ccc_comm and the ccc_ubob Others are installed From time to time if you add with options like the PN200 Every features or certain upgrades are plugin the folder will be seen by MACH installed there can be added The Configuration of a plugin folders and or changes to files We including enabled and disabled is make available specific files that stored in the specific XML profile so they can be differnt configurations in upgrade files in this structure In different profiles some cases the user must open the specific folder and copy the xmlBackups Backup copies of the Profiles XML s for new file into or overwrite an your system Can be renamed and existing file in a folder Being copied back to the MACH main folder to famili ith the struct k bring back a damaged XML You should am lhar wi e structure makes STILL perform file backups onto another this process easier media source of your XML files anytime you change settings CandCNC Page 27 MACHe2 LICENSE INSTALL INSTALLING THE MACH 3 LICENSE 1 Locate your Software Support CD It is a separate CD from the Support CD If you purchased either of the CandCNC Software bundles you should have the Software Support CD PlasmaSoftwareBundle cD Artwork Samples Aa een ha
22. ault or from checking cables and connections All Content Copyrighted 2008 2013 The owner of the equipment covered by this manual is authorized to make copies electronic or printed of this manual for their personal use only as long as this original copyright notice is included Owner is defined as the person in legal possession of the equipment No excerpts or reproductions are authorized for any other use without written permission from FourHillsDesign CandCNC For media reviews please contact CandCNC for permission to use any photos or text from this manual CandCNC Page 7 BladeRunner AIO QUIK START BLADERUNNER AIO QUIK START The following is a synopsis of the steps needed to get the BladeRunner installed and setup and moving the motors e Unbox and check the unit to make sure it s undamaged If there is any visible damage from shipping retain the shipping boxes If possible take digital pictures of the damage Contact CandCNC immediately e Load the version of MACH3 on the support CD to your PC Current version we provide is 3 42 029 If you have already installed a NEWER version then DO NOT REPLACE IT WITH the version we supply You must uninstall the newer version AND IMPORTANT remove the MACH Pulse Engine from the Device Manager list Remove hardware before you do the install from the CD We have not fully tested releases of MACH after 3 42 029 e Load your license file for MACH see Software section
23. ce of help is the CandCNCSupport Group at http groups yahoo com group CandCNCSupport 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 OVERVIEW There are a series of steps you must complete to setup and interface the BladeRunner AIO with your PC and Your Plasma torch Install and setup the Primary Parallel Port in your PC Setup and configure the first serial port COM1 on your PC Install MACH3 software proper version Copy your MACHS license into the MACH3 main folder Run CandCNC install program from the CandCNC Support disk to load custom screens and setup files and Plug ins Open MACH3 and check screens and configurations e Connect the 2 PC port cables one 25Pin one 9 Pin to the side of the BladeRunner e Runa quick series of tests to confirm the ports are working and that MACHS3 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 Fire up the machine and cut a test file Proceed to the DTHCII setup Dragon Cut versions Serial port install and setup is not required for simple Router Mill operation Serial port is used to send and receive information from to the Expansion Modules DTHC amp ISS 02 It is also used to display the Power Supply parameters a
24. controllers Se Storage volumes 3 System devices Use automatic settings Conflicting device list No conflicts I CandCNC Page18 INSTALL and SETUP PRINTER PORT LPT Expansion Card Port NOTE USE THIS SECTION ONLY IF YOUR PC DOES NOT HAVE A BUILT IN PARALLEL PORT and or SERIAL PORT Use the same procedure to install a primary PORT1 Parallel Port if your PC does not have one or a secondary port PORT2 Do not attempt to use two separate parallel port cards of the same type to get two ports For two ports use a Dual Parallel Port card PC HARDWARE 0 Make sure the card you install has drivers for the version of Windows you are running Win2000 drivers may or may not work in XP or visa versa When you install the card in your computer and turn it back on it should find the new hardware and when prompted you should use the disk that comes with the port card to install the correct drivers There should be instructions with the card on the proper way to install the drivers After you install the parallel port and Windows recognizes the port s then open the device manager from the Hardware section under Windows Control Panel System and open the Ports icon and find the Port entries Open that and click on the resources tab PCI Parallel LPT2 Properties 2 x General Port Settings Driver Resources E PCI Parallel LPT2 i l WRITE PORT Resource settings ADDRESS HERE Re
25. der Manuals File Folder O OtherInstalls File Folder DSheetcam File Folder 5 BladeRunnerAlO Spindle UBOB3Update_Inst a 3 043 KB Application Bl BladeRunnerAIO UBOBIII_Install exe 3 607 KB Application ReadmeFirst txt R 2KB Text Document 3 Navigate to the MACH Program Folder x Mach3Version3 042 029 exe 26 456 KB Application Screent exe N 1 880 K6 Application 4 Double Click the Mach3Version3 042 029 exe line The sutomated install of MACH will start Welcome Welcome to the installer for Mach3 Version 3 042 029 It is strongly recommended that you exit all Windows programs before continuing with this installation If you have any other programs running please click Cancel close the programs and run this setup again Otherwise click Next to continue CandCNC INSTALLING MACHS 0 Mach3 Setup Installation Folder Where would you like Mach3 to be installed SOFTWARE INSTALL The software will be installed in the folder listed below it is recomended that you use the listed MACH will ask you for folder but you are welcome to setict a different location either type in a new path or click Change to browse for an existing folder the default installaion Disk and folder to use SELECT THE Install Mach3 to STUCTURE IT SHOWS CAMach3 DO NOT CHANGE IT OR OTHER INSTALLA MAY NOT WORK CORRECTLY Space required 39 8 MB Space available on selected drive 92 79 GB Mach3 Se
26. devices Universal Serial Bus controllers CandCNC Page 17 INSTALL and SETUP PRINTER PORT LPT Miotherboard Port In WINDOWS 6 Scroll down the list until you find the PORTS Com amp LPT line 7 Expand the line button 8 Find the PRINTER PORT LPT1 and click the line to open the TABS 9 Click the RESOURCES Tab You should see the screen below and the I O Range should start at 0378 If you do not see that LPT port in the list or you have another address for LPT1 under the RESOURCES proceed to the next section If you have the screen shown you have a Motherboard Parallel Port at the default address and your Bladerunner default install will use that address You can move to the COM port setup page u Ser wisn wives E Display adapters P m DVD CD ROM drives Printer Port LPT1 Properties x gy Human Interface Devices Gerrey i i iis Resources IDE ATAJATAPT controllers General Port Settings Driver Details gt Keyboard Se ae Keyboards F Printer Port LPT 1 lt Mach3 Pulseing Engine Mice and other pointing devices Monitors Resource settings BB Network adapters N IDIA Network Bus Enumerator Resource type Setting Y Ports COM amp LPT I O Range 0378 037F wy Communications Port COM1 4 Communications Port COM2 ay Printer Port LPT1 MB Processors Sound video and game
27. e your own PROFILES CandCNC Page 3 Starting The MACH PROFILE STARTING THE BLADERUNNER PROFILE a From the the Desktop on the computer piMieRunnerA 10 Plasma Look for the C3 Icon and select the Plasma or Tey Router Profile to run If the C3 icons are not Z present you may find it installed them with a Bladerunne generic icon like this Ei Router it will run from either Icon HOW TO RUN FROM THE MACH LOADER Z Mach3 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 Your display may have more or less profiles that the screen here You need to see at least the BladeRunnerAlO DTHC UBOB3 and the BladeRINNERAIO ROuter UBOBS3 in the list Current Profiles Receerenconcines A BladeRunner4lO DTHC LBOB3 F BladeRunnerAlO DTHC UBOB3 tom Create Profile Delete Profile BladeRunner4lO Router UBOB3 R Cancel oO Thereare several hings 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 3 SOFTWARE 0 INSTALL Wrroking with Create Profile Clone From New Profile Name a MyNewProfile BladeRunnerA amp IO DTHg BladeRunnerAlO DTH I Default Profile Value
28. ed in step 1 7 Removes default MACH profile links Icons from the Desktop 8 Puts two custom Icons on the Desktop for the BladeRunner Plasma and Router OuahWNM WHAT IT DOES NOT DO Load or install MACH3 Load or install any other software Setup the MACHS3 Profile 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 BladeRunnerAlO UBOBIII exe file The install will start with a series of windows In most you will just hit NEXT ie Setup Install BladeRunnerAIO UBOBIII Welcome to the Install BladeRunnerAIO UBOBIII Setup Wizard This will install Install BladeRunnerAlO UBOBIII Rev on your computer It is recommended that you close all other applications before continuing Click Next to continue or Cancel to exit Setup CandCNC Page 30 ie Setup Install BladeRunne Information CandCNic SUPPORT FILES Install rAlO UBOBIII Please read the following important information before continuing When you are ready to continue with Setup click Next MAKE SURE MACH3 1S NOT All support files on this CD are CandCNC grants all owners of IMPORTANT RUNNING WHEN THIS INSTALL IS RUNI protected by copyright CandCNC products the right to use these files in the operation of their products Some files are the property of other copyright holders and are used with their permisson to support products m
29. f the MACH3 folder on your drive using 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 14 Cc PC Requirements amp Preparation TO run MACHS with the Bladerunner and Bladerunner Dragon Cut Systems 1 Pentium 4 PC 2 4 to 3 4 GHz Processor 512M to 1G RAM 20G Harddrive 1280 X 1024 SVGA no shared system RAM tea 25 pin LPT Parallel Port 1ea 9 pin SERIAL COM Port Windows XP SP2 or SP3 Keyboard Mouse 2 Optimized Windows setup No automatic updates running Disable Remote Assistance No Virus Checker or background file checkers No unconnected Ethernet cards disable if not connected to a cable hub Turn off all non essential background processes in Windows 3 Disable Startup Items in Registry Click Start button Click Run Type MSCONFIG and press ENTER Click Startup tab Uncheck everything
30. g the INSTALL FILE for MACH Page 4 CandCNC BladeRunner AIO Table of Contents BLADERUNNER AIO TABLE of CONTENTS PART 1 SETUP CALIBRATION D Detailed Install amp Setup Software Cont 3 After the MACH Install a Sample Folder Structure b Folder Contents Defined 4 MACH3 License Install 5 CandCNC Support Files a General Info b BladeRunnerAlO 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 E The BladeRunner ESPII Power Control Unit 1 Making the External Connections a PC parallel amp Serial Ports b Power cables c Motor connections 1 Front panel Controls 2 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 AlO 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 preliminary F A 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 defaul
31. hand 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 DTHCII in MACH CandCNC Page 2 amp 0 SOFTWARE INSTALL CandCNic SUPPORT FILES aite 0 THE FOLLOWING PAGES COVER THE INSTALL OF THE BLADERUNNER CONFIGURATION FILES FROM A MASTER INSTALL EXE FILE SOFTWARE INSTALL The Auto Installer Files will automatically load all of the CandCNC support files for MACHS3 You must have MACH 3 version 3 42 029 off this CD installed and running first THEN run the appropriate installer Most installs will use the BladeRunnerAlO UBOBIII_ Install file YOU DO SHOULD NOT RUN THE MP3000E UBOBIII_ install unless you contact us and we tell you to run it 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 AIO Manual there as well We also post the latest manuals on our website http Awww CandCNC com Manuals htm Expansion Cards DTHC
32. ing important information before continuing When you are ready to continue with Setup click Next Each of the Profiles will appear in the selection list of MACH Loader To run any CandCNC equipment you need to start MACH using the Loader or from the Associated CandCNC Icon It is strongly suggested that you backup your entire MACH folder hhe drive to another drive or removable drive anytime you make a configuration change in any profile You can recover a lost SOFTWARE INSTALL Another screen of information we think you should know so humor me and please read it setup by reloading MACH and simply copying in the XML and Screen files you need i Setup Install BladeRunnerAlO UBOBIII FINISHED Completing the Install BladeRunnerAIO UBOBIII Setup Wizard Setup has finished installing Install BladeRunner4 O UBOBIII on your computer The application may be launched by selecting the installed icons Click Finish to exit Setup Once you have installed the BladeRunner 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 BladeRunner DTHC or the BladeRunner Router and how you can creat
33. nd report faults to the screen You can elect not to use a serial port if you are not using the DTHC or ISS 02 Modules AND you do not want to see the power supply operational specs Volts CandCNC Page 3 BladeRunner AIO Table of Contents BLADERUNNER AIO TABLE of CONTENTS PART 1 SETUP CALIBRATION CONT A Introduction Table of Contents B BladeRunner AIO Quick Start 1 Basic Connections a Parallel Port Cable b Serial Port Cable c Motor Cables 2 Quik Start list of Quik Steps 2 Slaved Axis Setup a 4 motor system b 5 motor NOTICE 3 Power Up Motor Check C 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 D 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 MACH3 from the Support CD a CD file structure b Runnin
34. nternally and is not part of the connections to the PC 1 Install a DB25 Male to Female extension cable All pins straight through between parallel port PORT1 on the PC to the part marked Port 1 INPUT Orange highlight below on the front of the MP3000 DTHC controller unit 2 Install a straight through DBY Male to Female cable not a null modem cable from your Com1 port on the PC to the Serial port on the BladeRunner iV THC SENSOR PWM Port2 INPUT st a a OPTION J P DTHC ii SPSI Ed UBOB III Technology INPUT _Port4 INPUT SERIAL INPUT pe cP PwRin 9 e PC PC Paraje Port 1 m Serial Port CandCNC Foleo Ul ala oe t oe eolalal leielelat A1 A2 B1 B2 B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 Lanao Laaa Lanao Laoao laaan Looag laaan Laag laaan Looao IMPORTANT Screw Terminals Face UP 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 If you take the connectors off for any reason either mark the wires by position or use an ohmmeter to test for coil pairs
35. s BladeRunnerAlO DTHt Do not put any extension on the new profile coc Session Profile Current Profiles MyNewProfile v Cancel MACH PROFILES Create Profile BladeRunner4I0 DTHC LBOB3 BladeRunnerAlO DTHC UBOB3 tom Delete Profile BladeRunner410 Router UBOB3 0 TO CREATE A NEW PROFILE SOFTWARE INSTALL 1 Select Create from the previous screen you will get a window similar to the one on the left 2 Type a 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 with 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 MACRO s 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 M
36. s you make sure that installed drivers are ae nee f i Tis compatible with Windows Windows Update lets you set up lt Mach3 Pulseing Engine how Windows connects to Windows Update for drivers Mice and other pointing devices 92 Monitors Driver Signing Windows Update BB Network adapters TA NVIDIA Network Bus Enumerator Har TEE EN Ports COM amp LPT S Processors Hardware profiles provide a way for you to set up and store different hardware configurations Drivers Sound video and game controller See Storage volumes System devices Hardware Profiles Universal Serial Bus controllers Note The PC can be used in the network or with a wireless card but it is important that if the network is not available card is not connected to a cable and hub that it be disabled Ethernet communications will interrupt MACH and the pulse stream An unconnected card will continually search for a hub every few seconds even if it has no traffic for the network When connected to a valid network it no longer will beacon Do not transfer files or use any Windows utilities when you are running code CandCNC Page1G Lu lt 5 ma lt lt S ou INSTALL and SETUP PRINTER PORT LPT Miotherboard Port System Properties System Restore Automatic Updates Remote Genetd Computes Name Hardware Advanced Systeme Microsc Windows XP SFA In WIND
37. source type Setting Setting based on Current configuration WS Input Output Range DEOO DEO I WH Input Output Range DCOO DCO3 TH Witsoe i JV Use automatic settings Conflicting device list No conflicts Cancel Write down the first number in the Input Output range DE00 in this case above We will have to enter that number in the MACH3 setup procedure later CandCNC Page 19 PC hardware COM Port Te Ven unive Display adapters lt 3 DVD CD ROM drives Floppy disk controllers amp Floppy disk drives lt IDE ATA ATAPI controllers Keyboards lt Y Mach X Pulsing Engines 3 Mice and other pointing devices G E E DESENE Modems Monitors 59 Network adapters av Ports COM amp LPT I Communications Port COM1 F Communications Port COM2 ov ECP Printer Port LPT1 g Sound video and game controllers amp Storage volumes System devices Universal Serial Bus controllers PC HARDWARE 0 1 You will have to setup the COM1 serial port in Windows It should be setup with 9600 baud 8 bits no parity 1 stop bit no Flow control Communications Port COM1 Properties 2 x General Port Settings Driver Resources Bits per second jso Data bits fe n Parity Noe y Stop bits hooo Flow control None Advanced Restore Defaults
38. t settings 5 Calculations amp Formulas 6 Recommended Settings Typically setup CandCNC Page 5 BladeRunner AIO Table of Contents G Detailed Install and Setup BladeRunner Hardware 1 Table I O card a Card location in the BladeRunner b Making the wiring connections 2 The Charge Pump CP 3 E STOP and it s variants a EPO jumper on Table I O b Power on Detection c Hardware E STOP Options 4 Setup and testing 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 H Final system checkout 1 Bringing it all together a Final Motion Test b Doing an Air Cut CandCNC Page 6 BladeRunner AIO QUIK START BLADERUNNER AIO QUIK START FOR THOSE THAT HAVE PRIOR INSTALL EXPERIENCE OR THAT DON T NEED OR WANT DETAILED MANUALS THE FOLLOWING PAGE WILL GIVE YOU A QUICK SETUP CHECKLIST The pages that follow that are a logical and detailed setup guide Your chances for success are greatly enhanced if you follow the detailed manual in the order it is written A PART II Manual is a SERVICE MANUAL with card level details and diagnostic tools to help you narrow down the possible cause Most issues are resolved from either reloading the BladeRunner INSTALL to return all of the settings to def
39. tup Several Features will be Select Packages fa selected by default Please select the program features that you want to install 7 a f checked Turn off Wizards LazyCam You can turn off Screen sets Program Features unless you want to use Parallel p Installs the Parallel Port Driver This is not the Default MACH C Wizards needed for external motion control devices screesn to build your XML s 328 KB own screens C LazyCam experienced MACH _ Screen sets users ONLY Make sure you leave Parallel Port Driver checked Hit the NEXT button Total space required 33 7 MB CandCNC Page 2 INSTALLING MACHS 0 Mach3 Setup SOFTWARE INSTALL Create Profiles and Desktop Icons Custom profiles will help to ensure that your settings do not get accidentally overwritten by future updates It is highly recommend that you create one Do not create any Mill Profile Create a custom Mill Router profile at this time profiles in this screen All of the Profiles you will need for the BladeRunner Create a custom A ET at this time System will be automatically created in the next section of the software install Turn Profile Create a custom Turn profile at this time section Mach3 Setup Install Information E Ps 4 Ye THIS IS AN Please read the following information je IMPORTANT SCREEN It indicates that MACH is adding in the Parallel Port Driver installing Parallel Port Driver This is a Hardw
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