ART2 Pages 70-134
Contents
1. 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 Slave Axis Selection A Axis Y Axis Z Axis Slaved Axis Slaved Axis Slaved Axis C A Axis C A Axis C Axis C B Axis C B Axis C B Axis C C Axis C C Axis C C Axis None None h 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 axis If you have a 5 motor system A 5 axis slaved sometimes called a 4 5 system Hardware slaves the 5th motor driver using settings on the UBOB card Factory default is for the 5th axis to be slaved to the Y motor and turn in the opposite direction The above Slave Axis Selection is set to None on all axis no slaving The A axis then is independant and is activated for testing with the numeric pad ui Cad NC Page 56 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 Ox lt OF Typical rectangular 3 table setup 4 motor setup dual drive on the gantry sixe Buo sixe ssoJo si X uoneoo Jno uUJOJJ JeuJoo YO Jewo SI 0 0 u u euiuoeul y uni o eJeu puejs NOK Jl Gi 1J p ou2. TYPICAL SPUR PINION 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 127mm Final linear resolution 005 Belt Reduction Ratio Belt Reduction Ratio R2 R1 Numbers for direct pinion drive are simply Psr Motor RPM IPM speed E Torque oz T1 R3 An nf 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 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 61 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 310
3. STOP Stops G FEEDHOLD Pauses code execution G Code at end of instantly dumps buffer Leaves outputs buffer Turns off active ouputs RUN Cycle Start runs g code that is loaded Will restart g code if in PAUSE or STOP PAUSE G CODE RUN G CODE STOP G CODE REGEN f TOOLPATH NOTE To stop gracefully no lost RESET Toggle position use the FEEDHOLD and ON OFF Stops all after machine motion has ceased use code Turns off all the STOP ouputs Stops any macro Turns off Charge Pump Toggle turns CandCNC Page 48 FAULT Displays ESPII and CandCNC specific faults here m ERROR Displays MACH based ERRORS here 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 RS485 port and optional HyT Connect RS485 SIM Kit ERROR messages 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 k Mach3 CNC Controller File Config Function Cfg View Wizards Operator Plugin Control Help Program Run MDI ToolPath Settings Offsets Diagnostics X Pos 0 X Vel Y Pos I Y Vel j Rete BB Limits ZPos Z Vel j aa om BB Limits APos i A Vel Zero All Bi Torch Ue English Metric idle Run Pause q Joy ONOFF CulANS Tool Request Torch Toggle Pu
4. lanl j SUUUUUU Ul Ill U UVUVI S000000 S00 Rotation Clockwise increase P Accessed from rear using small l flat blade screwdriver Do NOT D force Torque Limit 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 ON SW4 OFF SW5 ON Medium low gain SW3 ON SW4 ON SW5 OFF Medium high gain SW3 OFF SW4 ON SW5 ON High gain SW6 SW7 Sets the G320X pulse multiplier SW6 ON and SW7 ON Step pulse times 1 default SW6 ON and SW7 OFF Step pulse times 2 SW6 OFF and SW7 ON Step pulse times 5 SW6 OFF and SW7 OFF Step pulse times 10 SW8 SW9 Sets the G320X following error limit SWS8 ON and SW9 ON 256 count following error limit default SW8 OFF and SW9 ON 512 count following error limit SW8 ON and 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 EXAMPLES 50 oz in Servo motor 60 VDC with 10 1 gearhead and 1 dia pinion gear amp direct drive Max possible IPM 4700rpm 10 X
5. n DIR OPTION u51 A p PARALLEL S ER is jm Ol SERIAL a O 8090000008009 5 E O 9999W cl i 000000800000 d u 0000 URRH PLUG O O zl DIRECTION POLARITY JUMPER New on UBOBIII REV5 cards This option is used ONLY if you are hardware slaving the 5th axis option from the X or Y It allows you to change the direction of rotation of the 5th motor if needed You can reverse a stepper direction at the motor simply by swapping the polarity of one coil out of the two Wile that works for steppers you cannot reverse the direction of a servo that way We have added the Direction Polarity Jumper to allow you to reverse the DIR signal polarity in hardware To reverse the direction simply move the jumper from 1 2 to 2 3 position DIR OPTION CandCNC Page59 INITIAL 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
6. 4 to 8 Recommended plunge rate SheetCAM 50 100 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 CandCNC Page 3
7. 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 jog 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 PWM Base Jog ON OFF Ctrl Alt J Pulse Frequency Cycle Jog Step Alt J 4421 d Reduced lii SEND MPG Axis AltA 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 53 SETTING UP MACH3 FOR BLADERUNNER I When you install the BladerunnerAlO UBOB3 Install exe file auto installer it automaticaly sets up two profiles in MACH One for Router and one for Plasma with DTHC i
8. 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 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 38 Multiple Inputs Switches probes sensors BASIC BLADERUNNER AIO BLOCK DIAGRAM 48V 12A MODULAR POWER CONTROL See next page Connections to Motors TABLE I O AC Line Cord E in gt SWITCHED POWER G251 4 Card Universal Power Pak O I 9eiaer Expansion Module Option Kn UBO ic ee TO PC Port1 To PC Serial See Text CandCNC L G251 SOoLO N SthAxis OPTION P CandCNC 2 a CrossFlow FAN OPTION TABLE 1 0 CARD bk n KP EAR BladeRunner AlO Cover Removed Inside View d 4 AA XXX ane bf t L 2 d me DTHC EXPANSION _ MODULE OPTION DR n 3 je o J CandCcnliG ESP Il Enhanced Smart Power OFF MOTOR POWER e e e e e DRIVE 5VDC TEMP POWER DRIVES TEST
9. 3 142 1476 IPM linear force 100 servo motor continious torque X gear reduction 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 100 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 Speed in Ports amp Pins The number of pulses per second you need is the target R
10. 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 e To 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 67 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 valu
11. CandCNC CUSTOM CandCNC Screen SET provided with BladeRunnerAlO UBOB3 install file Some features may change over time DTHCII specific functions are covered in detail in the DTHCII User Manual Program Run MDI ToolPath Settings Offsets Diagnostics M3 P1001 03 c is 1X4 5Z22 F J 4 v 3 GEI Edit G Code Close G Code Run From Here g SE recorate 0 00 OUTPUT 3 PERCENT 00 AUX OUTPUTS BladerRunner DTHC PLASMA PROFILE SCREEN CandCNC Page45 Screen Sections explained H3 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 Mach CNC Controller Program Run al MDI ToolPath Settings Offsets Diagnostics DiedoDiumnnerhtlOr 40 0000 pri x 0 0000 Ki J 40 0000 E oz 3 p 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
12. E stop and the CP LED on the front panel active ON Without CP active you will not get motion Make sure all of the cables are connected Power up the BladeRunner Load Mach3 with the proper profile BladeRunner and Screen Turn on DC Motor power using the ON button on the Front Panel Motors should lock when power comes on to the motors Hit the Reset button The LED over the Reset in MACH will turn solid Green The 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 the 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 connection x ele se ee X AXIS MOTOR MOVEMENT PROFILE Velocity Axis Selection X Axis Y Axis 2 Axis 187 5 EM ve ime 150 1 A Axis m e 1125 75 I 375 0 0 01 02 03 04 05 086 07 O8 09 1 Time in Seconds Accel i i i iii l l velocity Accelera
13. FAULT OK 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 System DC status System Driver Status enable disable drives DC voltage level overvoltage shutdown DC current load level overload shutdown Internal Temperature overtemp shutdown System Fault Indicators LED s and Screen Text O Q gt Q N CandCNC Page 41 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 Sends Signal to OFF Button Processor to turn CandCcnic Sends Signal to Processor to turn REN ESP I OFF DC Power to Enhanced Smart Power the Motors ON LED b OFF LED On Green gt On RED when DC whenDC
14. G Code File Loaded or running RUNNING PROFILE Box Shows the current MACH PROFILE 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 Function Buttons allow control of the G code Loading and Closing G code and a rewind to REF XY Button performs a REF move on XY at the same time the start button but not on Z Useful on plasma after the first We REF has been done to locate 0 0 Rewind Ctrl W Set Next Line LOAD MATERIAL button Load Material initiates a move to a preset postion OUTPUTS ON OFF Buttons hin 0 Turns on off the two AUX relays E OUTPUT3 table i o Card Bladerunner AIO 100 g JOG ENABLE Button Jog Turns keyboard jog on off should stay on normally E FRO Feedrate Override changes feedrate on all PERCENT has two wired AC sockets that are Axis at the same time 6 0 00 ATTE controlled from these buttons CandCNC Page 46 Enter Value INDICATOR LED s TIP SAVER turns on when TIP saver is active TIP SAVER is a dynamic anti dive that keeps the torch from diving on corners or when crossing a void or existing kerf UP DOWN ARC OK shows the statues of those inputs from the DTHCII These are t
15. 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 43 Load and Testing MACH After you have installed MACH and run the BladeRunner INSTALL on the Support CD open MACH 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 listed 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 MACH3 folder and select BladeRunner Router set If it is missing any of the Bitmaps picture buttons and or backgrounds then confirm the
16. buttons above The Router setup only has 2 outputs available CandCNC Page 51 Diagnostics Screen allows you to LOAD and RUN 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 Jog Follow ToolPath on off To RUN Feedhold STOP Rewind of SINGLE STEP from the Diagnostics Screen use the Buttons shown English Metric Idle Run There are status LED s for UNITS and to Pause show running status and Dwell Tool Request Bl Dwell Active USING SINGLE STEP TO TROUBLESHOOT Run j CODE FeedHold Rewind Often a mistake in G Code or the setup is hard to Stop spot because it runs faster than you can watch the machine and the code execute The SINGLE _ Single E 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 AUTO 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 Page52
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18. 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 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 M command What M command is used to turn on off an OUTPUT is a setting in MACH and comes defaulted so a M03 or M04 turns on OUTPUT Torch on the Plasma Profile Spindle on the Router Profile MO5 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 on the TABLE I O Control OUTPUTS from DIAGNOSTICS SCREEN via the Toggle Buttons for each output NOTE Only 3 Outputs are availaible on a BladeRunner AIO Dragon Cut Large
19. the differences in the motor connections A1 A2 B1 B2 XN A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 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 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 CandCNC Page 37 BLADERUNNER 6251 4 MODULE FRONT PANEL FUNCTIONS A1 A2 B1 B2 A1 A2 B1 B2 A1 A2 B1 B2 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
20. CandCNC BLADERUNNER AIO RIGHT SIDE VIEW INPUTS FOR UBOB III AND EXPANSION OPTIONS CLOSE UP VIEW UBOB MODULE RIGHT SIDE Page 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 DTHCII or Spindle Speed as well The Table I O is connected Internally 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 DB9 Male to Female cable not a null modem cable from your Com port on the PC to the Serial port on the BladeRunner THC SENSOR PWM Port2 INPUT OPTION DTHC il SPS II INPUT UBOB IlI Technology Port INPUT SERIAL INPUT Z SPE s uS T mU bo CP PWR oe G e gt C DB25 M F 15 ft MAX 15 ft MAX CandCNC NOTE For BladeRunner Servo system please see the end of the F section for
21. 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 n Mach3 CNC Controller Fie Con Funci n Cigs View Wizard Operator PuginCortral Help Program Run Att MDI AN2 ToolPath And Offsets ARS Settings ANG Diagnostics Alt 7 Pendant Load G Code Edit G Code eres G Code Rewind Ctrl W Cul W Ban From Here Single BLK RISTE m Nm STOP Load Wizards Load Wizards Son Soft Limits REGEN DISPLAY LLLA m der Fake move J is INPUTS E SSS EEEDRATE 2 Load Material Port Input Bits Output3 REF XY BEBBSEBEHENENE Je E e FRO 6 00 A On4 Off4 muu F 6 00 G Shows actual input bits 1 Sonone to Port 1 and Pon2 ons ons E 100 Unts Mn 0 00 BladeRunner Montor Program Run a oxi Joy OWOFF _ Ca Volts Amps Temp Bi EES eat FAULT DETAIL ur CT TTT TTT Tre
22. O0z 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 in the center part of it s 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 PI 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 a vlaue of 60 to 8096 of that number Set your Beginning Acceleartion to a low number like 10 To fine tune the calibration see the next pages CandCNC Page 62 Setting the initial Steps per Unit in MACH3 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 Driv
23. PM max X the SPR 60 For a target RPM of 4000 and 250 line encoder you need 40000000 60 66 666 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 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 For 45 000 and 250 line encoder 45000 1000 45 RPS Pinion RPM RPS 10 X 60 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 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
24. YOJO M SIXe Z ez Zz ian lt gt lt Q gt N Es e Slave Master ES i Motor Z axis wl torch holder alternate mounting X Y Homes 3 If you stand here to run the machine then 0 0 is lower left corner from location X is cross axis short axis lt X axis gt CandCNC Page 57 Hardware Slaving Options ONLY USE THIS PAGE IF YOU HAVE A 5th AXIS CARD INSTALLED or INSTALL ONE LATER Even if you decide not to use the 5th axis the unit is shipped from the factory setup to use the 5th axis as the default Slave axis HARDWARE SLAVE If you decide NOT to use the Hardware Slave and instead want to use the A axis as a software slave then YOU MUST break the Hardware Slave using the Jumper Settings below If you elect to ignore the instructions and leave the settings as a Hardware Slave and try to use the A axis hardware slaved also you will get DRIVE FAULTS on the unused 5th axis 5 AXIS SYSTEM C3 FACTORY DEFAULT Hardware Slave shown in Y Position 4 AXIS SYSTEM FACTORY DEFAULT o w cO LO n Both OPTION BLOCKS MUST be jumpered the same m 1 2 External drive FROM PORT2 card 3 4 Slave 5th Axis to X 5 6 Slave 5th Axis to Y cN oT N e Factory Default setting if 5th axis not used Do not change unless you are going to use a 5th driver and motor In order to r
25. 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 troubleshooting port problems 9 If you have motion on all attached motors then proceed to the next section AAxis JOG DEFAULT HOTKEYS BladeRunner Profiles Z JOG KEYS unslaved ES 25 NJ LG ef N gt yz oN TIE S gA fz e E Ih fe s EA i L1 0 0000 vel 0 0000 Y vel 0 0000 Ze AXIS DRO s CandCNC LINEAR MOTION WITH RACK amp PINION Pitch Diameter Pressure Angle A 4 po i RACK Aas TAA AAA AYAY f
26. e 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 _ O O OOOO G00 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 it s 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 in 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 CandCNC Page 68 208d JOS 3lV1d SSVIN 91S30 Y g eko A0 ON ava 3WN zo 3Wd ou 2094 SNI TIALS QT g g SSYII NOLIVTOSNI uw Leh wo 00 30090 9NIQ10H NOLLOSNNOO S338 NOLLOINNOD MYM LHL D
27. ection 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 MACH3 out of E stop by pressing the Reset button e 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 66 e The MDI is a line to allow you to type in direct g code commands to make the machine make specific moves You don t need to have a deep knowledge of g code to use it for testing Diagnostics Tab Your MDI may look different e When you type in a 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 o G00 X3 0 o Enter key activates command e The X axis should move
28. eed 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 two 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 4 Start with the D 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 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 l
29. er 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 i 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 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 For a R amp P the distance traveled per rev of the pinion is given by the DP of the pinion X PI 3 1416 Ifwe use a 1 DP pinion the dista
30. es and settings for the DTHC to use The initial display is of the CURRENT SETTINGS in the DTHCII memory Profiles by material can be recalled selected and added Detailed use of the CUT PROFILES is covered in the DTHCII User Manual IMPORTANT There are Self Tests that can be preformed on the DTHCII modules and other modules in the setup They establish that the modules are functional and sending data to both the parallel port inputs and the PC serial input If you do not have proper display of values while cutting or the DTHC ONLINE is not ON you are missing critical signals See the DTHCII User Manual to run the tests Page 47 POWER SUPPLY DASHBOARD Displays realtime values of the ESPII Smart Power systems used in the BladeRunner controllers All critical parameters are monitored and if a level reaches a point that is too high it will trip a fault and shutdown the power to the motors Faults will display in the FAULT MESSAGE BOX previous CASE TEMP Internal temperature of the BladeRunner enclosure In deg F POWER Case Temp 75 SUPPLY READOUTS Drive Temp ON LOAD METER VOLTS Power Supply DC Volts Displays power supply voltage to motors ESPII Smart Control only on when DC power is on Volts AS Amps Si USED DRIVE TEMP NOT AMPS shows the total current drain of ALL motors that are attached Current increases with the load on each motor Dynamic Load Bar Graph
31. ettings go back to the Defaults Each time you make a change in CONFIG it gets stored in an XML file with the same name as the displayed Profile in the Program Run screen IT ONLY SAVES THE RUNNING PROFILE WHEN YOU CLOSE MACH NORMALLY MACH only reads the Profile when you start it up to a specific profile Some settings will change the RUNNING profile what you are currently running OTHERS DO NOT Plugins are only read once when MACH is started so a chage to a plugin config will require you stop and restart MACH3 CandCNC Page 544 CHECKING MACH3 CONFIG for Proper PORT1 ADDRESS In the PC Hardware Setup Section the PORT 1 Address was determined Use the CONFIG Ports amp Pins menu to check the address and if needed change the settings Note PORT 2 is disabled Default Kernel Speed is 45000HZ which will work with most PC s and will provide pulse rates for any BladeRunner setup Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Port 1 Port 2 MaxNC Mode Iw Port Enabled Port Enabled Max CL Mode enabled 0 378 Port Address 0x0 Port Address Max NC 10 Wave Drive Entry in Hex 0 9 A F only Entry in Hex 0 9 A F only Program restart necessary Pins 2 9 asi qr Re Aan Restart if chanqed Sherline 1 2 Pulse mode Kernel Speed ModBus InputOutput Support C 25000Hz 35000Hz e 45000Hz 60000hz ModBu
32. he COMMANDS from the DTHCII to MACH DTHC ONLINE shows the communication status of the DTHCII module to MACH3 It MUST be on to allow MACH to display screen values and to allow Cut Profiles to transfer to the DTHCII CandCNC 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 transferred 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 DCP201 Digital Current Probe has been installed Otherwise it reads zero IT IS NOT USED FOR THE CUT CURRENT PRESET value 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 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 RESET even during a run STORED SETTINGS CUT PROFILES This button opens a window that displays a range of valu
33. 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 Woo Output 1 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 Page50 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 BladeRunner That cord must be plugged in before the outlets can be used CAUTION there is high voltage 120VAC at the Relays and
34. isten 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 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 72 range centered between full CW and CCW rotation This limits current to 10A max Leave Dip Switch 10 set to OFF to prevent a 20A 1 sec peak cycle CandCNC Page G320X Top View Y L CEIA f
35. l port are connected the same way as the stepper version as is the DTHCII connections see DTHCII User Manual Plug for P d to THS SENSOR Inputs from PC MODULE Power and Encoder is Z Plugs for Motors Dual Switched AC HomelLimit Outlets from CODE wiring knockou OPTIONAL 5th Axis Module Right Side View Left Side View CandCNC Page O3N OQ 100 EZPLUGII Dual Wide Servo Interface Assembly 2 8 4 5 6 7 8 9 10 11 12 1 7 8 9 10 11 12 GECKO 2 EZplug Servo Rev 4 om GECKO_1 Temp e m me ce es DC NEG 2 M2 Disable MTR2_CONN MTR1 CONN Motor DC POS Motor Pos Motor Neg aiqesiq ZW eoejd ui jeduunf NO eq jsnuJ epis ey JO Jeduunf ajqesiq e qesiQ LIN eui uoneoo ZI JO LN OU u eAup JO OUJ BABY jou seop pJeo eui e ap eJou 104 enue A qnH Hoq v Sgrsu asn sngco ssed g Dau J uiejs s sixe e 10 uejs s sixe e UO exi pesn Buraq si pje e eeg uonoeuuoo snge2 JO dnjes jou peddius aie spieS dnjes aqoid duis uo J8AUp JNO luo u uA esn oj sI SIU JO UJO au Jo epis JeAup euo e qesip 0 pesn ae 9 q 8 Gld SNGED 94 ui Sseuppe enbiun e ney snui spied oAJegs naza U9 3 SgrSy Buisn suiejs s SJ030 N 0 synduj 19poou3 Snge2 ui
36. lse Frequency Cycle Jog Step Alt J Output2 Toggle 44215 0 0100 E TL trol Hi Reduced Output3 Toggle FeedHold Rewind cz Hoa ou Sto I Single 8 l ons off gl Regen JogFollow Ml Display TootPath onion LIJ Incremental THC Delay Count 0 000 gemeet U load aooaa U YQ Time Scale POWER SUPPLY CONFIGURATION po Time in int H one CPU Speed 0 00 3 4 3013 0000Mhz overRide E Temp N Volts ON Volts2 ESO H 100 FeedRate rive Temp O Amps1 EE Amps2 ON m Codes G Codes E Rst 41 B Tst 6 0 This section for display of ESP parameters Requires serial connection to ESP or ESPII Power Controllers CandCNC Page 49 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 correctly It turns the LIMITS OFF as soon as the LIMIT goes active The
37. n 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 YOU 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 or 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 sp
38. nce traveled is 3 1416 per rev of the pinion Soa direct coupled motor gives us over 3 of travel per rev 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 to 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 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 MACH please refer to the MACH 3 manual The exact tuning of the software is beyond the scope of this document Motor Tuning Screen in MACH3 Testing the BladeRunner for motor control In order to get motion and you need to have MACHS running with it out of
39. nterface The following pages will go though how to test and change any of the default settings for your specific table There are several sections of the MACH CONFIG that we will cover The access the MACH3 direct configuration menu find the TOP Menu on the screen and click the CONFIG select in the Drop Down Menu Select Native Units The selections in the CONFIG Drop Down Window DDW MotoP Tuning consists of several sections General Config Most of them are not used System Hotkeys setting up a BladeRunner Homing Limits Profile If you don t know what ToolPath a function is DO NOT change it Slave Axis unless you make a copy of Backlash your Profile and perform the Fixtures changes on it Making changes ToolTable to see what it will do is dangerous because cetain settings are critical to the full operation of UBOB Ill Config Plugins Spindle Pulleys Safe_Z Setup Save Settings A note here about configurations and MACH The config menu is a user interface to make changes to the current MACH3 PROFILE you are running Each Profile has it s own file with settings Virtually every setting is stored in that PROFILE Things like Motor Tuning Ports amp Pins and even which Screen Set it uses are stored If you make a change in one profile it DOES NOT propagate over to another profile s settings If things get really messed up you can reload from the INSTALL file off the CD but if the PROFILE name is the same then the s
40. on Wes Bios OF FONWSISSY NWO NYI Id IHH ISHIN ot Wry Ge LNIYYNI ETUI tT ui A 0 4 e 4 IIKO Y poe AUSF d319 039 TIONS C C3 2 me Sq Wide ES I0II03W00 S385 oun 19 ISM NOLLOINNOO usn SNOMVOLIIOJqdS YWT0d INN 8 YY 70019 SIUM QV37 30 S407109 Goz o 890 i i ip EP T s l SZE s eHO x O1 e e co amp 969 L i L Z 696 s uou ui suoisu uuiq Ww SA 19s Buljunow z g esf suoisuauliq JOJOW 49dd 1S 029 Jeuungsjopejg SNOISNINIG Page CandCNC FORMULA FOR CALIBRATING Steps per Unit on an axis Steps per unit in MACH Current Setting in Steps per UNIT Sc Actual Distance Traveled Dt Commanded Distance you entered Dc New Steps per Unit value Sn Sc X Dc Dt Sn Sn is in steps and will probably a decimal number Set the decimal amount to 3 decimal places CandCN C Page 69 ADDENDUM SECTION ADDED 11 15 12 For BladeRunner AlO 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
41. 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 counterproductive CandCNC Page HARDWARE DIFFERENCES for BladeRunbner SERVO system Towi Re AULT i Green RESIT Sr us ENCODER C em IK tasas nar men s wg Reeg lanoo ENCODER toooo lanoo E ee e EZPlugll Servo Drive BEIER 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 plugged in and transmit the encoder information back to the servo interface sub assembly you MUST HAVE THE ENCODER CABLES CONNECTED when a motor is powered up With no feedback to the electronics of where the motor is it will Run Away We have color 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 seria
42. power is power is OFF e LJ L DRIVE 5VDC TEMP POWER DRIVES TEST FAULT OK FAULT FAULT OFF Power Dashboard Displays status and FAULTS See 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 4 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 STATE MEANING NOTES DRIVE FAULT 1 flash pause X Drive Fault A Drive Fault indicates a shorted motor cable or a failed Motor Driver DRIVE 2 flash pause Y Drive Fault DRIVE 3 flash pause Z Drive Fault DRIVE 4 flash pause A Drive Fault DRIVE 5 flash pause 5th Drive Fault May indicate misconfigured Slave Axis Setup 5 VDC OK ON
43. r 74295 UOlUld dd 9 AHp j2eJiq xew sejnuiuJ oJy DL Usepjoeq jeipes Uui Zo QOZ NES enbJo Ul ZO Qgp snonunuo enbJo dd 0Zv XEN Wei uononpei LOL ones eip Gye yeys 1ndino OGZ ejeuey ndul pe uie o suoisueuiiq peeuaeo a i1o1lolN OA4 S 9UIEJ4 cz Jeuunyopelg yoz ul Zo gze enbJo xeed ui Zo 0G vg g Juano snonunuo UI ZO 0G enbJjo snonunuo25 004r 9GAO09 Wd Xen yeus GIL 1unouu eDue j ewes ez AOJO A OAJ9S 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 Eve
44. s Plugln Supported C amp 5000hz C 75000hz C 100khz TCP Modbus support Event Driven Serial Control Servo Serial Link Feedback Note Software must be restarted and motors retuned if kernel speed is changed CandCNC Page 55 CHECKING AXIS MOTION 4 Motor systems ial Setting 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
45. s 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 Page65 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 machine and so certain parameters have to be set based on your specific machine Engine Configuration Ports amp Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options Signal Enabled Step Pin Dir Pin Dir LowActive Step Low Ac Step Port Dir Port X Axis d 2 3 Ki x 1 1 Y Axis d 4 5 d x 1 1 Z Axis 6 7 ki x 1 A Axis d 8 9 ki x 1 I B Axis x 14 16 ki x 2 2 C Axis ar 0 0 ar ar 0 D Spindle ar 1 16 ar ar 2 2 x Note each axis has a Step and Direction pin At this point do not worry if the axis moves in the wrong dir
46. tion Step Pulse Dir Pulse Steps per In s or mm s per min insormm s sec sec 1 5us 0 5 om 59 fio l jo Cancel OK Velocity inches per Minute CandCNC Page 64 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 BladeRunner 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 The key may 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 i
47. un 5 separate independant axis not hardware slaved you have to install and setup a 2nd parallel port card in your PC and interface it through our OPTIONAL Port2 Interface Card See the addendum section for information about the Port 2 Interface THE UBOBIIII card in the drawing is located in the Top of the BaldeRunner AIO unit The PORT1 and COM1 connecors stick through the apnel on the right side of the enclosure see the photo on page tp locate the UBOB Card CandCNC Page58 ONLY USE THIS PAGE IF YOU ARE GOING TO DRIVE A 5th MOTOR FROM THE MTA150 Card or in the BladeRunner It sets up what that output B does If you want to SOFTARE slave an axis that is done in MACHS in the Axis Slaving under CONFIG s SS TES PORTZ INTERCONNECT 1 Li POWER oooNHooooooooN oooNOOOOOOOONM s 12 a z9oooooNoooooo 9000008000000 25 Bm OOO PR E Ls 9 FLT ___ o See previous n mj O page for Hardware doo 60 el RNI o o e e slaving option H ool NSION 5 Y umpers ENS um SH s0000000N 2 PS 000000m000000 E ooomoooo O l NWOOO00000NOOO Et 1 AXIS 1 0 PLUG CH DIHC m B ei J53 Duo I i m CandCNC L UBOBIII NM s e T C1
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