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Table of Contents

1. Introduction

1.1

System Overview

1.2

AJAX Components

1.3

Installer Supplied Components

1.4

Optional Supplied Components

2. Motion Control Card (CPU10)

3. Control Pendant

4. Software

5. System Schematic

6. Electrical Panel Layout

7. Servo Drive (DC3IO)

8. Motor and Encoder Cables

8.1

Motor and Encoder Cable Installation

8.2

Encoder Check

9. E-Stop Circuit

10. Limit Switches

11. Motor Power

11.1

Troubleshooting

12. Lube

13. Coolant Control

14. Spindle Speed

15. Other Outputs

16. Digitizing/Probe

Revisions on 03/01/05

\Manuals\AJAX.pmd

Summary of Contents for CNC10

Page 1: ...1 Ajax CNC CNC10 Installation Manual Rev 050301 2005 AjaxCNC Milesburg PA 16853...

Page 2: ...2...

Page 3: ...Control Pendant 4 Software 5 SystemSchematic 6 ElectricalPanelLayout 7 Servo Drive DC3IO 8 Motor and Encoder Cables 8 1 Motor and Encoder Cable Installation 8 2 Encoder Check 9 E Stop Circuit 10 Limi...

Page 4: ...1 AJAX System Overview 1 1 System Overview The Ajax CNC system is based on two main printed circuit boards and an optional control pendant Figure 1 shows 1 the CPU10 motion control card and 2 the DC3...

Page 5: ...supplied components Axis motors a 17in lb 29in lb and 40in lb DC brush motors with encoders areavailablefromAjaxCNC com b Pre wired motor cables are available from AjaxCNC com DC Power Supply consist...

Page 6: ...ARD RJ45 USB1 USB2 DB25F COM1 DB9M VGA DB15HD MIDI DB15F AUDIO IN OUT MIC SERVO PC N C N C 2 CPU10 Motion Control Card The CPU10 motion control card is an PCI PC interface card The CPU10 card accepts...

Page 7: ...cket Installation Install the backpanel connector bracket into the PC backpanel Connect the internal encoder ribbon cables to their respective axes on the CPU10 before plugging into the PCI slot Revis...

Page 8: ...Stop circuit hookup Red and Blue wires from the pendant E Stop button Revisions on 03 01 05 Manuals AJAX pmd Figure 4 Control Pendant Cable Hookup K K K K K Plug In CNC PC Encoder Control Panel Brack...

Page 9: ...It is suggested that the demo not be entered until the comple tion of the installation to take full advantage of the 10 day period Note that after software installation it is normal to have errors di...

Page 10: ...ery kit The schematic can also be found as an AutoCAD dwg file on the Ajax CD that came with your kit along with several other smaller schematics They are listed below for your reference Also provided...

Page 11: ...VDC OUT DRV 11 OUT DRV 10 OUT DRV 9 OUT DRV 8 OUT DRV 7 OUT DRV 6 OUT DRV 5 AUX OUTPUTS 1 H4 OUT DRV 39 OUT DRV 59 OUT DRV 60 OUT DRV 61 OUT DRV 62 SPARE DRV 5VDC 5VDC AUX OUTPUTS 2 OUT DRV 31 OUT DRV...

Page 12: ...into the X Y and Z encoder sockets on the PC s back panel Once again pay close attention to matching up each axis with its corresponding loca tion Wildly erratic motor motion will result if encoder a...

Page 13: ...tripped by pushing the E Stop button by a Servo Drive fault orby an Inverter fault 9 1 Blue Loop Installation The blue loop consists of two blue wires on the Intermediate Control Pendant cable These t...

Page 14: ...ne at powerup A typical Limit switch hookup is shown in the diagram below Figure 10 2 Connect each Limit switch on the X Y and Z axis to it s respective pin on H14 on the DC3IO as shown in the schemat...

Page 15: ...ors then a suitable transformer must replace the 83 VAC secondary winding transformer referred to in the Ajax CNC examples Do not attempt to apply voltages above the servo motor s maximum rating of 14...

Page 16: ...faulty Strange sounds or rough PID parameters not correct Run autotune swap encoder motion encoder problem or motor with a known good unit to problem locate problem source 11 Motor Power 11 Servo Moto...

Page 17: ...ly for the lube pump should also be connected to H10 as shown in the dia gram and on the schematic After the lube pump is installed you must connect the Low Lube warning circuit Connect the pump alarm...

Page 18: ...ed to the Reversing Contactor coils as shown on the schematic Terminal 2 on the 24 VAC supply must be connected to the Spin ENCOM pin on H5 as in the schematic Terminal 1 on the 24 VAC supply must the...

Page 19: ...19 Figure 14 1 Spindle Inverter Control Diagram 14 7 Spindle Inverter Fault Input Refer to yourAjax CNC schematic...

Page 20: ...Manuals AJAX pmd 14 8 Spindle Hi Low Range Refer to your Ajax CNC schematic and Hi Low schematic found on the supplimental CD for wiring details if your ma chine is equipped with a Hi Low gear range...

Page 21: ...y used for spindle encoder input Set P35 4 when connecting encoder cable to the 5th axis encoder input as per the Ajax CNC drawing P78 Spindle speed display Settings 0 Displays programmed spindle spee...

Page 22: ...T DRV 32 OUT DRV 31 OUT DRV 29 H6 OUT DRV 8 AUX OUTPUTS 1 OUT DRV 9 OUT DRV 10 OUT DRV 11 5VDC 5VDC OUT DRV 5 OUT DRV 6 OUT DRV 7 OUT DRV 1 H7 DC3IO SERVO DRIVE AND PLC CONNECTOR H4 H6 AND H7 5VDC REL...

Page 23: ...23 Figure 15 3 Ajax Dual Relay Board Revisions on 03 01 05 Manuals AJAX pmd Any H10 output driver DC3IO Any Output Driver...

Page 24: ...Visit our web site for free downloads of other PLC programs for specific machines www ajaxcnc com Keep in mind that just because a standard M code is labeled for a certain function that does not mean...

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