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FlashCut CNC

Section 10

Driver Module Upgrades

39

10.

Driver Module Upgrades

To upgrade your CNC controller such as adding a 4

th

or 5

th

axis you should install the

new drive module(s) using the following instructions.

Improper wiring can cause damage to your driver box and/or motors. Please take
care in following these instructions properly. Please refer to the drawings below for
the correct logic connectors.

1.

Set the Dip Switches to the appropriate settings for your application (default settings
pictured).

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Summary of Contents for Pro Series

Page 1: ...icro Stepping Pro Series CNC Controller Hardware Guide Midwest Office 444 Lake Cook Road Suite 22 Deerfield IL 60015 Phone 847 940 9305 Fax 847 940 9315 www flashcutcnc com Revised 11 02 2010 1998 2010 WPI Inc ...

Page 2: ......

Page 3: ...Expansion 22 JP33 Step Direction 22 JP40 Input Aux Header 23 JP50 Output Aux Header 23 JP80 Rear Panel Power 24 JP81 Rear Panel Fuse 24 JP82 Front Panel Switch 24 AXIS PLUG IN INTERFACES 24 6 DRIVE SETTINGS 26 CONFIGURING THE DRIVES 27 Selecting a Motor 27 Setting the Current 29 Setting Idle Current 29 Load Inertia 30 Step Size 30 STEP PULSE NOISE FILTERING 32 SELF TEST 33 ALARM CODES 33 7 MOTOR S...

Page 4: ...Signal Generator Board Layout 49 Connector Pin Out Table 50 POWER 52 OUTPUTS 53 INPUTS 54 CONNECTORS 55 AXIS PLUG IN INTERFACE 56 12 INTERNAL CONNECTIONS 57 CONNECTION SCHEMATIC 58 REVISION HISTORY 1 ...

Page 5: ......

Page 6: ...read all of these instructions before using the product Since automated machining is potentially dangerous please take the time to completely read through this manual and the software User s Guide to understand the operation of the electronics software and machine before cutting a part Turning Off The Controller Always turn off the CNC Controller when it is not in use ...

Page 7: ...from flying objects It is highly recommended that you build a safety shield around the entire tool envelope 5 Never place any part of your body within the tool envelope while the machine is online since unexpected machine movement can occur at any time 6 Always keep the tool envelope tidy and free of any loose objects 7 Be on alert for computer crashes at all times FlashCut CNC Inc is not responsi...

Page 8: ...functions AXIS LED s 1 2 3 4 5 Turns green when the respective axis is moving USB LED Turns yellow when connected to the host PC USB port POWER LED Turns green when the power switch is turned on POWER SWITCH Turns the unit on and off I is on and O is off If there is ever a communications error while running FlashCut CNC turn the switch off and on to reset the internal microprocessor ...

Page 9: ... of USB cable length you can use an active extension cable which comes in 4 5m lengths Note that when running an active extension cable the USB will run in Full Speed mode INPUT The connector for up to 8 input lines The most common use of the input lines is for limit or safety switches These lines are all TTL and CMOS compatible optically isolated inputs When a switch is open its input signal is h...

Page 10: ... for this non polarity sensitive connection 115 230 VAC SELECTION SWITCH This switch allows you to use an external power source of 115 or 230 VAC If your building is wired for 230VAC then simply flip the switch with a flat head screwdriver so that 230V is clearly visible If your building is wired for 115 VAC then flip the switch until 115V is clearly visible Note that severe damage can occur if yo...

Page 11: ...T GND INPUT 13 STEP AXIS 1 POWER CONNECTOR TO MOTORS The motors for axes 1 5 plug into these connectors The motor lines 1 5 are correlated to any combination of the X Y Z A and or B axes in the Motor Signal Setup menu in the FlashCut CNC software A dummy plug as installed on any unused motor connector for units with less than 5 axes Each motor connector is a Molex Mini Fit Jr 6 Pin Receptacle with...

Page 12: ...m 6 Pin Mini Fit Jr Receptacle Housing Part 39 01 2060 with Female Pins Part 39 00 0039 or 39 00 0047 Please see the section on Stepper Motor Cabling later in this manual for more information Never connect or disconnect motor cables while the power is on This will result in damage to the driver box ...

Page 13: ...FlashCut CNC Section 3 System Connections 13 3 System Connections ...

Page 14: ...4 Removing the Top Cover 14 4 Removing the Top Cover To remove the cover from the unit remove the 8 total screws located on the left and right sides of the unit There are 4 screws on either side Then lift the top cover off ...

Page 15: ...ource When JP85 shorts pins 1 and 2 OPT GND is directly connected to the Internal GND External Isolated Power For the best noise immunity connect an external 5V 24V power supply to the LED side of the optical couplers When JP84 shorts pins 2 and 3 OPT VCC gets its optically isolated power from the TB VCC When JP85 shorts pins 2 and 3 OPT GND is directly connected to the TB GND Choose only one of t...

Page 16: ...ground Mini Fit Jr Pin No Signal Mini Fit Jr Pin No Signal 1 OPT GND 9 INPUT 1 2 OPT GND 10 INPUT 2 3 OPT GND 11 INPUT 3 4 OPT GND 12 INPUT 4 5 OPT GND 13 INPUT 5 6 OPT GND 14 INPUT 6 7 OPT GND 15 INPUT 7 8 OPT GND 16 INPUT 8 Output This connector is for up to 8 output lines These lines are all compatible with TTL CMOS level outputs The Output ports are not setup to drive a 24V external system unl...

Page 17: ...his connector is a Molex Waldom Mini Fit Jr Series 10 pin receptacle part number 39 01 2100 with female pins part number 39 00 0039 or 39 00 0047 for 22 gauge or thinner wires The Molex 63811 1000 for 14 24 AWG universal or Molex 11 01 0197 Crimp Tools are recommended for installing the pins Kits containing connectors and pins are available through FlashCut CNC or an electronics distributor The ou...

Page 18: ... the Signal Generator and isolated power from an external source Both jumpers must be set on the same pair of pins either both must be on pins 1 and 2 or both must be on pins 2 and 3 Internal Power This is the most convenient option and works well for most applications but negates some of the signal isolation When JP84 shorts pins 1 and 2 OPT VCC gets its power from the Internal 5V power source Wh...

Page 19: ... OPT VCC TB GRD 5V 1 2 3 JP84 VCC JP85 GRD 3 2 1 Choose only one of the following methods to supply power 1 Connect a power source to the TB 40 screw terminal 2 Connect a power source through pins 23 and 25 of the DB 25 connector 3 Check the resistor value in RP41 to make sure it matches the voltage in TB40 TB40 Voltage RP41 Value 10 pin 9 Resistor SIP 5V 3 9k Default 12V 11k 24V 22k If you are pr...

Page 20: ...al Connections The diagram below shows the locations of the internal connectors The top of the diagram corresponds to the back side of the signal generator where the external connectors are located The small dot next to some of the connectors designates the number 1 pin position On the following diagrams the positions of the connectors will be highlighted in black Connectors JP30 JP31 JP32 JP33 ...

Page 21: ...I27 13 14 GPI6 GPI26 15 16 GPI7 GPI25 17 18 GPI8 GND 19 20 GND GPI24 21 22 GPI9 GPI23 23 24 GPI10 GPI22 25 26 GPI11 GPI21 27 28 GPI12 GPI20 29 30 GPI13 GPI19 31 32 GPI14 GPI18 33 34 GPI15 GPI17 35 36 GPI16 3 3V 37 38 3 3V GND 39 40 GND JP31 Status LEDs This is for connecting wired LEDs from a custom chassis to the 501A LED signals 5V 1 2 N C LED DIR1 3 4 LED STEP1 LED DIR2 5 6 LED STEP2 LED DIR3 7...

Page 22: ... 12 OUT1 STB OUT4 STB 13 14 OUT3 STB 5V 15 16 5V GND 17 18 GND A0 19 20 A1 DATA1 21 22 DATA2 DATA3 23 24 DATA4 DATA8 25 26 DATA7 DATA6 27 28 DATA5 7V 29 30 7V SPHOME 31 32 ENC CLK 3 3V 33 34 ENC DIR AGND 35 36 AV DAC2 37 38 DAC1 ADC1 39 40 AGND JP33 Step Direction This contains all of the step and direction signals for 5 axes of motion STEP5 1 2 ENA STEP4 3 4 DIR5 STEP3 5 6 DIR4 STEP2 7 8 DIR3 STE...

Page 23: ...nector on a custom chassis GPI1 1 2 OPT GND GPI2 3 4 OPT GND GPI3 5 6 OPT GND GPI4 7 8 OPT GND GPI5 9 10 OPT GND GPI6 11 12 OPT GND GPI7 13 14 OPT GND GPI8 15 16 OPT GND JP50 Output Aux Header This contains the same signals as the Mini Fit Jr Input Connector It is provided for the convenience of using a different input connector or an external input connector on a custom chassis GPO2 1 2 GPO1 GPO4...

Page 24: ...e current draw chart for power requirements JP81 Rear Panel Fuse This is for an optional power fuse The unit is shipped with a shunt instead of a fuse If you replace the shunt with a fuse it should be sized according to your power requirements JP82 Front Panel Switch Connect the main power switch here Axis Plug In Interfaces Axis Plug Ins JP71 JP75 ...

Page 25: ...ion JP 71 JP 72 JP 73 JP 74 JP 75 1 HV PWR High Voltage Power HV PWR HV PWR HV PWR HV PWR HV PWR 2 HV PWR High Voltage Power HV PWR HV PWR HV PWR HV PWR HV PWR 3 GND Ground GND GND GND GND GND 4 GND Ground GND GND GND GND GND 5 RxD2 Serial Com Receive RxD2 RxD2 RxD2 RxD2 RxD2 6 STATUS Status STATUS1 STATUS2 STATUS3 STATUS4 STATUS5 7 TxD2 Serial Com Transmit TxD2 TxD2 TxD2 TxD2 TxD2 8 FAULT Fault I...

Page 26: ...s Logic Connector for the Step Direction COM and Enable signals coming from the Axis Plug in connector on the Signal generator a Motor Connector for the A and B Coils of the motor a Power Connector and a group of DIP Switches for configuring the drive for your specific requirements The configuration of the DIP switches vary depending on your application ...

Page 27: ...tor providing the most power with minimum resonance To select a motor simply move the rotary switch to the letter or number that corresponds to the motor of your choice Make sure the power is off before changing this setting or damage could occur to your motor or drive If your motor is not on the list please set the switch to a selection whose rotor inertia holding torque and current are within 10...

Page 28: ...FlashCut CNC Section 6 Drive Settings 28 ...

Page 29: ...e is reduced to 70 and the heating to about 50 Two of the small switches on the front of the drive are used to set the percent of rated current that will be applied to the motor SW1 and SW2 Please set them according to the illustration below The factory default setting is 70 Setting Idle Current Motor heating and power consumption can also be reduced by lowering the motor current when it is not mo...

Page 30: ... inertia to determine the ratio then set switch 3 accordingly as shown Step Size The drive module requires a source of step pulses to command motion This may be a PLC an indexer a motion controller or another type of device The only requirement is that the device be able to produce step pulses whose frequency is in proportion to the desired motor speed and be able to smoothly ramp the step speed u...

Page 31: ...oothing that can provide smooth motion from coarse command signals If you select 200 SMOOTH or 400 SMOOTH this feature is automatically employed to provide the smoothest possible motion from a less than ideal signal source Because a command filter is used as part of the step smoothing process there will be a slight delay or lag in the motion If this delay is objectionable for your application plea...

Page 32: ...rives include a digital noise filter on the STEP and DIR inputs The default factory setting of this filter is 150 kHz which works well for most applications However as discussed in Step Size of this section if you are operating the drive module at a high number of steps revolution and at high motor speeds you will be commanding the drive at step rates above 150 kHz In such cases you should remove ...

Page 33: ...f you are having trouble getting your motor to turn you may want to try the built in self test Anytime switch 8 is moved to the ON position the drive will automatically rotate the motor back and forth two turns in each direction This feature can be used to confirm that is correctly wired selected and otherwise operational Alarm Codes In the event of a drive fault or alarm the green LED will flash ...

Page 34: ...to the driver box that you have Please refer to Motor Signal Setup section of the User s Guide for the best way to set up your drive for your software version For this drive the best signals are as follows Driver Model 8A Pro Micro Stepper 6501 X 080 M Step Pulse High Step Pulse Width 5 Min Time Between Steps 5 Direction Step Setup 5 Min Step Direction Lag 5 Enable Signal Polarity High ...

Page 35: ...and should not be connected to motor end Use Belden M 8723 CM 2PR22 Shielded Cable or equivalent Connector Molex Waldom 6 Pin Mini Fit Jr Receptacle Housing Part 39 01 2060 Female Pins Part 39 00 0039 or 39 00 0047 Motor Wiring for Other Stepper Motors If you have your own stepper motor you can use the following charts for your wiring Note that the motor wire colors will vary Molex Pin Motor Wire ...

Page 36: ...pairs and the center taps on a 6 wire motor A to A About 1 10 ohms Equal to B to B B to B About 1 10 ohms Equal to A to A A or A to B or B No Continuity A Center to A or A the resistance of A to A B Center to B or B the resistance of B to B B Center to A or A No Continuity A Center to B or B No Continuity If the A and A or the B and B are reversed the motor will spin the opposite direction This ca...

Page 37: ...oving USB LED Turns yellow when connected to the host PC USB port POWER LED Turns green when the power switch is turned on LOGIC AC INPUT This connector takes in the power from the transformer for the logic signals The AC voltage from the transformer is then converted to a DC voltage to be used for logic signals The two contacts are labeled as follows L is the hot N is the neutral MOTOR AC INPUT T...

Page 38: ...an for cooling the box When viewing the power board in the configuration above the top contact of the fan DC output is positive and the bottom contact is negative MOTOR DC OUTPUT This output sends a 40 80 VDC depending on the connection configuration DC signal to power the drive modules Power for up to 5 individually powered drive modules The contacts alternate positive and negative starting with ...

Page 39: ...install the new drive module s using the following instructions Improper wiring can cause damage to your driver box and or motors Please take care in following these instructions properly Please refer to the drawings below for the correct logic connectors 1 Set the Dip Switches to the appropriate settings for your application default settings pictured ...

Page 40: ...FlashCut CNC Section 10 Driver Module Upgrades 40 2 Mount the drive module to the driver box chassis using 2 6 32 conducting screws ...

Page 41: ...FlashCut CNC Section 10 Driver Module Upgrades 41 3 Connect the power cable from the power board into V and V on the drive making sure to note polarity ...

Page 42: ...FlashCut CNC Section 10 Driver Module Upgrades 42 4 Connect the wires from the motor receptacle to the drive module motor connector labeled B B A and A on the drive module ...

Page 43: ...FlashCut CNC Section 10 Driver Module Upgrades 43 To properly ground your motor cable shield connect Pin 2 of the motor cable directly to the base of the drive module using the 6 32 hold down screw ...

Page 44: ...FlashCut CNC Section 10 Driver Module Upgrades 44 5 Connect the step direction enable and fault lines from the drive module to the signal generator via the axis plug in interface located on the PCB ...

Page 45: ...Line 4 Output Line 2 The above schematic shows a typical connection of one solid state relay controlled by output line 1 of the Signal Generator A typical load would be a spindle a vacuum a laser etc In this example the solid state relay used is a Continental Industries model S505 0SJ610 000 It takes a 3 to 32VDC input and has an output of 24 330VAC Each of the output signals has a 22 ohm resistor...

Page 46: ... A DB25 Pin8 DB25 Pin7 DB25 Pin6 DB25 Pin5 DB25 Pin18 DB25 Pin17 DB25 Pin16 DB25 Pin15 OPT GND OPT GND NC NO U42 OPT_VCC RP41 GPI0 GPI1 GPI2 GPI3 820 PS2501L 4 IN0 IN1 IN2 IN3 GPI4 GPI5 GPI6 GPI7 PS2501L 4 U41 VCC IN4 IN5 IN6 2 7K 8 1 2 3 6 4 5 7 RP42 IN7 DB25 PIN22 DB25 PIN23 DB25 PIN24 DB25 PIN25 6 2 1 4 3 5 10 8 7 9 TB40 OPT GRD TB VCC OPT VCC TB GRD 5V 1 2 3 JP84 VCC JP85 GRD 1 2 3 2 1 9 10 ...

Page 47: ... A DB25 Pin8 DB25 Pin7 DB25 Pin6 DB25 Pin5 DB25 Pin18 DB25 Pin17 DB25 Pin16 DB25 Pin15 OPT GND OPT GND NC NO U42 OPT_VCC RP41 GPI0 GPI1 GPI2 GPI3 820 PS2501L 4 IN0 IN1 IN2 IN3 GPI4 GPI5 GPI6 GPI7 PS2501L 4 U41 VCC IN4 IN5 IN6 2 7K 8 1 2 3 6 4 5 7 RP42 IN7 DB25 PIN22 DB25 PIN23 DB25 PIN24 DB25 PIN25 6 2 1 4 3 5 10 8 7 9 TB40 OPT GRD TB VCC OPT VCC TB GRD 5V 1 2 3 JP84 VCC JP85 GRD 1 2 3 2 1 9 10 ...

Page 48: ...so that you can change the value if needed for your application The input lines are all optically isolated In this example JP84 and JP85 are shorted using the internal power to source the external side of the optical couplers However for the best isolation JP84 and JP85 should be open and power should be provided through pins 23 and 25 of the DB25 Motor Signal connector Input lines 1 4 and 5 8 are...

Page 49: ...FlashCut CNC Section 11 Appendix 49 Signal Generator Board Layout ...

Page 50: ... 11 12 GPI5 GPI27 13 14 GPI6 GPI26 15 16 GPI7 GPI25 17 18 GPI8 GND 19 20 GND GPI24 21 22 GPI9 GPI23 23 24 GPI10 GPI22 25 26 GPI11 GPI21 27 28 GPI12 GPI20 29 30 GPI13 GPI19 31 32 GPI14 GPI18 33 34 GPI15 GPI17 35 36 GPI16 3 3V 37 38 3 3V GND 39 40 GND JP31 STATUS LEDS 2 X 8 2MM SPACING 5V 1 2 N C LED DIR1 3 4 LED STEP1 LED DIR2 5 6 LED STEP2 LED DIR3 7 8 LED STEP3 LED DIR4 9 10 LED STEP4 LED DIR5 11...

Page 51: ...ATED BY A SMALL WHITE DOT PRINTED ON THE PCB JP83 DB TO USB GROUND ALWAYS LEAVE PIN 1 JUMPED TO PIN 2 PIN3 JUMPED TO PIN 4 AND PIN 5 JUMPED TO PIN 6 UNLESS DIRECTED OTHERWISE BY FLASHCUT TECH SUPPORT JP84 JP85 INPUT POWER SELECT SHOULD BE JUMPERED THE SAME WAY 1 2 INPUTS DRIVEN BY ON BOARD VCC 2 3 INPUTS BIASED BY VOLTAGE ON TB40 JP86 USB GROUND SHOULD BE JUMPED TO PULL USB GROUND TO CHASSIS GROUN...

Page 52: ...2 UF C83 22 UF 1 2 JP80 D80 TVS 26V 400W 1 2 JP81 FUSE POWER 1 2 JP82 SWITCH 7V 3 3V VIN 3 5 0 2 5 0 4 GND 1 U80 LM1085IS 5 0 FWB80 GBPC6005 1 2 TB40 MKDSN TB VCC TB GND OPT VCC OPT GND NOTE 1 FB80 434 6H 901 1 2 3 JP84 1 2 3 JP85 VIN 3 3 3 2 3 3 4 GND 1 U81 LM1085IS 3 3 NOTE 1 UPPER RIGHT SCREW MOUNT HOLE IS CHASSIS FOR U80 5734 FOR U81 5734 HEATSINK HEATSINK C80 330 UF C86 1 UF C84 330 UF C81 1 ...

Page 53: ...AT 24 MA THRU 22 OHMS VOH 3 8 V VOL 0 97 V VBUS OK PANEL LED DRIVER 5V OK VBUS OK AXIS1 AXIS2 AXIS3 AXIS4 1 2 CR51 GRN 1 2 CR52 GRN 1 2 CR53 GRN 1 2 CR54 GRN 1 2 CR57 YEL 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 RP51 22 OHM 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 RP54 470 5V AXIS5 1 2 CR55 GRN CR61 ORG FOR DEBUG OUT ENA LED ST1 LED ST2 LED ST3 LED ST5 LED ST4 SEE MAKO IF SHEET FOR DIR LED DRIVE U52B ...

Page 54: ...x 54 Inputs GPI0 GPI1 GPI2 GPI3 GPI4 GPI5 GPI6 GPI7 PS 2501L 4 U42 PS 2501L 4 U41 O P T V C C 3 3 V 1 2 3 4 5 6 7 8 9 10 820 R P41 S OC KE TED 1 2 3 4 5 6 7 8 1 6 15 14 13 12 11 10 9 2 7K R P42 IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 ...

Page 55: ...X PAN SION GPI0 GPI1 GPI2 GPI3 GPI4 GPI5 GPI6 GPI7 1 2 3 4 5 6 7 8 9 1 0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 He a de r 2 0X2 JP 30 S TATU S 6 FAU LT6 IN 8 IN 9 IN 11 IN 12 IN 13 IN 14 IN 15 IN 16 IN 17 IN 18 IN 19 IN 20 IN 21 IN 22 IN 23 3 3 V 1 2 3 4 5 6 7 8 9 1 0 11 12 13 14 15 16 HDR 8X 2 JP31 S TATU S LE DS G EM VISION LED DR 4 LED DR 5 LED...

Page 56: ... D 6 4 0 Q 6 9 D 7 3 8 Q 7 11 D 8 3 7 Q 8 1 2 74A C T1637 3DL U 52A S M 0 S M 1 C S1 C S2 C S3 C S4 S CO M 1 S CO M 2 S CO M 3 S CO M 4 C S5 S CO M 5 S TP 5 S T5 SCOM STB ILC S S TB O E 1 L E 4 8 D 1 4 7 Q 1 2 D 2 4 6 Q 2 3 D 3 4 4 Q 3 5 D 4 4 3 Q 4 6 D 5 4 1 Q 5 8 D 6 4 0 Q 6 9 D 7 3 8 Q 7 11 D 8 3 7 Q 8 1 2 74A C T1637 3DL U 51A DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 O E 2 4 LE ...

Page 57: ...FlashCut CNC Section 12 Internal Connections 57 12 Internal Connections ...

Page 58: ...rive JP83 JP33 JP50 JP40 JP71 JP72 JP73 JP74 JP75 JP85 JP84 JP30 JP31 JP32 JP80 JP81 JP82 JP23 TB40 TB80 Signal Generator P203 P108 P204 P103 P201 P101 C101 LED s Power Board Switch Voltage Selector 1 1A 1B 1A 1 2 2 2A 2A 2B GND N L AC Inlet To Fan 1 2 3 4 6 5 1 2 3 4 6 5 1 2 3 4 6 5 Axis 1 Axis 2 Axis 3 Axis 1 Axis 2 Axis 3 JP53 Relay Output ...

Page 59: ...t CNC Section 12 Internal Connections 1 Revision History Revision Date Description of Revision A 2 26 10 Initial write up B 5 3 10 1st Edit C 5 7 10 1st Revision D 8 17 10 2nd Revision E 11 03 10 3rd Revision ...

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