Table of Contents
Summary of Contents for Flashcut CNC Pro Series
- Page 1 8 Amp Micro 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.
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Page 3: Table Of Contents
Table of Contents GETTING STARTED ............................6 ..............................6 BOUT ANUAL ..........................6 URNING ONTROLLER ..........................7 AFETY AND SAGE UIDELINES STEPPER CNC CONTROLLER ........................8 ................................8 RONT ANEL ................................9 ANEL SYSTEM CONNECTIONS ..........................13 REMOVING THE TOP COVER ........................14 SIGNAL GENERATOR .......................... - Page 4 Signal Generator Board Layout ......................... 49 ......................50 Connector Pin-Out Table ..................................52 OWER .................................. 53 UTPUTS ..................................54 NPUTS ................................55 ONNECTORS ............................56 NTERFACE INTERNAL CONNECTIONS ........................57 ............................58 ONNECTION CHEMATIC ..............................1 EVISION ISTORY...
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Page 6: Getting Started
Getting Started 1. Getting Started About This Manual FlashCut CNC is a unique application involving hardware and software. We recommend that you 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,... -
Page 7: Safety And Usage Guidelines
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 responsible for the safe installation and use of this product. You and only you are responsible for the safety of yourself and others during the operation of your CNC machine tool. -
Page 8: Stepper Cnc Controller
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: Rear Panel
FlashCut CNC Section 2 Stepper CNC Controller Rear Panel The rear panel has connectors for input and output signals as described below. POWER INLET – Receptacle for the power supply. The unit is shipped with a standard grounded power cable for use with a 115VAC wall outlet. - Page 10 115 selected and your building is wired for 230VAC. DB-25 CONNECTOR FOR MOTOR SIGNALS – This uses a DB-25 Cable to send step and direction signals from the FlashCut CNC Signal Generator to an additional external drive box. The pin assignments are as follows:...
- Page 11 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.
- Page 12 FlashCut CNC Section 2 Stepper CNC Controller Never connect or disconnect motor cables while the power is on. This will result in damage to the driver box. The mating motor cable connector is a Molex - Waldom 6-Pin Mini-Fit Jr. Receptacle Housing Part # 39-01-2060 with Female Pins Part # 39-00-0039 or 39-00-0047.
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Page 13: System Connections
FlashCut CNC Section 3 System Connections 3. System Connections... -
Page 14: Removing The Top Cover
FlashCut CNC Section 4 Removing the Top Cover 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: Signal Generator
(NO) input lines using FlashCut CNC software. Please refer to the FlashCut CNC User’s Guide under “Input Line Settings” for further information. In the FlashCut CNC software, the Input Line Status dialog displays "OPEN" for a high-level input voltage, or open switch, and "CLOSED" for a low-level input voltage or closed switch. -
Page 16: Output
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 input lines as seen from the back of the box are arranged as follows (all connections denoted by “OPT-GND”... -
Page 17: Jumper Settings
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 output lines as seen from the back of the box are arranged as follows: 10 9 8 7 6 ◦... -
Page 18: Jp83 - Db To Usb Ground
FlashCut CNC Section 5 Signal Generator JP83 – DB to USB Ground This connects the DB 25 ground to the USB ground. By default pins 1 and 2, 3 and 4, and 5 and 6 are jumped as pairs JP84/JP85 – Input Power Select These two jumpers enable you to choose between the internal power of the Signal Generator and isolated power from an external source. -
Page 19: Jp 86 - Usb To Chassis Ground
FlashCut CNC Section 5 Signal Generator JP84 OPT-VCC DB25 PIN22 DB25 PIN23 TB40 TB-VCC TB-GRD DB25 PIN25 OPT-GRD DB25 PIN24 JP85 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. -
Page 20: Jp 87 - Internal Signal To Chassis Ground
FlashCut CNC Section 5 Signal Generator JP 87 – Internal Signal to Chassis Ground This jumper connects the internal signal ground to the chassis ground of the Signal Generator when jumped. Internal 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). -
Page 21: Jp30 - Auxiliary Inputs
FlashCut CNC Section 5 Signal Generator JP30 – Auxiliary Inputs +3.3V +3.3V This contains all of the Input GPI32 GPI1 Signals 1-8 which come out of GPI31 GPI2 the 501A board and Input GPI30 GPI3 Signals 9-32 which come out... -
Page 22: Jp32 - Bus Expansion
FlashCut CNC Section 5 Signal Generator JP32 – Bus Expansion +3.3V This contains signal and STATUS6 address lines for the I/O TXD2 FAULT6 Expansion board. RXD2 AUX1-STB OUT-ENA AUX2-STB OUT2-STB OUT1-STB OUT4-STB OUT3-STB DATA1 DATA2 DATA3 DATA4 DATA8 DATA7 DATA6... -
Page 23: Jp40 - Input Aux Header
FlashCut CNC Section 5 Signal Generator Connectors JP40, JP50 JP40 – Input Aux Header GPI1 OPT-GND This contains the same GPI2 OPT-GND signals as the Mini-Fit Jr. GPI3 OPT-GND Input Connector. It is GPI4 OPT-GND provided for the convenience GPI5... -
Page 24: Jp80 - Rear Panel Power
FlashCut CNC Section 5 Signal Generator Connectors JP80, JP81, JP82 JP80 – Rear Panel Power Connect the main power here. It can be 8.5V – 16V DC or AC. See current draw chart for power requirements. JP81 – Rear Panel Fuse This is for an optional power fuse. - Page 25 FlashCut CNC Section 5 Signal Generator The Axis plug-in interfaces are used to add additional functions to the main signal generator board. For example, a stepper drive plug-in card or cable will enable you to drive a stepper motor directly from the signal generator box.
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Page 26: Drive Settings
FlashCut CNC Section 6 Drive Settings 6. Drive Settings Inside of the controller box are the individual drive modules for axes 1-5. Each drive module has 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. -
Page 27: Configuring The Drives
FlashCut CNC Section 6 Drive Settings Configuring the Drives Selecting a Motor The drives are optimized for use with selected variety of stepper motors. Each setting matches the current and inertia of a given motor 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. - Page 28 FlashCut CNC Section 6 Drive Settings...
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Page 29: Setting The Current
FlashCut CNC Section 6 Drive Settings Setting the Current The maximum current for the motor you have selected is set automatically when you set the rotary switch. But you may want to reduce the current to save power or lower motor temperature. This is important if the motor is not mounted to a surface that will help it dissipate heat or if the ambient temperature is expected to be high. -
Page 30: Load Inertia
FlashCut CNC Section 6 Drive Settings Load Inertia The drives include anti-resonance and electronic damping features which greatly improve motor performance. To perform optimally, the drive must understand the electromechanical characteristics of the motor and load. Most of this is done automatically when you select the motor by setting the rotary switch. - Page 31 FlashCut CNC Section 6 Drive Settings 100,000 steps/sec.Six different settings are provided in the drive module, as shown in the table below. Please choose the one that best matches the capabilities for your system. At lower step resolutions such as 200 steps/revolution (full step) and 400...
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Page 32: Step Pulse Noise Filtering
FlashCut CNC Section 6 Drive Settings Step Pulse Noise Filtering Electrical noise can affect the STEP signal in a negative way, causing the drive to think that one step pulse is two or more pulses. This results in extra motion and inaccurate motor and load positioning. To combat this problem the drives include a digital noise filter on the STEP and DIR inputs. -
Page 33: Self Test
FlashCut CNC Section 6 Drive Settings Your maximum pulse rate will be the highest motor speed times the steps/revolution. For example, 40 revolutions/second at 20,000 steps/revolution is 40 X 20,000 = 800 kHz. Please consider this when deciding if you must increase the filter frequency,... -
Page 34: Motor Signal Settings
Motor Signal Settings 7. Motor Signal Settings The motor settings in the Motor Signal Setup Screen in the FlashCut CNC software need to be properly set according 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. -
Page 35: Stepper Motor Cabling
FlashCut CNC Section 8 Stepper Motor Cabling 8. Stepper Motor Cabling Motor Cable - 2 Twisted pair (one pair for A coil and one pair for B Coil) 22 gauge and shielded (18 gauge for 6A motors). Shield is only connected to noted pin on Molex- Waldom connector and should not be connected to motor end. - Page 36 No Continuity If the A and A~ or the B and B~ are reversed, the motor will spin the opposite direction. This can easily be corrected by changing the motor polarity in the Setup…Motor Settings menu in the FlashCut CNC software.
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Page 37: Power Board
FlashCut CNC Section 9 Power Board 9. Power Board The function of the Power Board is to supply DC voltage to the drive modules as well as to the cooling fan and logic signals to the Signal Generator. The power enters the board in the form AC voltage from a transformer;... - Page 38 FlashCut CNC Section 9 Power Board modules. The three contacts are labeled as follows: R is the reserve, L is the hot, N is the neutral. The reserve and the hot may be switched to vary the voltage. For example if R is red and L is purple the resulting DC voltage is approximately 67 VDC, where if R is purple and L is red the resulting DC voltage is approximately 80 VDC.
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Page 39: Driver Module Upgrades
FlashCut CNC Section 10 Driver Module Upgrades Driver Module Upgrades To upgrade your CNC controller such as adding a 4 or 5 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. - Page 40 FlashCut CNC Section 10 Driver Module Upgrades Mount the drive module to the driver box chassis using (2) 6-32 conducting screws.
- Page 41 FlashCut CNC Section 10 Driver Module Upgrades 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 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 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 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.
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Page 45: Appendix
FlashCut CNC Section 11 Appendix Appendix Sample Wiring Diagrams Typical Output Line Circuit Signal Generator M odel 501A L o a d O u tp u t1 Fu s e R 51 U50A GPO0 Output Line 1 GPO1 Output Line 2... -
Page 46: Typical Input Line Circuit - Internal Power
FlashCut CNC Section 11 Appendix Typical Input Line Circuit – Internal Power S ig n a l G e n e ra to r M o d e l 5 0 1 A JP 84 V C C + 5V... -
Page 47: Typical Input Line Circuit - External Power
FlashCut CNC Section 11 Appendix Typical Input Line Circuit – External Power S ig n a l G e n e ra to r M o d e l 5 0 1 A J P 8 4 V C C... - Page 48 23 and 25 of the DB25 Motor Signal connector. Input lines 1-4 and 5- 8 are internally connected to pins 15-18 and 5-8 respectively of the DB25 Motor Signal connector. Note that the FlashCut CNC limit switch kit has the same wiring as shown in this example.
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Page 49: Signal Generator Board Layout
FlashCut CNC Section 11 Appendix Signal Generator Board Layout... -
Page 50: Connector Pin-Out Table
FlashCut CNC Section 11 Appendix LED-AUX LED-USB Connector Pin-Out Table LED-PWR INTERNAL CONNECTORS (ORANGE) EXTERNAL CONNECTORS (RED) INTERNAL CONNECTORS (ORANGE) PIN 1 OF ALL HEADERS IS INDICATED CON1: STANDARD USB TYPE-A BY A SMALL WHITE DOT PRINTED ON JP32 – BUS EXPANSION THE PCB. - Page 51 FlashCut CNC Section 11 Appendix INTERNAL CONNECTORS (ORANGE) TERMINAL BLOCKS (GREEN) CONFIGURATION JUMPERS (BLUE) JP40 – INPUT AUX HEADER TB40: ISOLATED INPUT POWER 2 X 8 - 2MM SPACING PIN 1 OF ALL JUMPERS IS INDICATED BY VOLTAGE APPLIED HERE BIASES...
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Page 52: Power
FlashCut CNC Section 11 Appendix Power SYSTEM GROUNDING OPTIONS UPPER RIGHT SCREW MOUNT HOLE IS CHASSIS USBSHIELD JP86 0.001 UF OPT-VCC 24-40 V AT UP TO 10 A FOR FUNCTION SLOTS POWER JUMPERS CHASSIS TB80 TB40 HV-PWR HV-PWR TB-VCC JP84... -
Page 53: Outputs
FlashCut CNC Section 11 Appendix Outputs U50A RP51 DATA7 GPO7 DATA6 GPO6 DATA5 GPO5 DATA4 GPO4 DATA3 GPO3 DATA2 GPO2 DATA1 GPO1 DATA0 GPO0 LO-SIDE OUT1 RELAY DRIVE LO-SIDE OUT0 24V 300MA OUT1-STB 5-24V RAIL 22 OHM OUT-ENA SN75477D 74ACT16373DL JP53 VOH = 4.3 V... -
Page 54: Inputs
FlashCut CNC Section 11 Appendix Inputs PS 2501L-4 U 4 1 IN 7 GPI7 IN 6 GPI6 IN 5 O P T-V C C +3 .3 V R P4 2 GPI5 R P4 1 IN 4 GPI4 PS 2501L-4 U 4 2... -
Page 55: Connectors
FlashCut CNC Section 11 Appendix Connectors IN PU T A U X H EAD ER +5 V S TAT U S LE D S (G E M VISION ) JP4 0 C ON 4 JP31 G PI0 G PI0 G PI1... -
Page 56: Axis Plug-In Interface
FlashCut CNC Section 11 Appendix Axis Plug-In Interface R P5 2 U 51A 74A C T 16 37 3D L JP71 M A KO -1 D ATA 7 S M 1 H V-P W R H V-P W R H V-P W R... -
Page 57: Internal Connections
FlashCut CNC Section 12 Internal Connections Internal Connections... -
Page 58: Connection Schematic
FlashCut CNC Section 12 Internal Connections Connection Schematic 8 Amp Microstepping Drive 8 Amp Microstepping Drive 8 Amp Microstepping Drive Axis 2 Axis 3 Axis 1 Axis 1 Switch Axis 2 Voltage Inlet Axis 3 Selector JP84 JP31 JP82 JP81... -
Page 59: Revision History
FlashCut CNC Section 12 Internal Connections Revision History Revision Date Description of Revision 2/26/10 Initial write up 5/3/10 Edit 5/7/10 Revision 8/17/10 Revision 11/03/10 Revision...