MachBob2 (MB2) Owner Instruction manual. Doc E1.2 (22/03/59) Page 1

Transcription

1 MachBob2 (MB2) Owner Instruction manual Doc E1.2 (22/03/59) Page 1

2 Introduction It is known that the environment in the industry often have interference from electrical power such as motors, welding machines, magnetic contactor, etc. These signals interfere personal computer and control board. Bringing personal computer to this environment is a challenge. We can improve the environment by placing the devices in the control cabinet in the correct manner. Including installing noise reduction, such as installing Noise filter, Isolated transformer, etc. However, using computers and control board designed for industrial applications is more important. MachBob2 (MB2) is designed for industrial applications. MB2 is designed to work with ESS the excellent motion controller for Mach3 and Mach4. Specification and Features With ESS, Ethernet connection helps controller and drives located away from PC and has more noise resistant than USB and parallel port connection. Run on Mach3 / Mach4 with Windows XP, Win7, Win8 both 32 and 64 bit, on both desktop and notebook computers. New! Utilizes All 3 ports of ESS. New! Motion command signal can be selected between Pulse/Sign, CW/CCW, and Quadrature. Frequency can be selected from 32 khz to 4 MHz. New! Differential line driver for motion signals makes a longer wiring with more resistant to interference when comparing to TTL open end. New! Single 24Vdc Power supply is needed. On the board consist of 5Vdc isolate and nonisolate dc2dc converter, thus saving installation space and wiring. New! OSSD outputs and safety circuit are implemented. When a peripheral device such as servo motor drive and/or spindle VFD causes alarm. Safety Circuit will disengage OSSD output. This method is used in big CNC machine to cut power out off the drives. New! LED status for all inputs and outputs including motion control signals. Makes it easy to diagnose the problem. Isolated power and ground between PC, ESS, I/O, which eliminates crossover noise and ground loop problem. New! Polarity and over voltage protection (in conjunction with fuse) for 24Vdc power supply. AnaSpeed circuit is implemented - the circuit is isolated from MB2 itself, But be a part of VFD inverter and acts as a digital VR. High voltage noise of inverter cannot interfere through this connection. A charge-pump signal is provided. This helps users to form a safety interlock condition among controller and devices. 22 isolated input points, consist of 17 points of NPN and 5 points of PNP type. 14 NPN isolated output points, sinks current up to 100mA for each channel (up to 500 ma per group). 2 relay, with both NO, NC contact. Spring terminal for quicker connecting and disconnecting cable and resistant to vibration. No more screws loose and tightening forgotten. Page 2

3 Precaution Take static discharge before touching any part of ESS/MB2. Grounding your body by wearing grounding strap or frequent touching the metal chassis of earthed to release electrostatics. Make sure that no high voltage leak from solder iron when soldering solder-bridge the safe way is to unplug solder iron off the power socket when it builds up enough heat for melting lead solder. Hi voltage leaking of most cheap solder irons can potentially damage the integrated circuit (IC) on MB2 board. Beware of Fragile, do not drop electronics board. Heat could build up if many of inputs and outputs are on at same time. In some circumstances a cooling fan is needed to ventilate heat to the ambient air. Page 3

4 L L L L L L L L L L L L L L Quick Reference 24Vdc Drive Drive (b)single end connection (a)differential connection *Output can sink current up to 100mA and up to 500mA per group of 8 pins Analog vi Foward VFD Inverter Power Supply 24Vdc Ports and Pins meaning X110 = input, port 1, pin 10 Y301 = output, port 3, pin 01 Shrinkage part Figure 1 MB2 Overview Connection Port1 (output) Port2 (Pins 2-9 as input) Port3 (Pins 2-9 as output) Pin I/O Term Name Description Pin I/O Term Name Description Pin I/O Term Name Description 1 O SPD Sink output 1 O NO1 Relay 1 O Y301 Sink output 2 O XS Axis step 2 I - OSSD feedback 2 O Y302 Sink output 3 O XD Axis direction 3 I X203 NPN input 3 O Y303 Sink output 4 O YS Axis step 4 I X204 NPN input 4 O Y304 Sink output 5 O YD Axis direction 5 I X205 NPN input 5 O Y305 Sink output 6 O ZS Axis step 6 I X206 NPN input 6 O Y306 Sink output 7 O ZD Axis direction 7 I X207 NPN input 7 O Y307 Sink output 8 O AS Axis step 8 I X208 NPN input 8 O Y308 Sink output 9 O AD Axis direction 9 I X209 NPN input 9 O Y309 Sink output 10 I X110 NPN input 10 I X210 NPN input 10 I X310 PNP input 11 I X111 NPN input 11 I X211 NPN input 11 I X311 PNP input 12 I X112 NPN input 12 I X212 NPN input 12 I X312 PNP input 13 I X113 NPN input 13 I X213 NPN input 13 I X313 PNP input 14 O CP ChargePump 14 O NO2 Relay 14 O Y314 Sink output 15 I X115 NPN input 15 I X215 NPN input 15 I X315 PNP input 16 O BS Axis step 16 O CS Axis step 16 O Y316 Sink output 17 O BD Axis direction 17 O CD Axis direction 17 O AO Analog output Figure 2 Summary Tables for Ports and Pins Quick Reference is a summary for experience users. Figure 1 is a shrinkage view of MB2 board. It shows a connection of inputs/outputs, power supply, analog output for VFD and axis signals including differential and single end connection. Suggest that you should try figure (a) first, the differential connections are more noise resistant than single end connection, figure (b) Figure 2 is summary table of ports and pins reference number. For example X110 meaning X is input, first digit is port number, last 2 digits is pin number. Precaution, Heat could build up if using many of inputs and outputs. In some circumstances a cooling fan is needed to ventilate heat to the ambient air. Page 4

5 MB2 Layout AWG 8 9mm Figure 3 MB2 Board Layout Input (CN1) Input terminals, consist of 18 channels of NPN type and 5 channels of PNP type Axis (CN2) Axis signal terminals, consist of 6 axes, naming X, Y, Z, A, B, C Output (CN6) Output terminals, consist of 14 NPN sink outputs, Analog signal, 2 Relay s NO/NC and inlet for 24Vdc power supply LPT1-3 (CN3-5) Connectors for ESS JP1 Charge Pump override RJ-45 Communication connector, part of ESS board Page 5

6 ESS and MB2 piggyback MB2 Connection Diagram Figure 4 Connection Diagram Page 6

7 Hardware Connecting The SmoothStepper to Your PC This part is taken from The best way to connect your ESS to your PC is to use the Direct Connect method: hook the Ethernet cable directly from your ESS to the network adapter in your PC. This will make trouble shooting easier since there are no switches or routers between the ESS and your PC. (A switch should be fine since it only operates in the lower 3 layers of the TCP/IP stack, but why add extra equipment if you don't need it. A router should be fine if you only have your ESS and PC connected to it, but this will require more work to configure and setup. As a result we highly recommend the direct connection, which is what the SCU [System Configuration Utility] expects.) If you don't have an Ethernet Adapter on your PC, we recommend using a a PCI or PCI Express Ethernet Adapter -OR- a USB 2.0 or USB 3.0 Ethernet Adapter. Quite a few people use these alternatives successfully, including myself. We STRONGLY discourage using a wireless connection to communicate with your ESS. There can be much more latency or delay involved with wireless communications, along with a much higher risk of dropped packets. The ESS needs a fast, stable, and consistent link to your PC. Many people use a second Ethernet connection or their wireless connection on the PC so they may easily connect to the internet, which is fine. While you are running Mach and your CNC system, we recommend that you refrain from browsing the internet, gaming or streaming music or videos. This can cause your computer to take too much time away from Mach which could cause lost communications with your ESS (which can ruin your project). We also recommend that you disable power saving options (monitor sleep and power off timers, hard drive sleep timers, and computer sleep timers); these have been know to cause lost communications with your ESS. We also recommend that you set Windows Update to notify you that there are updates available instead of automatically installing them on its own. We also know of cases where antivirus and anti-malware software have caused problems. We recommend that you disable them while you are running Mach, IF your PC is not connected to the internet. Note that you do not need to assign a static IP address to your computer if you program the ESS to use an address that is in the same subnet as your computer. The subnet is the same if the first 3 groups of numbers in the IP addresses are the same. Quite often Internet routers will assign addresses in the x or x ranges. If you wish to use a DHCP server for your Page 7

8 computer, you can do that but the ESS still needs to use a static IP address in the same subnet. A direct connection to the ESS is the preferred way to go because there is no question as to whether there is enough bandwidth available to run your machine reliably. We STRONGLY RECOMMEND THAT YOU DO NOT hook your ESS up to the same Ehternet adapter that you connect to the Internet with. There is no telling how much CPU and Ethernet bandwidth is being used up by other applications or other devices on the network. It is therefore officially discouraged. You are on your own if you wish to mix the Internet with your CNC data. However, if you wish to change the IP address of the ESS, you may do so with the Configurator Utility. If the remainder of this section confuses you, don't worry. The SCU in the next section will do all of the work for you in just a few mouse clicks! The remainder of this section is just to document what the ESS uses and needs, you may skip to the SCU section. The ESS comes configured from the factory with a default static IP address of With your ESS at , you will need to assign your network adapter to use or another valid and unused address in the subnet. We recommend that you keep the IP address assigned to your ESS, since all of our documentation and videos will use that value. In fact MOST users keep this value assigned to their ESS. However, if there is a need to change it, you may do so with the Configurator Utility. Page 8

9 Axis Connection X, Y, Z, A, B, C AXIS CN2 terminal supplies motion command for drives. MB2 Cable Drive Input XS+ Twisted pair Step+ Optocoupler XS- Step- XD+ Dir+ XD- Dir- XS+ Step+ Line Reciever XS- Step- XD+ Dir+ XD- Dir- (a) differential connection *grounding at drive side XD- VCC XS- optocoupler Step+ Step- Dir+ Dir- *grounding at drive side (b) single end connection Figure 5 Axis command terminal and various connection mode There are two modes to make connection to CN2. (a) Differential mode is best noise immunity. Recommended to use differential mode if possible. (b) Single end mode is used if drive is not compatible with differential mode. There are two points of VCC to share with all axes. Page 9

10 Inputs Figure 6 Input terminal Figure 6 shows 22 points of inputs. There are 17 points of NPN type which are X110-X115, X203-X215 and 5 points of PNP type which are X310-X315. There are solder-bridges underneath of MB2 board for user to bridge input status of X203 X210 to safety circuit. The OVR input is override signal for the circuit. Safety circuit will form AND logic for all involved signals. This helps user to eliminate extra effort to build separately circuit. 24V X211 MB2 NPN inputs connect to Figure 7 Connection of NPN inputs, it references to Figure 7, shows conventional way to connect a switch to NPN input, X211 with Page 10

11 24V X310 24V MB2 PNP input connect to external source (a) external supply 24V Jumper wire connect to nearby terminal MB2 (b) internal supply PNP inputs connect to internal source Figure 8 Connection of PNP inputs, it refer to 24V Figure 8, (a) shows the way we connect PNP input to external source. This connection is totally isolated from any part of MB2 circuit. The external circuit is maybe fault output of VFD drive or servo drive. Figure 8, (b) shows conventional way we connect PNP input to internal source. 24V 24V Brown X211 Black or white Blue 24V X310 COM- COM- MB2 NPN type connection (a) NPN connection 24V 24V Brown X310 Black or white COM- Blue MB2 PNP type connection (b) PNP connection Figure 9 Sensors connection Page 11

12 Figure 9, (a) shows connection of NPN type of sensors. This connection is applied for X110- X115 and X203-X215 inputs only. Figure 9, (b) shows connection of PNP type of sensors. This connection is applied for X310- X315 inputs only. X203 X204 E-Stop X+ Limit X- Limit Y+ Limit Y- Limit Z+ Limit Z- Limit X211 X Home Y Home Z Home MB2 external circuit Figure 10 an example of E-STOP, LIMIT and HOME connection Figure 10, shows conventional way to connect Estop, Limit and Home switches. This will form a AND circuit. Notice that all use NC contact (normally close). Output Figure 11 Output terminal Figure 11, show 14 points output, each output can sink current up to 100mA and cannot sink more than 500 ma per one group of 8 as shown in Figure 1. 24V VCC นอ มสเ ท พ ทาอเ ร จงว Ynnn 100 ma (max) L หร อ L * External power supply 5-3dc MB2 External circuit * a diode is needed to parallel with coil Figure 12 Connecting various load to Y output Page 12

13 Analog AnaSpeed circuit + - AH AO AL 5V or 10 V Analog Output Connect to Analog Input of VFD K2 MB2 CM2 NO2 Connect to Forward input of VFD Figure 13 VFD connection AnaSpeed circuit converts PWM signal into analog signal. The maximum voltage level is depending upon external power supply. For example connect to 0-1 analog input of VFD, it demands 1dc from VFD as well. AnaSpeed has about ± 0.2V top and bottom margin. It is able to generate voltage up to 9.8V only (1-0.2V) when given external power supply at 1. Compensation of this margin can be done in VFD s parameter. Normally, VFD need forward command to rotate the motor. Thus, any NO contact of K1 or K2 can be used for this purpose. OSSD Output and Safety Circuit MB2 has an OSSD (Output Signal Switching Device) output for users to form a simple safety circuit in their system. MB2 energizes OSSD output if there is no any error feeding in and it will de-energize OSSD output if there is an error occurred. Most drives will give an OK signal or Servo Ready or similar meaning by energizing its output and external devices will take this status. In this case, MB2 collects OK signals from various devices thru X203-X210 inputs and send out OK signal to the next device. However, if there an error feeding in, MB2 will send out Not OK signal by de-energize OSSD output and external safety circuit will stop the hazard. It is simply to use magnetic contactor as external device to disconnect power supply from drives or VFD. Override input also provided for temporary energizing the magnetic contactor which lets machine operator to recover the error. Figure 14 shows safety circuit block and relevant I/O including, inputs, solder-bridge, an override input and outputs Warning. MB2 has used a simple safety circuit. There is no guarantee of failure. Thus, users MUST always check the functioning of the circuit. Page 13

14 i202 OSSD Safety Circuit Safety OVR (override) X203 X204 X205 X206 X207 X208 X209 X210 Figure 14 On board safety circuit Power Supply MB2 needs only single 24Vdc power supply to operate the board. The Figure 15 shows input terminal for and 24V. There is a non-isolate step down switching regulator converts 24V (12-24Vdc) down to 5V to power most parts of circuit including inputs and output. However, there is also a special isolated DC2DC convertor generates 5V for only ESS board. On board has a small fuse protection against over voltage and polarity reversal. 24Vdc Figure 15 Power supply connection Page 14

15 Modification MB2 has a number of places where users can conduct modification. Instead of using pin jumper, the solder-bridges are implemented to save cost and space. Users need to solder or de-solder these bridges to archive their purpose. *1. Safety circuit inputs; primary function of X203-X210 are normal inputs just like the others. But these inputs are chose to be inputs for the safety circuit by soldering the bridge. *2. Pin for PWM Analog, let users choose between Y101 and Y317 (set to Y317 by default) *3. DC converter Soldering the bridge to use onboard 5V isolated DC2DC converter (default). In some cases there are necessary to use external 5V power supply instead of using a tiny converter. This bridge has to be de-soldered then connect external 5V power supply to VCC channel at AXIS CN2 terminal. *4. Free terminal In some circumstances, users need few extra terminals for their work. User needs to free terminal by de-solder the bridge. These free terminals are meant to use with low voltage signal only, not over than 24V. Figure 16 underneath layout of MB2 Page 15

16 Software Users can obtain up to date software, plugins and tutorials from following link. User also can obtain MB2 pre configuration file from product link below. Mach3 Configuration Users can obtain pre configuration XML file and copy to their system. However, there are some value needs to be set to suite for user s application. After downloading and extracting pre configuration profile. You will find MB2.xml that need to be copied and pasted into C:\Mach3 which is shown in picture below. Run Mach3 Loader and choose MB2 profile. Figure 17 Copy and Paste MB2 pre-configuration Page 16

17 Figure 18 Mach3 first screen Menu Config > Ports and Pins Figure 19 Mach3 Ports and Pins dialog Page 17

18 Figure 20 Motor output tap Specify value as shown in the picture. Figure 21 Mach3 Input tap Users need to set suitable value by themselves Page 18

19 Figure 22 Mach3 Output tap (1/4) Users need to set suitable value by themselves Figure 23 Mach3 Output tap (2/4) Specify Charge Pump value as shown in the picture. Page 19

20 Figure 24 Mach3 Output tap (3/4) Specify value as shown in the picture. Figure 25 Mach3 Output tap (4/4) Specify value as shown in the picture. Page 20

21 Figure 26 Mach3 Spindle tap Spindle Setup Menu Config > Motor Tuning Figure 27 Mach3 Motor tuning dialog Motor Tuning and Setup, Users need to set suitable value by themselves Page 21

22 Menu PlugIn Control > ESS-v10r2d1d Config Mach4 Configuration Figure 28 ESS General Configuration Users can obtain pre configuration profile from product link above. However, there are some value needs to be set to suite individual system. After downloading and extracting pre configuration profile. You will find a folder name MB2, let copy and paste this folder into C:\Mach4Hobby\Profiles as shown in picture below. Run Mach4 loader, then pickup MB2 profile. Figure 29 Copy and Paste Mach4 pre- configuration Page 22

23 Figure 30 Mach4 fist screen Page 23

24 Menu Configure > Select Motion Dev Figure 31 Mach4 Select motion device Menu Configure > Plugins Figure 32 Mach4 Configure Plugins dialog Page 24

25 At Configure Plugins dialog, ESS- Warp9 Tech need to be ticked then close and reopen Mach4 before clicking on Configure button Figure 33 Mach4 ESS Configuration General tap In General tap, specify IP Address of ESS board Page 25

26 Figure 34 Mach4 ESS Configuration I/O tap (1/4) I/O tap (1/4), specify as shown in the picture. Page 26

27 Figure 35 Mach4 ESS Configuration I/O tap (2/4) I/O tap (2/4), specify as shown in the picture. Figure 36 Mach4 ESS Configuration I/O tap (3/4) I/O tap (3/4), specify as shown in the picture. Page 27

28 Figure 37 Mach4 ESS Configuration I/O tap (4/4) I/O tap (4/4), specify as shown in the picture. Page 28

29 Figure 38 Mach4 ESS Configuration Homing tap Menu Configure > Mach Homing tap, users need to specify by themself Figure 39 Mach Configuration General tap Page 29

30 General tap, Users need to set suitable value by themselves. Figure 40 Mach Configuration Axis Mapping tap Axis Mapping tap, specify as shown in the picture. Page 30

31 Figure 41 Mach Configuration Motors tap Motors tap, Users need to set suitable value by themselves. Figure 42 Mach Configuration Homming/SoftLimits tap Homing/ SoftLimits tap, Users need to set suitable value by themselves. Page 31

32 Figure 43 Mach Configuration Input Signals tap Input Signals tap, Users need to set suitable value by themselves. Figure 44 Mach Configuration Output Signals tap Page 32

33 Output Signals tap, Users need to set suitable value by themselves. Figure 45 Mach Configuration Spindle tap Spindle tap, specify same value of rpm in item 0 and Max Spindle Motor to get full analog range Page 33

34 Appendix I MB2 Specifications Dimensions 115 x 155 mm Supply voltage 12-24Vdc ±10%, 500mA (without load) Supply voltage ripple 5% Outputs NPN, 5-24Vdc Output current 100mA Max (total 7 outputs 500mA) Analog output range ( + 200mV) ~ (Vin 200mV) Inputs NPN, PNP, 5-24Vdc Ambient operating temperature 0-40 C Appendix II MB2 Board Dimensions Page 34

35 Appendix III Safety connection Notice. Safety class in this manual is NOT related to any safety standard. And the connections given here is just a guideline for users to follow. Safety Class 1 Safety class 1 is a simple safety connection with fewer component and wiring. Mostly, it relies on good functional of computer and electronics components to disengage drive power thru servo on signal or similar. Note. 1.Make X203, X209, X210 as inputs of safety circuit by soldering thier bridges underneath of MB2 board. Then assign X202 as the E-Stop input. 2.Assign X115 as Limit input 3.Assign Y316 as Enable2. To main power 1ph, 3ph Noise Filter Circuit Breaker 24V 24V 24Vdc Power supply X115 (Limit signal) Series of limits switches Noise Filter MB2 Board X203 (E-Stop signal) Step command 24V Y316 Direction command X209 (Fault input) X210 (Fault input) 24V Servo On Fault (Drive1) Fault (Drive2) Servo Drive Control circuit E-Stop PANASONIC MINAS-A Control share power with Main Servo Drive Power circuit PANASONIC MINAS-A PANASONIC MINAS-A External Circuit Figure 46 Safety Class1 connection Page 35

36 Safety Class 2 Safety class 2 is more concern about disengaging power from drives or hazard devices by unintelligent components, such as limit switches, Estop button and magnetic contactor. In situation of motor runs away that caused by electromagnetic interference or even an error of human. A good design system should be able stop by limit switches themself or stop by hitting of Estop button. However, in normal circumstance, MB2 with external circuit and computer should work well together. In some drive connections may need timer relays to handle an error of under voltage. Note. 1.Make X203, X209, X210 as inputs of safety circuit by soldering thier bridges underneath of MB2 board. Then assign X202 as the E-Stop input. 2.Assign X115 as Limit input 3.Assign X110 as OEM Trigger, Then assign Reset oem code or 1021 to System hotkey > External button. 4.Assign Y214,Y316 as Enable1, Enable2 respectively. To main power 1ph or 3ph Noise Filter Circuit Breaker 24V 24V 24Vdc Power supply M1 24V 1N2004 Noise Filter Limit override MB2 Board Series of limit switches X115 (Limit signal) OVR (safety override) X110 (Reset signal) X203 (E-Stop signal) Step command Direction command 24V Y316 M1 X209 (Fault input) X210 (Fault input) 24V Servo On Alarm clear Servo Drive Control circuit Reset Fault (Drive1) Fault (Drive2) E-Stop.2 PANASONIC MINAS-A NO2 (Y214) On board relay 1 body, 2 contacts E-Stop.1 External Circuit Control power Servo Drive Power Cicuit M1 Main power Magnetic Contactor PANASONIC MINAS-A PANASONIC MINAS-A Figure 47 Safety Class2 connection Page 36