9 Amp Platinum Series CNC Controller Hardware Guide

Transcription

1 9 Amp Platinum Series CNC Controller Hardware Guide Midwest Office 444 Lake Cook Road, Suite Deerfield, IL 6005 Phone (847) Fax (847) Revised /0/ WPI, Inc.

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3 Table of Contents. GETTING STARTED... 6 ABOUT THIS MANUAL... 6 TURNING OFF THE CONTROLLER... 6 SAFETY AND USAGE GUIDELINES SERVO CNC CONTROLLER... 8 FRONT PANEL... 8 TOP PANEL... 9 LEFT PANEL... 9 RIGHT PANEL... 0 BACK PANEL... OVERALL DIMENSIONS SYSTEM CONNECTIONS OPENING THE FRONT COVER SIGNAL GENERATOR... 7 INPUT... 7 OUTPUT... 8 JUMPER SETTINGS JP83 DB to USB Ground JP84/JP85 Input Power Select JP 86 USB to Chassis Ground... 3 JP 87 Internal Signal to Chassis Ground... 3 INTERNAL CONNECTIONS... 3 JP30 Auxiliary Inputs JP3 Status LEDs JP3 Bus Expansion JP33 Step & Direction JP40 Input Aux Header JP50 Output Aux Header JP80 Rear Panel Power JP8 Rear Panel Fuse JP8 Front Panel Switch AXIS PLUG-IN INTERFACES FLASHCUT SOFTWARE SETTINGS RESETTING YOUR SERVO DRIVE UPGRADING A SERVO DRIVER SERVO SOFTWARE MOTOR WIRING: POWER BOARD SUPPORT: APPENDIX: SIGNAL GENERATOR WIRING DIAGRAMS Typical Output Line Circuit Typical Input Line Circuit Internal Power Typical Input Line Circuit External Power SIGNAL GENERATOR BOARD LAYOUT... 60

4 CONNECTOR PIN-OUT TABLE... 6 POWER OUTPUTS INPUTS CONNECTORS AXIS PLUG-IN INTERFACE REVISION HISTORY...

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6 6 FlashCut CNC Section Getting Started. 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, software and machine before cutting a part. Turning Off the Controller Always turn off the CNC Controller when it is not in use.

7 FlashCut CNC Section Getting Started 7 Safety and Usage Guidelines When running an automated machine tool, safety is of the utmost importance. For proper and safe use of the FlashCut CNC program and your CNC machine, the following safety guidelines must be followed:. Never let the machine tool run unattended.. Require any person in the same room as a running machine tool to wear safety goggles, and to stay a safe distance from the machine. 3. Allow only trained operators to run the machine tool. Any operator must have: Knowledge of machine tool operation. Knowledge of personal computer operation. Knowledge of Microsoft Windows. Good common sense. 4. Place safety guards around the machine to prevent injury 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 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. FlashCut CNC supplies this product but has no control over how it is installed or used. Always be careful! FlashCut CNC, Inc. or its affiliates are not responsible for damage to any equipment or workpiece resulting from use of this product. If you do not understand and agree with all of the above safety guidelines, do not use this product.

8 8 FlashCut CNC Section Servo CNC Controller. Servo CNC Controller Front Panel The front panel of the CNC controller has the power switch, push buttons and indication LED s with the following functions: EMERGENCY STOP BUTTON Normally closed maintained mushroom push button which can be released by twisting. When pressed the enable signal and high voltage is interrupted to the servo drives. The enable signal as well as the high voltage is reinstated to the servo drive after releasing the emergency stop button and then pressing the rest button. WARNING: due to a high capacitance in the servo drives the internal voltage bus is not immediately interrupted and may take several minutes to dissipate.

9 FlashCut CNC Section Servo CNC Controller 9 RESET BUTTON Normally open momentary flush push button. The reset button must be pressed after and emergency stop has occurred in order to clear the emergency stop condition and reinstate the enable signal and high voltage to the servo drive. MOTOR ENABLE LAMP Turns green when the FlashCut CNC software enables the servo drives. After an emergency stop condition is cleared lamp will be illuminated indicating the servo drives are enabled. To clear an emergency stop condition:. Release the emergency stop by twisting the mushroom button.. Press and release the reset button. 3. In the FlashCut CNC software, reset the drive amplifiers. For further information on resetting the drive amplifiers see Resetting your Servo Drive later in this manual. POWER LAMP Turns yellow when the power switch is turned on. POWER SWITCH Turns the unit on and off. I is on and O is off. This is the main power switch for the whole box, when using operating a unit equipped with an integrated computer, make sure to properly shut down the computer before turning off the main power. Top Panel *Pictured with optional expansion options

10 0 FlashCut CNC Section Servo CNC Controller The top panel has connectors for input and output signals as described below. AC-IN AC supply to the control unit passes through a cord grip and terminated with a L6-30P plug. The control unit operates between VAC 30A. (Note: the motors will achieve a higher RPM with a higher AC supply) USB In units equipped with an integrated computer the USB connector is a breakout for external devices to be used with the integrated computer. These devices may include a FlashCut CNC Control Pendant, USB thumb drives, keyboards or mice. In units without an integrated computer the USB connector is used for communications between a customer-supplied computer and the signal generator installed in the control unit. ETHERNET In units equipped with an integrated computer the Ethernet connector is a breakout for Ethernet connectivity to the integrated computer. In units without an integrated computer, the Ethernet connector allows communication of the internal drive modules with a PC. Use an RS-485 to RS-3 adapter cable to connect the RJ-45 port on the control unit to the serial port on your PC. The drive parameters can then be modified using the Power Tools Pro software included with your FlashCut CNC installation. For more information on tuning see Servo Software later in this manual.

11 FlashCut CNC Section Servo CNC Controller INPUTS -8 Supplies input breakouts 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 CMOScompatible optically isolated inputs. When a switch is open, its input signal is high (+5V). When the switch is closed, its input signal is grounded low (0V). If you need more than 8 input lines, an I/O extension board is available. The 6 pin connector part number is SCR-7-6-T S-BC and is manufactured by Samtec. Pin # Function OPT- GND OPT- GND 3 OPT- GND 4 OPT- GND 5 OPT- GND 6 OPT- GND 7 OPT- GND 8 OPT- GND 9 INPUT 0 INPUT INPUT 3 INPUT 4 3 INPUT 5 4 INPUT 6 5 INPUT 7 6 INPUT 8

12 FlashCut CNC Section Servo CNC Controller OUTPUTS -8 Supplies output breakouts 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 4V external system unless it accepts TTL/CMOS levels. They are all driven by HCT family logic. Output logic high is normally 5V and can go down to 3.9V at full load. Output logic low is normally 0V and can go up to 0.3V at full load. Each of these signals can provide up to 0mA of current. If you need more than 8 output lines, an I/O extension board is available. The 6 pin connector part number is SCR-7-6-T S-BC and is manufactured by Samtec. Pin # Function OUTPUT OUTPUT 3 3 OUTPUT 5 4 OUTPUT VDC 6 OUTPUT 7 OUTPUT 4 8 OUTPUT 6 9 OUTPUT 8 0 GND N/C N/C 3 N/C 4 N/C 5 N/C 6 N/C

13 FlashCut CNC Section Servo CNC Controller 3 ACCESSORIES The accessory connector creates an interface to utilize the functionality of the emergency stop circuit, 4 VDC out, the reset circuit, and two motor brakes. The pin out can be seen below. The 6 pin connector part number is SCR-7-6- T S-BC and is manufactured by Samtec. Pin # Function +4V OUT +4V RETURN 3 + BRAKE OUT 4 - BRAKE OUT 5 + BRAKE OUT 6 - BRAKE OUT 7 + ESTOP IN 8 - ESTOP IN 9 + RESET IN 0 - RESET IN N/C N/C 3 N/C 4 N/C 5 N/C 6 N/C

14 4 FlashCut CNC Section Servo CNC Controller INPUTS 9-6 Supplies input breakouts 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 CMOScompatible optically isolated inputs. When a switch is open, its input signal is high (+5V). When the switch is closed, its input signal is grounded low (0V). These input breakouts are only available in units equipped with an I/O Expansion board. The 6 pin connector part number is SCR-7-6-T S-BC and is manufactured by Samtec. Pin # Function OPT GND OPT GND 3 OPT GND 4 OPT GND 5 OPT GND 6 OPT GND 7 OPT GND 8 OPT GND 9 INPUT 9 0 INPUT 0 INPUT INPUT 3 INPUT 3 4 INPUT 4 5 INPUT 5 6 INPUT 6

15 FlashCut CNC Section Servo CNC Controller 5 OUTPUTS -8 Supplies output breakouts 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 4V external system unless it accepts TTL/CMOS levels. They are all driven by HCT family logic. Output logic high is normally 5V and can go down to 3.9V at full load. Output logic low is normally 0V and can go up to 0.3V at full load. Each of these signals can provide up to 0mA of current. These input breakouts are only available in units equipped with an I/O Expansion board. The 6 pin connector part number is SCR-7-6- T S-BC and is manufactured by Samtec. Pin # Function OUTPUT 9 OUTPUT 3 OUTPUT 3 4 OUTPUT VDC 6 OUTPUT 0 7 OUTPUT 8 OUTPUT 4 9 OUTPUT 6 0 GND N/C N/C 3 N/C 4 N/C 5 N/C 6 N/C

16 6 FlashCut CNC Section Servo CNC Controller MOTOR POWER The motors for axes -5 plug into these connectors. The motor lines -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. In units equipped with Pro Series Motors, each motor connector is a Neutrik XLR 3 Pin Receptacle P/N NC3FP-. The pin assignments for the Motor Connector are as follows (looking from the rear of the unit): XLR Pin Wire R S 3 T In units equipped with High Performance Motors, each motor connector is a Neutrik XLR 4 pin receptacle P/N NC4FD-LX-BAG. The pin assignments for the motor connector are as follows (looking form the rear of the unit).4 XLR Pin Wire R S 3 T 4 GND

17 FlashCut CNC Section Servo CNC Controller 7 MOTOR FEEDBACK The feedback for axes -5 plug into these connectors. In units equipped with Pro Series Motors, each encoder connector is a NorComp DB-5 female connector P/N 7-E5-03R0. The pin assignments for the motor feedback are as follows. DB-5 Wire Pin HALL S ENC VCC 3 HALL S3 4 B (-) 5 A (-) 6 N/C 7 Z (-) 8 GND (Opt.) 9 HALL S 0 ENC GND Z (+) B (+) 3 A (+) 4 N/C 5 LIM (+) (Opt.) Optional limit switch connection through the encoder cable.

18 8 FlashCut CNC Section Servo CNC Controller In units equipped with High Performance Motors, each encoder connector is a NorComp HD-5 female connector P/N L0. The pin assignments for the motor feedback are as follows. DB-5 Pin Wire A A/ 3 B 4 B/ 5 Z 6 Z/ 7 U 8 U/ 9 V 0 V/ W W/ 3 +5 VDC 4 COMMON 5 MOTOR TEMP

19 FlashCut CNC Section Servo CNC Controller 9 Left Panel FILTER-FAN Nema rated filter assembly with fan. 50 CFM DC fan mounted to a 9% filtration efficient filter assembly. When filter becomes saturated with contaminates replace with PFF0000 filter. PULL HANDLE Recessed spring-loaded pull handle for carrying unit. Locks at 90.

20 0 FlashCut CNC Section Servo CNC Controller Right Panel FILTER Nema exhaust filter assembly rated at 9% filtration efficiency. When filter becomes saturated with contaminants replace filter. For filter part number see above. PULL HANDLE Recessed spring-loaded pull handle for carrying unit. Locks at 90.

21 FlashCut CNC Section Servo CNC Controller Back Panel Back panel contains four 5/6-8 threaded inserts for unit mounting. The inserts are arranged in a rectangular pattern with the spacing as specified above.

22 FlashCut CNC Section Servo CNC Controller Overall Dimensions Front View Side View

23 Top View FlashCut CNC Section Servo CNC Controller 3

24 4 FlashCut CNC Section Servo CNC Controller Never connect or disconnect motor cables while the power is on. This will result in damage to the driver box. The mating Pro Series motor cable connector is a Neutrik XLR 3-pin male connector P/N NC3MX. The mating High Performance motor cable connector is a Neutrik XLR 4-pin male connector P/N NC4MXX-BAG. The mating Pro Series encoder cable connector is a NorComp DB-5 male connector P/N 7-E5-03R00. The mating Pro Series encoder cable connector is a NorComp DB-5 male connector P/N 7-E5-03R00. Please see the section on Servo Motor Cabling later in this manual for more information.

25 3. System Connections FlashCut CNC Section 3 System Connections 5

26 6 FlashCut CNC Section 4 Removing the Top Cover 4. Opening the Front Cover To open the cover from the unit loosen the 5 total screws located on the front of the unit. Then open the cover. When the cover make sure the door stop locks into the stop to make sure the lid will stay open. In order to close the lid push the support arm toward the bottom of the control unit.

27 FlashCut CNC Section 5 Signal Generator 7 5. Signal Generator Input The default setting for each of the input lines is normally closed (NC). The input line settings can be individually changed between normally closed (NC) or normally open (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. The input lines are all optically isolated. Jumpers J84 and J85 enable you to choose between the internal power of 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 and or both must be on pins 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 and, OPT VCC gets its power from the Internal 5V power source. When JP85 shorts pins and, OPT GND is directly connected to the Internal GND. External Isolated Power For the best noise immunity, connect an external 5V-4V power supply to the LED side of the optical couplers. When JP84 shorts pins and 3, OPT VCC gets its optically isolated power from the TB-VCC. When JP85 shorts pins and 3, OPT GND is directly connected to the TB-GND. Choose only one of the following methods to supply power:. Connect a power source to the TB 40 screw terminal.. Connect a power source through pins 3 and 5 of the DB-5 connector. If you are providing an external voltage through pins 3 and 5 of the DB5 Motor Signal connector or via TB-40, then you must have both JP84 and JP85 jump pins and 3, OTHERWISE SEVERE DAMAGE COULD RESULT. BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER WIRING WILL DAMAGE THE SIGNAL GENERATOR. Input lines,, 3 & 4 are also connected through pins 5, 6, 7 & 8 respectively of the Motor Signal connector, and input lines 5, 6, 7 & 8 are also connected through pins 5, 6, 7 & 8 respectively of the Motor Signal connector. This makes it convenient to send any signals from an external motor driver box, such as limit lines or servo position error signal, back to the Signal Generator through the DB5 cable without

28 8 FlashCut CNC Section 5 Signal Generator using a separate input cable. Note that if an input line is being used through the Motor Signal connector, that line must remain open in the Input connector. The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr. Series 6 pin receptacle (part number ), with female pins (part number or for gauge or thinner wires). The Molex for 4-4 AWG universal or Molex 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 are optically isolated ground.): Mini-Fit Jr. Signal Mini-Fit Jr. Signal Pin No. Pin No. OPT-GND 9 INPUT OPT-GND 0 INPUT 3 OPT-GND INPUT 3 4 OPT-GND INPUT 4 5 OPT-GND 3 INPUT 5 6 OPT-GND 4 INPUT 6 7 OPT-GND 5 INPUT 7 8 OPT-GND 6 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 4V external system unless it accepts TTL/CMOS levels. They are all driven by HCT family logic. Output logic high is normally 5V and can go down to 3.9V at full load. Output logic low is normally 0V and can go up to 0.3V at full load. Each of these signals can provide up to 0mA of current. Two additional pins on this connector are provided for your output lines: ground and +5V. These are connected to GND and +5V and are not optically isolated. This 5V circuit can source up to 00 ma. Any larger current demand would require a larger power source.

29 FlashCut CNC Section 5 Signal Generator 9 BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER WIRING WILL DAMAGE THE SIGNAL GENERATOR. The output lines are all initialized to low (0V) when you turn on the Signal Generator. Output lines and are also connected through pins and respectively of the Motor Signal connector. This makes it convenient to connect up to output signals to an external motor driver box to drive devices such as solid-state relays that might be in an external motor driver box. The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr. Series 0 pin receptacle (part number ), with female pins (part number or for gauge or thinner wires). The Molex for 4-4 AWG universal or Molex 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: Mini-Fit Jr. Signal Mini-Fit Jr. Signal Pin No. Pin No. OUTPUT 6 OUTPUT OUTPUT 3 7 OUTPUT 4 3 OUTPUT 5 8 OUTPUT 6 4 OUTPUT 7 9 OUTPUT V 0 GROUND

30 30 FlashCut CNC Section 5 Signal Generator Jumper Settings Pin of all jumpers is indicated by a small white dot printed on the PCB. JP83 DB to USB Ground This connects the DB 5 ground to the USB ground. By default pins and, 3 and 4, and 5 and 6 are jumped as pairs. In order to isolate only the USB shield only jumper pins 3 and 5 as well as removing JP 86. In order to isolate only the chassis jumper pins and, 3 and 5, and 4 and 6 as well as removing JP 86 and JP 87.. 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. Both jumpers must be set on the same pair of pins (either both must be on pins and or both must be on pins and 3). Internal Power

31 FlashCut CNC Section 5 Signal Generator 3 This is the most convenient option and works well for most applications, but negates some of the signal isolation. When JP84 shorts pins and, OPT VCC gets its power from the Internal 5V power source. When JP85 shorts pins and, OPT GND is directly connected to the Internal GND. External Isolated Power For the best noise immunity, connect an external 5V-4V power supply to the LED side of the optical couplers. When JP84 shorts pins and 3, OPT VCC gets its optically isolated power from the TB-VCC. When JP85 shorts pins and 3, OPT GND is directly connected to the TB-GND. Choose only one of the following methods to supply power:. Connect a power source to the TB 40 screw terminal.. Connect a power source through pins 3 and 5 of the DB-5 connector. 3. Check the resistor value in RP4 to make sure it matches the voltage in TB40. TB40 Voltage RP4 Value (0 pin 9 Resistor SIP) 5V 3.9k (Default) V k 4V k If you are providing an external voltage through pins 3 and 5 of the DB5 Motor Signal connector or via TB-40, then you must have both JP84

32 3 FlashCut CNC Section 5 Signal Generator and JP85 jump pins and 3, OTHERWISE SEVERE DAMAGE COULD OCCUR. JP 86 USB to Chassis Ground This jumper connects the USB shield to the chassis ground of the Signal Generator when jumped. In order to isolate the USB shield remove this jumper and make sure only pins 3 and 5 are jumper on JP 83. In order to isolate the DB 5 shield and the USB shield remove this jumper. In order to isolate the DB 5 shield, the USB shield, and the chassis remove this jumper as well as JP87. JP 87 Internal Signal to Chassis Ground This jumper connects the internal signal ground to the chassis ground of the Signal Generator when jumped. In order to isolate the chassis ground remove this jumper in addition to JP 86 as well as jumping pin 3 and 5, and 4 and 6 on JP 83. In order to isolate the DB 5 shield, the USB shield, and the chassis remove this jumper as well as JP86. 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). The small dot next to some of the connectors designates the number pin position. On the following diagrams, the positions of the connectors will be highlighted in black.

33 FlashCut CNC Section 5 Signal Generator 33 Connectors JP30, JP3, JP3, JP33 JP30 Auxiliary Inputs This contains all of the Input Signals -8 which come out of the 50A board and Input Signals 9-3 which come out of the I/O Expansion board. +3.3V GPI3 3 GPI3 5 GPI30 7 GPI9 9 GPI8 GPI7 3 GPI6 5 GPI5 7 GND 9 GPI4 GPI3 3 GPI 5 GPI 7 GPI0 9 GPI9 3 GPI8 33 GPI V 37 GND V 4 GPI 6 GPI 8 GPI3 0 GPI4 GPI5 4 GPI6 6 GPI7 8 GPI8 0 GND GPI9 4 GPI0 6 GPI 8 GPI 30 GPI3 3 GPI4 34 GPI5 36 GPI V 40 GND

34 34 FlashCut CNC Section 5 Signal Generator JP3 Status LEDs This is for connecting wired LEDs from a custom chassis to the 50A LED signals. +5V N/C LED-DIR 3 4 LED-STEP LED-DIR 5 6 LED-STEP LED-DIR3 7 8 LED-STEP3 LED-DIR4 9 0 LED-STEP4 LED-DIR5 LED-STEP5 LED-AUX 3 4 LED-USB GND 5 6 LED-PWR JP3 Bus Expansion This contains signal and address lines for the I/O Expansion board. +3.3V GND CS6 3 4 STATUS6 TXD 5 6 FAULT6 RXD 7 8 AUX-STB OUT-ENA 9 0 AUX-STB OUT-STB OUT-STB OUT4-STB 3 4 OUT3-STB +5V V GND 7 8 GND A0 9 0 A DATA DATA DATA3 3 4 DATA4 DATA8 5 6 DATA7 DATA6 7 8 DATA5 +7V V SPHOME 3 3 ENC CLK +3.3V ENC DIR AGND AV+ DAC DAC ADC AGND JP33 Step & Direction This contains all of the step and direction signals for 5 axes of motion. STEP5 STEP4 3 STEP3 5 STEP 7 STEP 9 GND ENA 4 DIR5 6 DIR4 8 DIR3 0 DIR DIR

35 FlashCut CNC Section 5 Signal Generator 35 Connectors JP40, JP50 JP40 Input 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. GPI GPI 3 GPI3 5 GPI4 7 GPI5 9 GPI6 GPI7 3 GPI8 5 OPT-GND 4 OPT-GND 6 OPT-GND 8 OPT-GND 0 OPT-GND OPT-GND 4 OPT-GND 6 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. GPO GPO4 3 GPO6 5 GPO8 7 GND 9 GPO 4 GPO3 6 GPO5 8 GPO7 0 VCC

36 36 FlashCut CNC Section 5 Signal Generator Connectors JP80, JP8, JP8 JP80 Rear Panel Power Connect the main power here. It can be 8.5V 6V DC or AC. See current draw chart for power requirements. JP8 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. JP8 Front Panel Switch Connect the main power switch here. Axis Plug-In Interfaces Axis Plug-Ins JP7 JP75

37 FlashCut CNC Section 5 Signal Generator 37 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 Each of these plug-in cards is a SKT0X connector, with the pin configuration on the left. Pin numbers -5, 7, 3, 5 and 7-0 perform the same function on each jumper. Per the chart below, pins 6, 8-, 4 and 6 have different values of Status, Fault, InputA, Dir, InputB, Step, SCOM and CS respectively for each plug-in card. Pin No. Label Function JP-7 JP-7 JP-73 JP-74 JP-75 HV-PWR High Voltage Power HV-PWR HV-PWR HV-PWR HV-PWR HV-PWR 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 RxD Serial Com. Receive RxD RxD RxD RxD RxD 6 STATUS Status STATUS STATUS STATUS3 STATUS4 STATUS5 7 TxD Serial Com. Transmit TxD TxD TxD TxD TxD 8 FAULT Fault Indicator FAULT FAULT FAULT3 FAULT4 FAULT5 9 INPUTA Input A IN8 IN0 IN IN4 IN6 0 DR Direction DR DR DR3 DR4 DR5 INPUTB Input B IN9 IN IN3 IN5 IN7 ST Step ST ST ST3 ST4 ST5 3 SM0 SM0 SM0 SM0 SM0 SM0 SM0 4 SCOM SCOM SCOM SCOM SCOM3 SCOM4 SCOM5 5 SM SM SM SM SM SM SM 6 CS Chip Select CS CS CS3 CS4 CS5 7 ENA Enable ENA ENA ENA ENA ENA 8 +5V +5V +5V +5V +5V +5V +5V 9 GND GND GND GND GND GND GND 0 GND Ground GND GND GND GND GND

38 38 FlashCut CNC Section 6 FlashCut Software Settings 6. FlashCut Software Settings Motor Signal Setup: In FlashCut CNC go to Configuration, System, Motor Signals and choose the appropriate servo box that you have under Driver Model. Input Lines Setup: If you overdrive the servomotors, they will get out of position beyond their programmed tolerance. If this occurs a fault signal will be sent from the servo drive amplifier to the signal generator through one of the above input lines. This signal is automatically routed to the Signal Generator via the internal servo cables. There is no need to connect wires to lines 7-3 of the input line connector on the back of the Signal Generator.

39 FlashCut CNC Section 6 FlashCut Software Settings 39 Please note that if you are using input lines, make sure to not occupy inputs 7-3 as a conflict will occur and the input connected to these lines will malfunction.

40 40 FlashCut CNC Section 7 Resetting Your Servo Drive 7. Resetting Your Servo Drive. If a Servo Fault occurs you must reset the Servo Module. To reset the module, go to Controller on the main screen and select Reset Motor Drivers.. Check your feedrate/ramping settings to make sure they are not too aggressive. 3. Resume movement. You may need to re-home the axes as they have most likely lost position. Note that a servo fault might show up by a message that says, A limit switch has briefly been tripped and reset In this case the error will not show up if you check the input status.

41 FlashCut CNC Section 8 Upgrading a Servo Driver 4 8. Upgrading a Servo Driver The servo box is ready to accept up to 5 servo drive modules. If you want to add a drive module or you need to replace a servo drive module, follow these instructions:. Open the front cover. For more detailed instructions see Opening the Front Cover earlier in this manual.. If you are replacing a drive, carefully remove all of the cabling from the drive that you are replacing 3. Remove the four screws that fasten the bottom flange of the servo drive to the sub panel. It is actually easiest if you remove two of the screws and loosen the others. 4. Remove the drive module. 5. Install the new drive module and secure it with the four screws to the bottom of the chassis. 6. Install all of the connectors of the cabling onto the drive module. 7. There are two RJ-45 connections on the top of each drive module (J). On units equipped with an integrated computer the first RJ-45 cable goes from the serial port on the computer to J of the first drive. On units without the integrated computer the first RJ-45 cable goes from the Ethernet breakout on the back panel to J of the first drive. The next cable goes from J of the first module to J of the following module. This continues up to the last drive module which only has one RJ-45 port connected from the preceding drive module.

42 4 FlashCut CNC Section 8 Upgrading a Servo Driver 8. Do a final check on all of the connections 9. Close the cover and secure the 5 screws.

43 FlashCut CNC Section 9 Servo Software Servo Software Included with the FlashCut CNC software is a servo drive amplifier communication utility called PowerTools Pro. This allows the user to define inputs and outputs of the drive in addition gain tuning for your specific machine. For information regarding the functionality and use of the PowerTools Pro application please reference the help section in the PowerTools Pro utility.

44 44 FlashCut CNC Section 0 Motor Wiring 0. Motor Wiring: The motor connectors contain all of the drive and encoder signals going out to the motors. The motors can be either brush or brushless and the encoder signals can be either differential or single ended. See the Appendix with the Schematics at the end of this manual for details.

45 . Power Board FlashCut CNC Section Power Board 45

46 46 FlashCut CNC Section 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; the AC voltage is then converted to DC voltage. The Power Board also contains the indication LED s: AXIS LED s,, 3, 4, 5 Turns green when the respective axis is moving. Not utilized in Platinum Series units. USB LED Turns yellow when connected to the host PC USB port. Not utilized in Platinum Series units. DIAGNOSTIC LED Indicates the state of power being distributed through the power board. Flashing Red: indicates the emergency stop circuit is open, meaning the emergency stop button is pressed or the switch to use the button is on but no button is connected. Solid Red: indicates the system is in a reset state, meaning the reset circuit must be momentarily closed in order to clear this state. If no reset button is connected and a solid red LED is seen then the switch for use of the reset circuit may be incorrectly activated. Solid Green: indicates all emergency stop and reset conditions are cleared and the system is in a ready state. CONFIGURATION SWITCHES - This bank of DIP switches controls the configuration of the internal emergency stop, external emergency stop, reset, brake polarity, relay out and logic out circuits. Switch Function Default Setting Use reset to clear emergency stop state (On=yes Off=no) Brake input polarity (On=high Off=low) Logic out to use emergency stop state (On=yes Off=no) Relay out to use emergency stop state (On=yes Off=no) Use internal emergency stop (On=yes Off=no) Use external emergency stop (On=yes Off=no) On On On On On Off 7 Unused N/A 8 Unused N/A

47 FlashCut CNC Section Power Board 47 BRAKE INPUT - Input for controlling the functionality of brake. Can activate or deactivate brake using normally open or normally closed brake control circuit. The brake input is tied into an output from the drive amplifiers in systems using a brake; otherwise the brake input is left open. The polarity of the input is configurable using the Configuration Switches. For further information on the brake input polarity please see Configuration Switches above.

48 48 FlashCut CNC Section Power Board BRAKE INPUT - Input for controlling the functionality of brake. Can activate or deactivate brake using normally open or normally closed brake control circuit. The brake input is tied into an output from the drive amplifiers in systems using a brake; otherwise the brake input is left open. The polarity of the input is configurable using the Configuration Switches. For further information on the brake input polarity please see Configuration Switches above. SIG GEN POWER OUTPUT - This output sends 9 VDC to power the Signal Generator. When viewing the power board in the configuration above the top contact of the signal generator DC output is positive and the bottom contact is negative. PROGRAMMING HEADER This header is user for programming the logic IC which controls the functionality of the power board including the reset, emergency stop and brake circuits. This header is for manufacturing purposes only.

49 FlashCut CNC Section Power Board 49 FAN OUTPUT - This output sends a 4 VDC signal to power the fan for cooling the box. When viewing the power board in the configuration above the top contact of the fan DC output is negative and the bottom contact is positive. 4 VDC INPUT This input is the voltage used to power the components on the power board. The power board is energized using a 4 VDC power supply mounted in the unit. The maximum power consumption of the 4 VDC power supply is 75W. DC INPUT FUSE This fuse is used to protect the system from incorrect wiring of the DC input. The fuse is a 4.48mm X 4.5mm, 4A, 5V Slo-Blo fuse

50 50 FlashCut CNC Section Power Board AXIS -6 4 VDC OUTPUT- This output sends a 4 VDC signal to power the drive amplifier logic. Power for up to 6 individually powered drive modules. The 6 connectors have identical pin assignments. Based on the orientation of the power board above the top pin is positive and the bottom pin is negative. AXIS -6 I/O- This connector takes in an output from the drive amplifier in addition to supplying the enable and power signals the drive amplifier I/O circuit. The pin configurations are identical on all six connection and are as follows: Pin Function 4 VDC I/O Power N/C 3 Drive Reset (Input) 4 Drive Enable Drive Fault 5 (Output) 6 I/O Ground L INPUT AC line input into power distribution circuit. This is the AC line input for the main power to be distributed to all drive amplifiers and accessories. The acceptable voltage range is VAC. Not utilized in Platinum Series units. L FUSE AC line fuse to protect the system from over current. The fuse is a ¼ in. X ¼ in., 0A, 50V Slo-Blo fuse. L INPUT AC line input into power distribution circuit. This is the AC line input for the main power to be distributed to all drive amplifiers and accessories. The acceptable voltage range is VAC. Not utilized in Platinum Series units. L FUSE AC line fuse to protect the system from over current. The fuse is a ¼ in. X ¼ in., 0A, 50V Slo-Blo fuse. ACC AC OUTPUT AC output for the AC powered accessories. These 3 outputs are used to power the 4 VDC power supply, the VDC power supply for the computer and the monitor. Not utilized in Platinum Series units.

51 FlashCut CNC Section Power Board 5 AXIS -6 AC OUTPUT AC output for up to 6 drive amplifiers. Not utilized in Platinum Series units. FAULT OUTPUT This output connects the input lines on the signal generator to the fault outputs on the drive amplifiers. For correct input line assignments see FlashCut CNC Software Settings earlier above. For pin assignments see below. JP40 INPUT AUX HEADER X 8 - MM SPACING GPI GPI 3 GPI3 5 GPI4 7 GPI5 9 GPI6 GPI7 3 GPI8 5 OPT-GND 4 OPT-GND 6 OPT-GND 8 OPT-GND 0 OPT-GND OPT-GND 4 OPT-GND 6 OPT-GND ENABLE INPUT. This connects the enable signal from the Signal Generator to the drive amplifiers. The enable signal must be connected in order for the motors to move. Otherwise the drive amplifiers will remain in a disabled state. When the system is in an emergency stop condition the enable signal is cut from the drive amplifiers leaving then disabled. For pin assignments see below. STEP5 STEP4 3 STEP3 5 STEP 7 STEP 9 GND JP33 STEP & DIRECTION X 6 - MM SPACING ENA 4 DIR5 6 DIR4 8 DIR3 0 DIR DIR POWER LAMP OUTPUT Supplies a 4 VDC power signal to a lamp on the front panel to indicate when the power is turned on to the system. Base on the orientation of the power board above the top pin is positive and the bottom pin is negative.

52 5 FlashCut CNC Section Power Board INTERNAL ACC OUTPUT Supplies breakouts for the internal accessories including an emergency stop and reset circuit. The emergency stop and reset buttons on the front cover are wired to this connector. The functionality of this connector is controlled by the configuration switches. For more information on the configuration switch see above. The pin assignments for this connector are as follows. Pin Function + Estop - Estop 3 + Reset 4 - Reset ACCESSORY OUTPUT Supplies breakouts for an external emergency stop, and external reset, brake, brake and a 4 VDC switched output. The switched 4 VDC is used to control a contactor which will, under an emergency stop condition, remove the high voltage from the drive amplifiers. The accessories are broken out on the top panel. For further information please see Top Panel above. The pin assignments for this connector are as follows. Pin Function + 4 VDC Out + 4 VDC Return 3 + Brake 4 - Brake 5 + Brake 6 - Brake 7 + Estop 8 - Estop 9 + Reset 0 - Reset

53 FlashCut CNC Section Power Board 53 LAMP OUTPUT Supplies a 4 VDC switched power signal to a lamp on the front panel to indicate when the motors are enabled and energized. Based on the orientation of the power board above the left pin is positive and the right pin is negative. RELAY OUTPUT Supplies a breakout for a 0.5A relay as well as a TTL level output. The 0.5A relay is simply a switch closure to interrupt a circuit. The TTL level output can control an external device such as a 5 VDC relay coil. Both the relay out and the TTL level output can be controlled by an emergency stop state and this is configurable using the configuration switches. For further information on the configuration switches see above. The pin assignments for this connector are as seen below. Not utilized in Platinum Series units. Pin Function Relay + Relay - 3 Output + 4 Output - RELAY INPUT Supplies a connection to an output line on the signal generator. This output is used for the relay out as well as the TTL level output. Not utilized in Platinum Series units.

54 54 FlashCut CNC Section Power Board LED INPUT- This input receives logic signals from the signal generator in order to illuminate any of the 6 LED s indicating axis movement or USB connectivity. The contact connections for the LED input are as follows. Not utilized in Platinum Series units. JP3 STATUS LEDS X 8 - MM SPACING +5V N/C LED-DIR 3 4 LED-STEP LED-DIR 5 6 LED-STEP LED-DIR3 7 8 LED-STEP3 LED-DIR4 9 0 LED-STEP4 LED-DIR5 LED-STEP5 LED-AUX 3 4 LED-USB GND 5 6 LED-PWR

55 FlashCut CNC Section Support 55. Support: FlashCut CNC Midwest Office 444 Lake-Cook Road Suite Deerfield, IL 6005 (847) (847) Fax -

56 3.3K 56 FlashCut CNC Section 3 Appendix 3. Appendix: Signal Generator Wiring Diagrams Typical Output Line Circuit Signal Generator Model 50A O u tp u t Load AC U50A Q Q Q3 Q4 Q5 Q6 Q7 Q8 RP GPO0 GPO GPO GPO3 GPO4 GPO5 GPO6 GPO7 Output Line Output Line Output Line 3 Output Line 4 Output Line 5 Output Line 6 Output Line 7 Output Line O PT Fu se OHM 4 74ACT6373DL So lid Sta te Rela y Contin e n ta l In d u strie s S SJ G ND The above schematic shows a typical connection of one solid state relay controlled by output line 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 S505-0SJ It takes a 3 to 3VDC input and has an output of 4-330VAC. Each of the output signals has a -ohm resistor in series with their outputs. This is to reduce any ringing at the transient switching points. Ground and 5V are provided on this connector for your convenience. The FlashCut Spindle On/Off Relay Box is wired as shown in the above schematic.

57 FlashCut CNC Section 3 Appendix 57 Typical Input Line Circuit Internal Power S ignal G enerator M odel 50 A TB40 TB-VCC +5V OPT-VCC JP84 VCC 3 DB5 PIN DB5 PIN3 TB-GRD OPT-GRD 3 DB5 PIN5 DB5 PIN4 OPT GND VCC JP85 GRD RP4.7K In p u t 8 In p u t 7 In p u t 6 In p u t 5 U4 GPI7 GPI6 GPI5 GPI NC-NO IN7 IN6 IN5 IN4 In p u t 4 In p u t 3 In p u t In p u t PS50L-4 U4 GPI3 GPI GPI GPI0 IN3 IN IN IN0 DB5 Pin5 DB5 Pin8 DB5 Pin7 DB5 Pin6 DB5 Pin5 DB5 Pin8 DB5 Pin7 DB5 Pin6 OPT_VCC RP4 80 PS50L-4 OPT GND

58 FlashCut CNC Section 3 Appendix Typical Input Line Circuit External Power S ignal G enerator M odel 50 A TB40 TB-VCC +5V OPT-VCC JP84 VCC 3 DB5 PIN DB5 PIN3 TB-GRD OPT-GRD 3 DB5 PIN5 DB5 PIN4 OPT GND VCC JP85 GRD RP4.7K In p u t 8 In p u t 7 In p u t 6 In p u t 5 U4 GPI7 GPI6 GPI5 GPI NC-NO IN7 IN6 IN5 IN4 In p u t 4 In p u t 3 In p u t In p u t PS50L-4 U4 GPI3 GPI GPI GPI0 IN3 IN IN IN0 DB5 Pin5 DB5 Pin8 DB5 Pin7 DB5 Pin6 DB5 Pin5 DB5 Pin8 DB5 Pin7 DB5 Pin6 OPT_VCC RP4 80 PS50L-4 OPT GND

59 FlashCut CNC Section 3 Appendix 59 The above schematic shows a typical connection of 5 normally closed switches. These switches are connected between input lines -5 and ground. Lines 6-8 are connected directly to ground with jumper wires. All external connections shown are made through the Input connector on the back of the Signal Generator. This resistor pack (RP4) is socketed 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 3 and 5 of the DB5 Motor Signal connector. Input lines -4 and 5-8 are internally connected to pins 5-8 and 5-8 respectively of the DB5 Motor Signal connector. Note that the FlashCut CNC limit switch kit has the same wiring as shown in this example.

60 60 FlashCut CNC Section 3 Appendix Signal Generator Board Layout

61 FlashCut CNC Section 3 Appendix 6 Connector Pin-Out Table EXTERNAL CONNECTORS (RED) CON: STANDARD USB TYPE-A CON3 DB5F GPO 4 ENA GP0 5 GPI STEP5 3 6 GPI DIR5 4 7 GPI3 GPI5 5 8 GPI4 GPI6 6 9 DIR4 GPI7 7 0 DIR3 GPI8 8 DIR DIR 9 VCC STEP4 0 3 OPT-VCC STEP3 4 GND STEP 5 OPT-GND STEP 3 SHIELD CON4 - INPUTS OPT-GND 9 GPI OPT-GND 0 GPI OPT-GND 3 GPI3 OPT-GND 4 GPI4 OPT-GND 5 3 GPI5 OPT-GND 6 4 GPI6 OPT-GND 7 5 GPI7 OPT-GND 8 6 GPI8 CON5 - OUTPUTS GPO 6 GPO GPO3 7 GPO4 GPO5 3 8 GPO6 GPO7 4 9 GPO8 VCC 5 0 GND INTERNAL CONNECTORS (ORANGE) PIN OF ALL HEADERS IS INDICATED BY A SMALL WHITE DOT PRINTED ON THE PCB. JP30 AUXILIARY INPUTS X 0 - MM SPACING +3.3V +3.3V GPI3 3 4 GPI GPI3 5 6 GPI GPI GPI3 GPI9 9 0 GPI4 GPI8 GPI5 GPI7 3 4 GPI6 GPI6 5 6 GPI7 GPI5 7 8 GPI8 GND 9 0 GND GPI4 GPI9 GPI3 3 4 GPI0 GPI 5 6 GPI GPI 7 8 GPI GPI GPI3 GPI9 3 3 GPI4 GPI GPI5 GPI GPI6 +3.3V V GND GND JP3 STATUS LEDS X 8 - MM SPACING +5V N/C LED-DIR 3 4 LED-STEP LED-DIR 5 6 LED-STEP LED-DIR3 7 8 LED-STEP3 LED-DIR4 9 0 LED-STEP4 LED-DIR5 LED-STEP5 LED-AUX 3 4 LED-USB GND 5 6 LED-PWR INTERNAL CONNECTORS (ORANGE) JP3 BUS EXPANSION X 0 - MM SPACING +3.3V GND CS6 3 4 STATUS6 TXD 5 6 FAULT6 RXD 7 8 AUX-STB OUT-ENA 9 0 AUX-STB OUT-STB OUT-STB OUT4-STB 3 4 OUT3-STB +5V V GND 7 8 GND A0 9 0 A DATA DATA DATA3 3 4 DATA4 DATA8 5 6 DATA7 DATA6 7 8 DATA5 +7V V SPHOME 3 3 ENC CLK +3.3V ENC DIR AGND AV+ DAC DAC ADC AGND JP33 STEP & DIRECTION X 6 - MM SPACING STEP5 ENA STEP4 3 4 DIR5 STEP3 5 6 DIR4 STEP 7 8 DIR3 STEP 9 0 DIR GND DIR

62 6 FlashCut CNC Section 3 Appendix INTERNAL CONNECTORS (ORANGE) JP40 INPUT AUX HEADER X 8 - MM SPACING GPI OPT-GND GPI 3 4 OPT-GND GPI3 5 6 OPT-GND GPI4 7 8 OPT-GND GPI5 9 0 OPT-GND GPI6 OPT-GND GPI7 3 4 OPT-GND GPI8 5 6 OPT-GND JP50 OUTPUT AUX HEADER X 5 - MM SPACING GPO GPO GPO4 3 4 GPO3 GPO6 5 6 GPO5 GPO8 7 8 GPO7 GND 9 0 VCC JP53 OUT & LOW SIDE DRIVER X 6 - MM SPACING +5V VCC CLAMP for GP0 GPO Low Side Driver 3 GPO Low Side Driver 4 CLAMP for GP0 5 LOGIC GND 6 JP80 - REAR PANEL POWER JP8 - REAR PANEL FUSE JP8 - FRONT PANEL SWITCH CONFIGURATION JUMPERS (BLUE) PIN OF ALL JUMPERS IS INDICATED BY A SMALL WHITE DOT PRINTED ON THE PCB. JP83: DB TO USB GROUND ALWAYS LEAVE PIN JUMPED TO PIN, 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 -: INPUTS DRIVEN BY ON-BOARD VCC -3: INPUTS BIASED BY VOLTAGE ON TB40 JP86: USB GROUND SHOULD BE JUMPED TO PULL USB GROUND TO CHASSIS GROUND JP87: CHASSIS GROUND SHOULD BE JUMPED TO PULL INTERNAL SIGNAL GROUND OF THE SIGNAL GENERATOR TO CHASSIS GROUND. TERMINAL BLOCKS (GREEN) TB40: ISOLATED INPUT POWER VOLTAGE APPLIED HERE BIASES INPUTS IF JP84/JP85 ARE SHORTED PINS -3; DO NOT EXCEED 5V ON THIS TERMINAL UNLESS SPECIFICALLY ARRANGED WITH FLASHCUT TECH SUPPORT. TB80: SMC POWER (4V) APPLY 4 VDC HERE TO BIAS THE STEPPER MOTOR CONTROLLER BOARD(S) PLUGGED INTO SLOTS SMC-SMC5

63 FlashCut CNC Section 3 Appendix 63 Power SYSTEM GROUNDING OPTIONS UPPER RIGHT SCREW MOUNT HOLE IS CHASSIS USBSHIELD 4-40 V AT UP TO 0 A FOR FUNCTION SLOTS TB80 HV-PWR HV-GND 0 A! MKDSN UL CLASS C: V WITH 4 AWG HV-PWR +5V OPT-VCC POWER JUMPERS TB40 MKDSN TB-VCC TB-GND OPT-GND 3 JP84 VCC 3 JP85 GND DBSHIELD R87 M JP Header 3X C UF CHASSIS USBSHIELD JP86 JP87 D80 TVS 6V 400W +7V JP8 SWITCH JP8 FUSE JP80 POWER FWB80 GBPC6005 C88 0. UF FB H-90 + C UF + C UF C8 UF 3 HEATSINK FOR U U80 VIN GND NOTE LM085IS V 3000 MA 6.5 TO 5 V IN +5V + C8 UF LOW ESR C86 UF 3 HEATSINK FOR U U8 VIN GND NOTE LM085IS V 3000 MA 4.8 TO 5 V IN +3.3V C85 0. UF +3.3V + C83 UF LOW ESR LOGIC POWER 9-4 A

64 64 FlashCut CNC Section 3 Appendix Outputs +5V R57 0K DATA7 DATA6 DATA5 DATA4 DATA3 DATA DATA DATA0 OUT-STB OUT-ENA U50A D8 Q8 D7 Q7 D6 Q6 D5 Q5 D4 Q4 D3 Q3 D Q D Q LE OE 74ACT6373DL RP5 OHM GPO7 GPO6 GPO5 GPO4 GPO3 GPO GPO GPO V U53 S VCC 8 A 3 A Y 6 Y GND CLM 5 SN75477D LO-SIDE OUT LO-SIDE OUT0 5-4V RAIL JP53 RELAY DRIVE 4V 300MA VOH = 4.3 V VOL = 0.44 V AT 4 MA THRU OHMS: VOH = 3.8 V VOL = 0.97 V STEP LEDS SEE MAKO-IF SHEET FOR DIR LED DRIVE U5B AXIS AXIS AXIS3 AXIS4 AXIS5 +5V VBUS OK 5V-OK LED-STEP LED-STEP LED-STEP3 LED-STEP4 LED-STEP5 ENCODER DIR FOR DEBUG VBUS-OK +5V PANEL LED DRIVER U50B D8 D7 D6 D5 D4 D3 D D LE OE 3 Q8 Q7 0 Q6 9 Q5 7 Q4 6 Q3 4 Q 3 Q LED-ST LED-ST LED-ST3 LED-ST4 LED-ST5 LED-AUX LED-USB LED-PWR RP CR5 GRN CR5 GRN CR53 GRN CR54 GRN CR55 GRN CR6 ORG CR57 YEL CR58 GRN 74ACT6373DL

65 SOCKE TED FlashCut CNC Section 3 Appendix 65 Inputs U 4 PS 50L-4 IN 7 GPI7 IN 6 R P4 O P T-V C C GPI6 GPI5 GPI4 GPI3 U 4 PS 50L-4 IN 5 IN 4 IN 3 IN R P4.7K V 80 GPI IN GPI IN 0 GPI0

66 66 FlashCut CNC Section 3 Appendix Connectors IN PU T A U X HEAD ER +5 V STATUS LE DS (G EMVISION ) GPI0 GPI GPI GPI3 GPI4 GPI5 GPI6 GPI7 JP C ON GPI0 GPI GPI GPI3 GPI4 GPI5 GPI6 GPI7 S EE U S B.S CH DOC FOR U S B C ON N EC TOR X4 SEE POWE R.SCHDO C FOR PW R & SHIELDIN G JU M PER S HV & 5V T E RM IN AL BLOC K S LED-DR LED-DR LED-DR 3 LED-DR 4 LED-DR 5 LED-AU X JP LED-ST LED-ST LED-ST 3 LED-ST 4 LED-ST 5 LED-U SB LED-P W R HDR 8X OUTPUT AUX HEAD ER JP HDR 5X O P T-G N D PINO UTS ARE FOR : MAPPING TO MINI-FIT JR. GPO GPO 3 GPO 5 GPO 7 GPO 0 GPO GPO 4 GPO 6 +5 V +5 V O P T-G N D W M BACK PANEL MINI-FIT JR.S C ON 5 GP O 0 GPO 6 GP O GPO 3 7 GP O 4 GPO GP O 6 GPO W M S EE M AK O -IF.S C HDO C FOR M A KO HEAD ER S X 0 (5 EA ) S EE M C U.SC HDO C FO R FOR JTAG H EAD ER X5 S T 5 S T 4 S T 3 S T S T GN D HDR 8X S T EP & DIR (GEM V IS IO N ) JP W M 85 6 EN A DR 5 DR 4 DR 3 DR DR +3.3 V EX PAN SION A ND PA CU JP V +3.3 V EX PAN SION A ND PA CU JP3 ENA GPI0 GPI GPI GPI3 DR 4 DR 3 DR + 5V OPT-V C C GN D OPT-G ND GPO 0 GPO S T 5 DR 5 GPI4 GPI5 GPI6 GPI7 DR ST4 ST3 ST ST C ON V IN 3 IN 30 IN 9 IN 8 IN 7 IN 6 IN 5 IN 4 IN 3 IN IN IN 0 IN 9 IN 8 IN 7 IN 6 < < < < < < < < < < < < < > < > < > < > He a d e r 0X > > > > > > > > > > > > IN 0 IN IN IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 0 IN IN IN 3 IN 4 IN V C S6 > > S TATU S TO M C U Tx D < > FAU LT F RO M M CU R x D > < A U X-S T B 7 8 OU T-EN A > < A U X-S T B 9 0 OU T -S T B > < OU T -S TB +5 V OU T 4 -S T B > < OU T3 -S TB +5 V A 0 > < A 9 0 DATA 0 DATA DATA DATA DATA 7 DATA V DATA 5 DATA V V S P HOM E < > ENCO DER CLK 3 3 > ENCO DER DIR V AV MCU -D AC > < MCU -D AC AGND M C U -A DC 0 < He ade r 0X A GN D DB -5M

67 FlashCut CNC Section 3 Appendix 67 Axis Plug-In Interface HV-P W R HV -G ND R xd FRO M MCU T xd TO M C U IN 8 IN 9 S M 0 S M ENA EA RT H IN 0 IN IN IN 3 IN 4 IN 5 IN 6 IN 7 < < < < < < < < < < JP S KT 0X JP S KT 0X JP S KT 0X JP S KT 0X JP M A KO - M A KO - M A KO -3 M A KO -4 M A KO -5 HV-P W R HV -G ND S TAT U S FAU LT DR S T S CO M C S S TAT U S FAU LT DR S T S CO M C S S TAT U S 3 FAU LT 3 DR 3 S T 3 S CO M 3 C S3 S TAT U S 4 FAU LT 4 DR 4 S T 4 S CO M 4 C S4 S TAT U S 5 FAU LT 5 DR 5 S T 5 S CO M 5 C S5 HV-P W R + 5 V + 5 V + 5 V + 5 V + 5 V + 5 V S W R 56 0K DATA 7 DATA 6 DATA 5 DATA 4 DATA 3 DATA DATA DATA 0 SCOM-STB DATA 0 DATA DATA DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 ILC S-S T B U 5A 74A C T 637 3DL R P55 DIR3 37 D8 Q8 8 9 DR 3 DIR DR DIR 40 D7 Q7 9 6 DR S T P 5 4 D6 Q6 D5 Q5 8 5 S T 5 S T P 4 43 D4 Q S T 4 S T P 3 44 D3 Q S T 3 S T P S T S T P 47 D Q 6 S T D Q S T P -E N A 48 LE OE LE OE S TPX & DIRX FRO M CPL D U 5B DIR5 6 D8 DIR4 7 D7 ENA B LE 9 D6 DIR4 30 DIR5 3 D5 D4 DIR 33 D3 DIR 35 D DIR3 36 D + 5 V S W 5 S T P -E N A 4 LE OE U 5A 74A C T 637 3DL D8 Q8 D7 Q7 9 D6 Q6 8 D5 Q5 6 D4 Q4 D3 Q3 5 D Q 3 D Q U 5B 74A C T 637 3DL 3 D8 Q8 D7 Q7 D6 Q6 0 D5 Q5 9 7 D4 Q4 6 D3 Q3 4 D Q D Q 3 LE OE 74A C T 637 3DL 3 Q8 Q7 0 Q6 9 Q5 7 Q4 6 Q3 4 Q 3 Q R P5 O HM R P53 O HM O HM S M S M 0 FALLING ED GE OF IL-CSX IS LATCH FOR SM0: ON MAKO-X R 5 R 5 R 53 S CO M 5 S CO M 4 S CO M 3 S CO M S CO M C S C S C S3 C S4 C S5 C S6 L ED-DR 5 L ED-DR 4 ENA DR 4 DR 5 L ED-DR L ED-DR L ED-DR 3 S KT 0X