Hardware List The 3000M Crusader II Upgrade system has been custom configured to provide the necessary hardware required for installation on your machine. Verify that you have received all the correct parts, and then follow the instructions to ensure a proper installation. Caution: Do not turn on the system until instructed to do so. Follow the procedures as outlined. Be sure to read through all the instructions first before beginning the actual installation. The system comes with the following parts: 1. One 3000M Console to match your existing Crusader Console: A7323010 2-Axis M-Functions Level 1 A7333013 3-Axis Standard A7333015 3-Axis SMT Level 2 Each console includes the following: 33001024 A/R Cable A4320014 2-Axis Software Package, or A4330024 3-Axis Software Package 33000205 M-Function option key (Level 1 or Level 2) 85300009 Console Filter Kit 2. One console mounting kit selected for your machine: 33001081 Side Mount Upgrade mounting kit, or 33000844 Eye Bolt Bottom Mount, or 33000960 Eye Bolt Top Mount, or 32500333 Standard Ram Arm Mount. 3. An A/R interconnection cable: 36000273 7 ft., or 36000274 15 ft. 4. A servo control adapter cable, if required: 36000379 37-Pin to 20-Pin, or 36000380 37-Pin to 20-Pin with 19-Pin for M-Functions 5. An AC Adapter cable; if required: 36000179 Rubber boot version All rights reserved. Subject to change without notice. 1
Highlights of the Upgrade 6. Any of the following options, if ordered: 33000119 Spindle Control Option 33000951 Networking Option 33000907 Handy Pulser with Emergency Stop Switch 33000122 Remote Start and Stop Switch 36000382 19-Pin cable for adding M-Functions to a 20-Pin System The 3000M upgrade console has a user configurable Setup Utility to match the system parameters to those of the Crusader II. The default parameters have been set to most closely match a basic Crusader II system. Changes may need to be made if your system was configured differently. See Section 8 in the Installation Instructions and refer to the 3000M CNC Setup Utility Manual, P/N 70000499. The most critical defaults are as follows: Rapid Speed is set at 100 IPM. Resolution is set for Glass Scales (Linear Encoders) 0.01 mm (0.0005 ) resolution. If your system has a higher rapid speed, uses encoders, or has different resolution scales, changes will definitely need to be made in the Setup Utility. The 3000M upgrade rear panel accepts all existing wiring and options except the Program Saver (Cassette). The Auto/Manual Switch and Servo Reset are located on the new console and will be disconnected from the existing Servo Cabinet. One cable, 33001024, will need to be installed inside the existing Servo Cabinet to link Auto/Manual and Reset to the new console. The RS-232 connection is a standard 9-Pin DB computer port. If the previous system had RS-232, either use a 25-Pin 9-Pin adapter cable, or replace existing cable with a standard RS-232 cable, not supplied. All rights reserved. Subject to change without notice. 2
Installation Instructions: 1. Remove the existing Crusader 2 Console. a) Unplug all connections to the Console. Only the Cassette and its cable should be completely removed, as they are not used on a 3000M. b) Remove the console from whatever mounting hardware and brackets were used to mount the console. In some installations, the previous mounting hardware may be useful when installing the new console. 2. Install the 3000M console: a) Follow the appropriate directions for your particular mounting kit. See accompanying sheets. Use existing mounting hardware if desired. b) Connect all the cables into their appropriate locations on the rear panel. Use the adapter cables supplied with this kit if required. NOTE: Refer to Drawing Package, P/N 70000537, for wiring details. 3. Installing the A/R Cable. 33001024 into the Servo Cabinet. a) Locate the A/R cable. b) You install the connector in any convenient location by drilling a hole to 11/16 (0.688 mm). 4. Connecting the two wires of the A/R Cable harness. a) There were a number of versions of servo cabinets, install the two wires according to the version you have. The four short additional wires are spares to be used in special applications requiring extra connections between the console and servo. Ignore them. b) If your cabinet has a PCB 801 relay board and a PCB 803 interconnect board proceed as follows: If not, skip to step 4c. i. Remove the +24V power supply connection from P5 of the PCB 801 board. Install into P5, the cable with the 4-position plug on the end. Make sure the red wire is on Pin 1. ii. On the PCB 803 board, look at the P7 connector. If there is no wire in Pin 11, insert the white wire making sure it locks in place. iii. If there is a wire in Pin 11 of P7, remove the wire, tape, and secure the wire. Add the white wire to Pin 11. c) For all other styles of servo cabinets. Proceed as follows. i. Remove the red wire from the 3-position connector on the A/R cable. Remove the terminal from the wire and strip off the end of the wire. Connect the red wire to 24 volt common, K1 relay terminal 6. Leave the blue wire that is on pin 6 and keep it connected. All rights reserved. Subject to change without notice. 3
ii. On the 24 VDC relay K1, connect the white wire of the A/R cable to terminal 10 (usually has the yellow wires). Do not remove any of the wires connected to terminal 10 of K1. Caution: If there is a second 24 VDC relay with resistors across some terminals, do not wire to this relay it is not the K1 relay. 5. Interconnecting the A/R Cable between the Console and Servo. a) Locate either the 36000054 7 ft. or 36000056 15 ft. cable. b) Connect between the A/R cable installed in Step 4, and the A/R connection on the rear of the Console. 6. Removing the 24 VDC Power Supply a) Not all servo cabinets contained a 24 VDC supply. If you do not have a supply, skip this section. b) If you do not have a PCB 801 relay board, proceed to step 6c. If your system has a PCB 801 relay board, unplug the connection to P5 on the PCB 801 board. This removes power to the supply as well as the 24 VDC from the circuit. c) If you have a terminal block system, or it is hard wired, you will have to remove the supply itself. d) There are a number of different wiring schemes used to bring AC to the supply, as well as how the 24 VDC was distributed to the circuit. Perform either of the following methods to remove the supply: i. Trace the wires to the first junction point from the supply and remove them. For example: The blue +24 VDC wire might go to a fuse first. Remove it from the fuse on the power supply side. The 24 VDC common will most likely go to a terminal block, remove from the block. The AC will usually originate at a terminal block. ii. Cut the AC input and DC output wires at the supply, making sure to trim off any exposed wire and then tape and seal the ends to avoid shorting. Hide the wires. This is not a preferred method as it leaves a live AC wire. Caution: Any one of the 4 wires from the power supply may be connected to a terminal on a relay or other junction point. There may be other wires connected to these same points. Only remove the wire directly connected to the supply. Do not remove any other wires connected to these locations. All rights reserved. Subject to change without notice. 4
7. Setting up the Configuration File for the System Turn on the Console. Go to the Menu Selection Screen. Select SETUP UTILITY. The 3000M is configured at the factory to run a standard Crusader 2 kit style system. There are non-standard systems that were manufactured by ANILAM and or other vendors for specific machines or applications. These systems may require setup parameters to be changed. If your system differs from the specifications that follow, you will need to modify the Setup Utility in the appropriate sections. See the 3000M CNC Setup Utility Manual, P/N 70000499, for further instructions. a) Builder Setup Z-Axis Type Verify that it matches your system. None If you have no feedback device on the Z-axis. DRO If you have a feedback device but no control. Linear If you have servo motor control of the axis. b) Builder Setup General Axis Resolution Set for scales (Linear Encoder) with 0.01 mm (0.0005 ) resolution. If you have a different resolution or are using encoders as feedback, you will need to modify this. NOTE: The Z-axis used an encoder on standard systems, however it is setup as a scale with 0.01mm (0.0005 ) resolution. Do not change it if this is your situation. c) Builder Setup General Axis In Position: For scale feedback, match the resolution. Default is.0005 For encoder feedback set accordingly, usually.0004. d) Builder Setup General Axis Backlash Compensation: Default Off for scales. Make appropriate entries if using encoder feedback. e) Builder Setup General Axis Encoder Phase: Default is Not Invert on each axis Adjustment may be required after initial setup. Do not enable the servo until you perform this test and verify proper phasing. Exit the Setup Utility and open the Motion Setup and Testing module. DO NOT ENERGISE THE SERVO AT THIS TIME. Manually move the X, Y, and Z-axis. Determine if the count is in the proper direction for each axis. If counting in the opposite direction, set that axis to Invert and test again. All rights reserved. Subject to change without notice. 5
f) Builder Setup General Axis Default Rapid: Set for 100 IPM. Adjust accordingly. g) Builder Setup General Axis No Motion Filter Parameters: Configured for scales. X, Y, Z, has a KP value of 3, and a value of 0 in all other settings. If you are using encoder feedback, enter the values used in the Rapid Filter Parameter tables. h) Builder Setup General Axis Vector Limits Default is Not Enabled. If you have Vector Limits, enable them accordingly. i) Builder Setup Basic I/O Interface I/O Nodes Can Node 0 Inputs (Source) Configured for Level 1 Inputs as follows: Active High External Start (Bit 8) Stop (Bit 7) Feed hold (Bit 6) j) Builder Setup Basic I/O Interface I/O Nodes Can Node 1 Outputs (Sink) Configured for Level 1 Outputs as follows: All Pulse 200ms M3 = Spindle Forward (Bit 2) M4 = Spindle Reverse (Bit 3) M5 = Spindle Off (Bit 1,4) M8 = Coolant On (Bit 0) M9 = Coolant Off (Bit 1) M2 = Spindle and Coolant Off (Bit 1,4) M30 = Spindle and Coolant Off (Bit 1,4) If you are using any other combination of inputs and outputs, or desire a different setup you will need to configure them. These are configured to control the standard package manufactured by ANILAM. All rights reserved. Subject to change without notice. 6
k) Level 2 SMT No entries required in Setup Utility System pre-wired for standard SMT outputs and Finish Input. Requires an IPI program to be written. Contact ANILAM Technical Support for details. Can Node 0 Inputs (Source) Finish (Bit 9) Active High Can Node 1 Outputs (Sink) SMT 0 (Bit 0) SMT 1 (Bit 1) SMT 2 (Bit 2) SMT 3 (Bit 3) SMT 4 (Bit 4) SMT 5 (Bit 5) Can Node 2 Outputs (Sink) SMT 6 (Bit 0) SMT 7 (Bit 1) S Strobe (Bit 2) M Strobe (Bit 3) T Strobe (Bit 4) l) Tuning the system. The servo system is ready to be turned on once you have verified the Setup Utility matches your machine. Be sure you are prepared to press the EMERGENCY STOP in case you have not configured the system correctly. Refer to the 3000M CNC Motion Setup/Testing Utility, P/N 70000635, for instructions on testing the machine. Be sure to set the Balance and Signal on each axis. You need to enter the Motion Setup and Testing section of the software. Enable the servo and begin. After tuning the machine, it will be ready for use. All rights reserved. Subject to change without notice. 7
Network Connection (Option) Installation To install the network connection, plug the standard CAT5, 8-pin, RJ-45 connector into the RJ-45 plug located on the back of the console. The CNC provides access to network drives via Ethernet. Procedure: 1. Use a standard CAT5, RJ-45 cable for the network connection. Refer to Figure 1. CII REAR PANEL Network Connection Figure 1, Console Rear Panel Refer to CNC Network Setup, P/N 70000483, for an overview of network setup. NOTE: A qualified networking engineer must set up the networking software. Software varies based on the type of network operating system used. All rights reserved. Subject to change without notice. 8
Remote Start/Stop (Option) Installation Objective: To install a remote start/stop pushbutton station on the console. Tools: Small Flat Screwdriver Kit: Part Number Description 33000122 Remote start/stop kit, including preassembled pushbutton station and a 10-32, 3/8 shoulder bolt, P/N 86100853. Procedure: NOTE: Changes to Setup Utility parameters are necessary before operation is possible. To install the Remote Start/Stop (Option): 1. Locate the Start/Stop pushbutton station and the shoulder bolt, P/N 86100853. 2. Remove one of the 10-32 black Phillips head screws on the right side of the console and replace it with the shoulder bolt. 3. Plug the remote start/stop cable into the back of the console at the START/STOP connector. Refer to Figure 1, Console Rear Panel. 4. Hand-tighten both screws on the connector. 5. Mount the pushbutton station on the bolt. Remote Start/Stop Configuration Refer to Figure 2, Remote Start/Stop Setup Map. To configure the Remote Start/Stop (Option): 1. In Manual Mode and with the control turned on, press the red Emergency Stop button; then, press EXIT (F10) to display the Software Options Menu. 2. Highlight Setup Utility, and press ENTER to activate the Setup Options Menu, Menu A. 3. Highlight Builder Setup, and press ENTER to activate the Builder Setup Menu, Menu B. 4. Highlight Basic I/O Interface, and press ENTER to activate the Basic I/O Interface Setup Menu, Menu C. 5. Select I/O Nodes, and press ENTER to activate the I/O Nodes Setup Menu, Menu D. All rights reserved. Subject to change without notice. 9
6. Select DSP2 Node, and press ENTER to activate the DSP2 Input 0 Setup Menu, Menu E. 7. Select Ext Start, and press ENTER to activate the DSP2 Options Setup Menu, Menu F. (The CNC may prompt for a password. If necessary, enter the service level password, and press ENTER. Refer to 3000M CNC Setup Utility Manual, P/N 70000499, Password Restricted Parameters, for more information.) 8. Select Active High, and press ENTER to activate the DSP2 Input 0 Setup Menu, Menu E. 9. Select BIT (F1), and press ENTER to activate the DSP2 Node Setup Menu, Menu G. 10. Select Input 1, and press ENTER to activate the DSP2 Input 1 Setup Menu, Menu E. 11. Select Ext Stop, and press ENTER to activate the DSP2 Options Setup Menu, Menu F. 12. Select Active Low. 13. Press EXIT (F10) successively until the Save Changes? prompt is displayed in the middle of the screen. 14. Select Yes (F1) to save the configuration changes. 15. Enter control software and verify that the Start and Stop button on the push button station function the same way as the green and red START and STOP keys on the keyboard. NOTE: The Start/Stop device must be plugged in. If it is not, the inputs activated above must be set to Off. All rights reserved. Subject to change without notice. 10
Software Options 2. Setup Utility Startup Screen Select Software Package I/O Nodes - Setup 1. DSP2 Node 2. CAN Node 0 3. CAN Node 1 Menu D I/O Nodes Setup Menu Setup Options 1. Builder Setup Menu A Select Setup Menu Builder Setup 3. Basic I/O Interface Menu B Builder Setup Menu DSP2 Input 0 - Setup Function States Curr. Bit 1. Ext Start 2. Ext Stop 3. Auto/Man 2 Menu E DSP2 Input 0 Setup Menu 1. Off 2. Active Low 3. Active High Menu F DSP2 Options Setup Menu Basic I/O Interface - Setup 1. Type... 2. Timeout... 3. Issue SpStop on SvoFlt or Estop... 4. I/O nodes... Menu C Basic I/O Interface Setup Menu DSP2 Node - Setup 1. Input 0 2. Input 1 3. Input 2 Menu G DSP2 Node Setup Menu 33MAP9 CAN I/O 10,000 Yes 3000M Crusader II Upgrade Installation Guide Bit Figure 2, Remote Start/Stop Setup Map All rights reserved. Subject to change without notice. 11
Handy Pulser (Option) Installation The Handy Pulser (Option) combines the functionality of axis selection, jog resolution, and a handwheel in a remote device. Refer to the programming manual for operating instructions on these features. Installation Procedure The following procedure describes how to install the Handy Pulser Kit, P/N 33000949 or 33000965, on 3000M and 5000M Kit style systems. Kit: Part Number 33000949 for 3- and 4-axes systems only 33000965 for 3-, 4-, and 5-axes systems Description Handy Pulser Kit, including preassembled Handy Pulser, one 10-32 X 3/8-inch shoulder bolt, P/N 86100853, and mounting bracket, P/N 23000178. Handy Pulser Kit, including preassembled Handy Pulser, one 10-32 X 3/8-inch shoulder bolt, P/N 86100853, and mounting bracket, P/N 23000178. Required Tools: Small, flat screwdriver To install the Handy Pulser: 1. Locate the preassembled Handy Pulser and the shoulder bolt. Refer to Figure 3. HANDY PULSER X OFF Y Z U W X1 X10 X100 Figure 3, Handy Pulser All rights reserved. Subject to change without notice. 12
2. Facing the console, use the small, flat screwdriver to remove the 10-32, black, Phillips-head screw on the right side of the console. 3. Take the shoulder bolt, P/N 86100853, and place it through the mounting bracket, P/N 23000178, and the washer, P/N 86300090. 4. Screw the shoulder bolt into the hole on the right side of the console and hand-tighten. 5. Hang the Handy Pulser on the bracket. 6. Remove the E-STOP jumper plug, P/N 33000601, from the HANDWHEEL connector and store it in a safe place. NOTE: If the Handy Pulser is not connected to the back of the console, make sure the E-STOP jumper plug is inserted in the HANDWHEEL connector. 7. Plug the Handy Pulser cable into the back of the console at the Handwheel connector. Refer to Figure 1, Console Rear Panel. Figure 4 illustrates the harness handwheel connector. Table 1 shows the Handy Pulser connector pin assignment. 8. Hand-tighten both screws on the connector. PIN 1 PIN 14 Figure 4, Harness Handwheel Connector Table 1, Handy Pulser Connector Pin Assignment Pin Signal Pin Signal 1 Phase A 14 Jog100-8 2 Phase B 15 n.c. 3 +5 VDC 16 Hold In 4 Ground 17 Cool In 5 +24 VDC 18 E-STOP 1 6 X Select-0 19 E-STOP 2 7 Y Select-1 20 E-STOP 3 8 Z Select-2 21 E-STOP 4 9 U Select-3 22 Hold Out 10 n.c. 23 Cool Out 11 W Select-5 24 +24 VDC 12 Jog1-6 25 Shield 13 Jog10-7 All rights reserved. Subject to change without notice. 13
Setup Utility Navigation NOTE: If you purchased your Handy Pulser separately from the CNC, you must configure Setup Utility parameters before operating the Handy Pulser. If you purchased your Handy Pulser with the CNC, Setup Utility parameters are already configured and you only need to mount the Handy Pulser. The Setup Utility provides access to all CNC settings through a layered organization of menus. Each menu contains a list and provides access to configuration settings or another menu. To select a listed choice, highlight the selection. Press ENTER to activate the highlighted selection. For some settings, press ENTER to toggle the setting On or Off. Other settings require you to enter a specific value. To automatically save a highlighted setting, press ENTER or press Exit (F10). To return to a previous menu, close the current menu by pressing F10. Handy Pulser Setup NOTE: Some steps in these procedures may require you to enter a service-level password. Refer to 3000M CNC Setup Utility Manual, P/N 70000499, Password Restricted Parameters. To configure the handwheel in the Handy Pulser: 1. Refer to Figure 5, Handy Pulser Setup Menus, for the menus referenced in this procedure. In Manual Mode or Power-Up Mode, press EXIT (F10) to display the Software Options Menu. 2. In the Software Options Menu, highlight Setup Utility, and press ENTER. The Setup Options Menu, Menu A, is displayed. 3. Highlight Builder Setup, and press ENTER. 4. In the Builder Setup Menu, highlight Handwheel/DRO, and press ENTER. The Handwheel/DRO Setup Menu, Menu C, is displayed. 5. Highlight Handwheel/DRO #1, and press ENTER. The Handwheel DRO #1 Setup Menu, Menu D, is displayed. 6. Verify that Type is set to Handwheel. If necessary, press ENTER to display the Options popup menu, and select Handwheel. 7. Highlight Handwheel in the Handwheel DRO #1 Setup Menu, and press ENTER. The Handwheel #1 Setup Menu, Menu E, is displayed. 8. Highlight Scaling Factor, and press ENTER. 9. Type the Scaling Factor (usually 1.00), and press ENTER. 10. Press EXIT (F10) successively until the Save Changes? prompt is displayed in the middle of the screen. 11. Select Yes (F1) to save the changes. The handwheel is now ready for use. All rights reserved. Subject to change without notice. 14
Startup Screen Software Options Menu Builder Setup 3. Basic I/O Interface 4. Z AxisType 5. Handwheel/DRO Menu B Builder Setup Menu Menu A Setup Options Menu Handwheel/DRO - Setup 1. Handwheel/DRO #1... 2. Handwheel/DRO #2... 3. Coupled DRO Tolerance.. 0.00000 Menu C Handwheel/DRO - Setup Menu Handwheel/DRO #1- Setup 1. Type... Handwheel 2. Phase... Not Invert 3. Handwheel.. 4. DRO... Handwheel #1- Setup 1. Scaling Factor... 1.00 3000M Crusader II Upgrade Installation Guide 3000M HPULSER Software Options 2. Setup Utility Setup Options 1. Builder Setup Menu D Handwheel/DRO #1 - Setup Menu None Handwheel Linear DRO Rotary DRO Coupled DRO Options Menu E Handwheel #1 - Setup Menu Figure 5, Handy Pulser Setup Menus All rights reserved. Subject to change without notice. 15
Peripherals Installation Printer Installation Refer to Figure 1, Console Rear Panel. To install a printer, plug the printer cable into the DB-25 connector located on the back of the console. Keyboard Installation Refer to Figure 1, Console Rear Panel. Plug any standard PC keyboard into the 5-pin mini-din socket on the back of the console. (Use a size adapter, if required.) Installing a keyboard deactivates the console keypad. To reactivate the keypad, unplug the keyboard. Maintenance Procedures You cannot activate the E-STOP function or reset the servos using an external keyboard. These functions require the corresponding keys on the console keypad. NOTE: ANILAM recommends industrial grade keyboards. Objectives: To replace the console fan filter. Tools: Phillips screwdriver Parts: Table 2, Console Rear Panel Parts, lists the parts needed to replace the console fan filter. Procedure: Perform the procedure for the appropriate filters you need to replace. NOTE: ANILAM provides replacement filters P/N 85300009 with each 3000M Crusader II Upgrade. All rights reserved. Subject to change without notice. 16
Replace the Console Fan Filter, P/N 85300009 Refer to Figure 6. Table 2 lists the parts shown in Figure 6. To replace the console fan filter: 1. Remove the screws that hold the frame to the rear panel of the console. 2. Replace the console filter, and reattach the frame. Inspect rear panel filter and verify the fan s airflow monthly. ANILAM recommends that you replace the console filter every three months. However, under some adverse environmental conditions, such as oil vapor contamination and/or high levels of particulate, more frequent filter changes may be required. The suggested interval, in such cases, is once a month. PANEL INSIDE Figure 6, Console Rear Panel Inside View Table 2, Console Rear Panel Parts Item Part No. Description QTY. 1 23000211 Console, Rear Panel, 3000M Crusader II 1 2 85400011 Fan, 12VDC, 0.72 A, 105 CFM 1 3 85400013 Fan Finger Guard 1 4 85300009 Filter, POLY-U 1 5 21900112 Bracket, Fan Filter, Console 1 6 86100238 Screw, #6-32 x 1-7/8 LG PHL PAN HD 4 7 86100166 Screw, #6-32 x 5/8 LG PHL PAN HD, BLK 4 All rights reserved. Subject to change without notice. 17