Centroid GPIO4D Manual

CENTROID
GPIO4D Install Manual
Velocity Mode For 3rd party drives
Without Optic Direct Interface
Last revised 20 June 2014 (277)

Table of Contents
1. Introduction
2. What's included
3. Connecting major components on Bench for testing.
4. CNC11 & PLC Software Installation and Network Configuration.
5. Windows 7 configuration
6. Configuring CNC11 For Bench Testing
7. Bench Testing the MPU11 and GPIO4D
8. Electrically Configuring Inputs On GPIO4D
9. Mounting major components in electrical cabinet
10. Connecting and testing major components in the electrical cabinet
11. Wiring Limit, Estop and Fault Inputs
12. Encoder Wiring
13. Estop Coil wiring
14. Wiring 3rd Party Servo Amplifiers to the GPIO4D
15. Configuring motors, encoders and limit switches in software
16. Wiring auxiliary sub-systems
16.1 Lube pump
16.2 Coolant pump
16.3 Spindle contactors
16.4 VFD Automation Direct GS2 Spindle wiring
17. System Test
Appendix A: Troubleshooting Communication Data Issues
1. Error Initializing MPU11.
2. 452 PC Receive Data Error.
3. Jog Panel Communication In Fault.
4. PLC Communication In Fault (Fiber 3)
Appendix B: Troubleshooting Motion and Encoder Issues
1. Encoders don't count
2. Motors don't move
3. Axis or motor shaft jumps and then faults when motor is put under power.
4. Motion is not smooth
5. Axis does not move correct distance.
Appendix C: Troubleshooting Errors Reported By CNC11
1. Software Ready Fault.
2. Spindle Fault.
3. Lube Fault.
4. Limit Tripped.
5. Encoder differential error.
6. Check MPG cable.
7. Counts differ on homing.
8. Option not available.
9. Parameter missing.
10.Position error.
11. FPWOM

Introduction
This manual describes how to install the Centroid CNC (Computer Numerical Control) system. It is
strongly recommended that you follow each step in order without skipping steps. The PC based
system provides up to 4 axes (upgradable to 8 axes) of closed loop servo interpolated motion,
controlled by industry standard G-Codes. The system is intended for CNC control of milling
machines, routers, lathes, flame, plasma, laser/water jet cutters, and other specialized applications.
This system is intended for to be installed by competent installers, retro-fitters, and machine tool
builders who want to do their own installation. This installation manual is not intended for casual
end users.
Before You Begin:
Installing your new Centroid CNC11 based GPIO4D System is a straight forward process if you
follow the directions included here. Before getting started, please take the time to familiarize
yourself with the schematics, manuals and installation instructions.
While doing the installation, it is very important that you follow the instructions in order and that you
follow them exactly. Your system will not function if you attempt to take shortcuts by skipping steps.
Doing the installation incrementally and testing as you go will allow you to immediately isolate the
cause of any problems that you may run into. A troubleshooting procedure is included for each
section of the installation so that if you do run into any problems, you will be able to quickly isolate
the cause and correct it. In addition to the troubleshooting procedures you can find answers to
many questions in our support forum www.ajaxcnc.com/ajaxbb
If you run into a problem that you can not solve using the troubleshooting procedure or through the
support forum, please fill out the appropriate troubleshooting form included in Appendix A and send
it via email to [email protected]. Fee based phone support is also available if needed. Please
see http://ajaxcnc.com/tech_support.htm for details.

2. What's included:
Make sure your kit is complete and has not been visibly damaged in shipment. The basic
GPIO4D kit includes:
The Centroid CNC11 Based CNC Kit you purchased contains: Qty
1. GPIO4D 4 axis 3rd party Servo Drive interface with integrated PLC 1 ea.
2. MPU11 Motion Controller 1 ea.
3. Fiber Optic Cable 2 ea.
4. +-12VDC, 5VDC Digital Power Supply 2 ea.
6. Power Cable - Digital PS to MPU11, GPIO4D 2 ea.
7. – 11. Connectors & Misc
8. Software Install & Documentation CD

3. Connect major components on your bench for testing.
AThe 110VAC from the power strip to the digital power supplies.
BConnect the digital power cables to the MPU11 and GPIO4D
CShielded CAT5 network cable from the PC to the MPU11. Centroid recommends purchasing the
blue Cat5e shielded F/UTP snag-less patch cables from StarTech, ID # S45PATCH25BL.
DFiber optic cables (2) from the GPIO4D to the MPU11
B-
A-
Z-
COM
N/C
+5V
B+
A+
Z+
ENCODERS
3
1
4
ETHER
NET
4
1
2
56
3
5
2L
5L
MPU11
Digital Power Supply
85-264VAC
PC ETHER
NET
110VAC
110VAC GPIO4D System Interconnect Diagram
IMPORTANT: The MPU11 and GPIO4D MUST be powered on and off
simultaneously.
Digital Power Supply
85-264VAC
1 3
Spindle Analog Spin Analog Com
5 VDC 5V Com 12 VDC -12 VDC 12 Com
PLC ADD 4 PLC ADD 2 PLC ADD 3 PLC ADD 1
GPIO4D
Out 7
Out 10
Out 12
Out 11
Out 13
Out 15
Out 16
Out 6
Out 5
Out 4
Out 3
Out 2
Out 1
Not Used
Not Used
Not Used
5 VDC: Red
5 COM: Black
+12VDC: Orange
-12VDC: Violet
12 COM: Gray
Must Use Shielded CAT5 or Better
A
B
C
D

3. Connecting major components on Bench for testing. (cont)
Powering up for the first time With the major components all connected, confirm that all
components are resting on a non-conductive surface and turn on your power strip to power up your
components and PC. While powering up, you notice that there are 4 LED's next to the power
connector (see red rectangle below) on the MPU11 that flicker while the MPU11 is initializing. After
15-30 seconds the LED's should be in the following states:
FPGA-OK = Solid green
DSP Debug = Flashing ~1 per sec
DSP -OK = Solid Green
+5V = Solid Green

4. CNC11 & PLC Software Installation and Network Configuration.
NOTE: Before installing installing CNC11, all anti-virus and 3rd party firewall
software should be uninstalled (not disabled) and your computer rebooted.
Nearly 100% of all communication problems between CNC11 and the MPU11 are caused by
anti-virus and 3rd party firewall software.
CNC11 & PLC Software Installation and Network configuration on Windows 7 With
your bench configuration completely connected and your PC running and powered up as
described in section 3. Install the CNC11 Software as follows:
1. Download the latest CNC11 Software version. It is important that you download the
latest version of the Centroid CNC11 software before continuing. Click on the link below to
download the latest version of CNC11 software: CNC11 Software download
2. Copy the downloaded file to your desktop. Depending on your Windows 7 settings,
the file you downloaded will be displayed as either cnc11_latest.zip or cnc11_latest. Copy
this file to your desktop and then double click on the file from your desktop.
3. Drag the installation folder from the compressed file to your desktop. The folder in
this example is called centroid-cnc11-v312-D, your version maybe newer but the name will
be the same other than the “v312” which signifies the CNC11 version number.
4. Double click the install folder and double click setup to begin CNC11 install

4. CNC11 & PLC Software Installation and Network Configuration.
5. Select CNC11 Mill and WinPcap for installation. Click “Next”, accept default installation
drive and directory (c:\) and click “Install”
6. Install WinPcap Click “Next” in the WinPcap Setup Wizard window and and check the
“Automatically start the WinPcap at boot” box when prompted.
7. Click “Next” to continue. After the WinPcap installation has finished, click “Next” in the
“Installation Complete” window (above) to continue.
8. Network Adapter Setup. Click the down arrow to display the network adapters that are
currently installed and select the network adapter that is connected to the MPU11. Click
“Next” to continue. When asked if you would like to change the ip address for the adapter
selected, click “yes”.

4. CNC11 & PLC Software Installation and Network Configuration.
9. Installing a PLC program After the CNC11 software has been installed, the installer will
prompt you to install a PLC program, select “Yes”. Click on the “+” signs next to Mill &
GPIO4D and then click on “basic” under Mill->GPIO4D to select it and click “Install”
NOTE: If your install does not contain gpio4d-basic-v2.src, download it here:
gpio4d-basic-v2.zip Once downloaded, copy the files in the zip file to c:\cncm.
Overwrite/replace all files when prompted.
10. Click “Finish” to complete CNC11 software installation. After the PLC program
installation has completed, click “Finish” to complete the installation.
11. Power off the computer, MPU11 and GPIO4D and restart

5. Configuring Windows 7
1. Configuring Windows Firewall To Allow CNC11 to Communicate With The MPU11.
The first time you run CNC11 under Windows 7, you will see a pop up window asking you if
you wish to allow CNC11 to communicate with the MPU11. Check both the “Private” and
“Public” check boxes, in the “Allow cncm to communicate on these networks” section and
then click “Allow access” to continue. If CNC11 timed out while trying to initialize the MPU11,
simply double click the CNC11 icon on the desktop and proceed to section 6.

6. Configuring CNC11 For Bench Testing
If CNC11, Windows and your network have been configured correctly, you should see the
screen below. Press F10 to continue to the main screen. If CNC11 does not start because it
timed out waiting for the MPU11, see Appendix A – Troubleshooting Communication Errors”
Initial Screen on Power Up Main Screen
To do the bench testing you will need to temporarily disable the fault protection logic built
into CNC11 and the PLC program. CNC11 monitors the signal levels of all configured
hardware such as jog panels and encoder inputs and will generate a fault if any hardware
does not respond as expected or if any channel of any encoder is not at it's expected
signal level. In addition, the GPIO4D Basic PLC program contains default logic that
monitors the inputs for Limit Switches (inputs 1-8), Lube Fault(input9), Spindle Fault
(input10), Estop (input11), and Axis Drive Faults (inputs 17-20). If ANY of these inputs are
open and a fault will be issued.
1. Disable encoder faults in CNC11 To disable encoder faults for the spindle encoder input
and the first 8 encoder inputs, set parameter 35 to 0 and parameters 332-335 to a value of
255 and press F10 to save. Use F7/F8 to page down/up though the parameter pages as
needed. To navigate to the parameter menu from the main screen press:
F1-Setup->F3 -Config (pw = 137)->F3 Parms

6. Configuring CNC11 For Bench Testing
2. Home Configuration, Max Spindle and Disable Jog Panel Communication Faults For
Bench Testing, set Max spindle to 3000 and set the home configuration to “Jog”. Also, the
optional Jog Pendant is not connected for Bench Testing, to disable Jog Panel
Communication faults. To change these, go to the “Control Configuration Screen”, use the
arrow keys to select “Machine Home at Powerup” and “Jog Panel Required” respectively
and, when selected, press the space bar to toggle the selections as shown below and press
F10 to save.
To navigate to “Control Configuration” from the main screen press:
F1-Setup->F3 -Config (pw = 137)->F1 Contrl
fig 6.2
After Saving, Press escape to go back to the Main Screen, press F10-Shutdown,
press F2 Power Off, and then power off the MPU11 and GPIO4D. Wait 30 seconds and
power everything back up.
3. Disable PLC faults for Limit Switches, Lube, Spindle, Estop and Axis Faults. At the
main screen press the alt and i keys simultaneously to bring up the real-time I/O display.
Using the arrow keys, move the selection box to the top left LED Ax1_MinusLimitOk (input1)
and press the ctrl alt and i keys simultaneously to invert this input. You will notice that the
LED will turn from red to green and a line will be drawn over the top to indicate that it the
state of the input has been programmatically inverted. Repeat the process until inputs 1-11
and inputs 17-20 are green as shown below.

6. Configuring CNC11 For Bench Testing
4. Enter your Software Unlock Demo Code To enter a software unlock:
From the Main screen press, F7-”Utilities”->F8-”Options”->F1-”Unlock Option”
a. In “Enter Unlock #:” enter 297, in “Unlock Value:” and press enter to display the
“Unlock Value” window.
b. Look at the value in the “Software Unlocks” sheet that shipped with control and
enter the value next to Unlock 297.
5. Clear Any Existing Faults Before Beginning Bench Testing To confirm that all faults
have been cleared before continuing, press F3 to enter MDI. If all faults have been cleared
correctly, the following screen should be displayed:
If the above screen is not displayed, there is an existing fault, please check the status
window to determine the cause of the fault and then clear it. Review sections 6.1 to 6.3
to confirm that all parameters are set as required and that all inputs (1-11 & 17-20 green) are
in the correct state. NOTE: All of the faults highlighted below (as well as others) are “Stop
Faults”. “Stop Faults”, cancel existing jobs, prevent new jobs from being started, stop the
spindle, prevent motion and require that the Estop PLC input be cycled (opened and closed)
in order to clear the fault before continuing. For further instructions on clearing a “Stop Fault”
during Bench Testing” see the next section 6.6 Software Ready Faults

Configuring CNC11 For Bench Testing
6. Software Ready Faults Anytime the CNC11 software has been exited and restarted,
without the hardware also being powered off and restarted, the CNC11 software will report a
“Software Ready Fault”. A “Software Ready Fault”, like spindle, lube, encoder and position
fault is a “stop fault”. A “stop fault” removes power from all motors, prevents program or MDI
operation, turns off all drive and spindle enables and requires that the Estop input MUST be
cycled in order to clear the fault.
To clear a stop fault, press the alt-i keys to bring up the real-time I/O screen, use the arrow
keys to select the EstopOk input(11), press the ctrl-alt-i keys simultaneously to toggle the
input to red, and press the crtl-alt-i keys again to toggle it back to green.
Notice that as you toggle the EstopOk input to red, “Emergency Stop Detected” is displayed
in the status window, toggling it back to green displays “Emergency Stop Released” and the
“stop fault” is cleared.

7. Bench Testing the MPU11 and GPIO4D
Bench testing the MPU11 and GPIO4D will confirm that the MPU11 and GPIO4D are
operational and that the software has been properly configured to begin the installation
process. Bench Testing is required as it provides a known base configuration that our
support engineers can refer to when trying to diagnose any issues that may have arisen. To
complete Bench Testing, a USB thumb drive and DVM (Digital Volt Meter) is required.
1. Set Home and load benchtest.cnc: Press the alt-s keys simultaneously to display the
DRO, press F2”Load”, use the arrow keys to select the file benchtest.cnc and press
F10”Load”. If the DRO does not display when you press alt-s, see section 6.5 Clear Any
Existing Faults Before Beginning Bench Testing
NOTE: If benchtest.cnc is not present in the c:\cncm\ncfiles directory it can be
downloaded here: benchtest.cnc Once downloaded, copy it to c:\cncm\ncfiles directory
and proceed as described above. When ready to begin Bench Test, your screen should be
as displayed:

7. Bench Testing the MPU11 and GPIO4D
2. Testing the analog output for the spindle The GPIO4D provides a 0 to +10VDC
analog output to provide programmable spindle speed control using a VFD. The
default maximum spindle speed specified in the Control Configuration is 3000rpm (fig 6.2).
This configures the control to scale the 0 to +10VDC from 0-3000rpm. A spindle speed
command of S1500 will therefore output +5VDC, a command of S1000 will output +3.33VDC
and so on. Set the DVM to VDC and place the probes at the points indicated below.
Probe Terminals Here -Screw terminals must be tightened down to measure voltage.
With benchtest.cnc loaded, press Cycle start
(alt-s) to begin. The following screen will be
displayed: (You may have to press Cycle start twice)
From there, placing your probes as depicted and
enter the voltage the readings and press Cycle start
to continue.
There a 4 voltage check in the spindle analog
section. After completion the program will continue
to the next section (7.3) Testing the analog
outputs for each axis
NOTE: All analog voltage adjustments are calibrated at the factory. No user adjustments are
necessary. Any adjustments made by the user will void the warranty.
1 3
Spindle Analog Spin Analog Com
5 VDC 5V Com 12 VDC -12 VDC 12 Com
PLC ADD 4 PLC ADD 2 PLC ADD 3 PLC ADD 1
GPIO4D
Out 7
Out 10
Out 12
Out 11
Out 13
Out 15
Out 16
Out 6
Out 5
Out 4
Out 3
Out 2
Out 1
Not Used
Not Used
Not Used

7. Bench Testing the MPU11 and GPIO4D
3. Testing the analog outputs for each axis The GPIO4D outputs -10 to +10VDC signals
for control of up to 4 axes. When testing the -10 to +10VDC analog output for each axis,
place your probes in the appropriate location as indicated below for the axis being tested.
Remember to tighten down the terminals before when measuring voltage.
Probe between Analog Out(+) and Analog
COM(-) at the locations indicated each
axis.
Each axis is tested from 0 to +10VDC and
from 0 to -10VDC in 2.5VDC increments. In
total, 8 measurements are made for each
axis. Enter your readings as prompted.
Bench Testing Completed. Power off and disconnect the components.
Axis 1
Axis2
1 3
Spindle Analog Spin Analog Com
5 VDC 5V Com 12 VDC -12 VDC 12 Com
PLC ADD 4 PLC ADD 2 PLC ADD 3 PLC ADD 1
GPIO4D
Out 7
Out 10
Out 12
Out 11
Out 13
Out 15
Out 16
Out 6
Out 5
Out 4
Out 3
Out 2
Out 1
Not Used
Not Used
Not Used
Axis 4
Axis 3

8. Electrically Configuring Inputs On GPIO4D
1. Selecting the correct SIPS for you input configuration All inputs on the GPIO4D can
be configured for sourcing or sinking operation using either 5VDC, 12 or 24 VDC. The
inputs are arranged in groups of 4 with a common shared by each input in a group. In order
for the control to see an input open and close, for whatever voltage is connected to the COM
of a group of inputs, it's opposite must be switched to each the input. In the example below,
12VCOM is fed to the COM for inputs 1-4 so +12VDC must be switched to each input. For
inputs 5-8, the common is connected to +24VDC so 24Com must be switched to each input.
Voltage Level SIP Value
5VDC 470 Ohm(471)
12VDC 1K Ohm(102)
24VDC 2.2K Ohm(222)
Input Group SIP Number
Inputs 1-4 4
Inputs 5-8 3
Inputs 9-12 2
Inputs 13-16 1
Sips are located behind input headers H9 & H10
IN1
IN2
IN3
IN4
COM 1-4
IN5
IN6
IN7
IN8
COM 5-8
+12VDC
+12VDC
+12VDC
12VCOM
GPIO4D Board

10.Connect major components in your cabinet
Connect the major components in your electrical cabinet just you had done on your desktop in
section 4 but wire your 110VAC service through your cabinet disconnect instead of a power strip.
a) Connect the 110VAC from the disconnect to the GPIO4D & MPU11 power supplies
b) Connect the digital power cable from the MPU11 power supply to the MPU11
Connect the digital power cable from the MPU11 power supply to the GPIO4D
c) Connect the Shielded CAT5 network cable from the PC to the MPU11
d) Fiber optic cables (2) from the GPIO4D to the MPU11
A
B B
D
C

11. Wiring Limit, Estop and Fault Inputs
1. Limit switch, Estop, Spindle Fault & Lube Fault PLC input wiring All inputs used
for Limit switches, Estop, Spindle Fault & Lube Fault must be wired in Normally closed
configuration. The switch should be closed when the machine is in it's operational state.
Wiring any of these inputs in a Normally Open configuration is dangerous as there is no
way to stop the machine in the event that a wire breaking. It also prevents noise from
causing spurious faults because the signal is being electrically held at the operational
level.
The I/O configuration on every machine is different. While the examples below assume
dry contact type switches and utilize 12VDC, your machine may utilize different voltage
levels and different type devices devices such npn, or pnp proximity sensors. If your
devices are proximity sensors, they MUST be 3-wire sensors, 2-wire sensors will not
work reliably. Make sure the SIPS you installed in section 8 match the voltage levels for
your devices as voltage levels.
Failure to install the proper SIPS to match the voltage levels being used will damage the
GPIO4D
Connect your limit switches, lube fault spindle fault & Estop as shown:
Spindle Fault -NC Relay in VFD or OL Spin contacter
Lube Fault -NC Switch on Lube Pump
IN1
IN2
IN3
IN4
COM 1-4
IN5
IN6
IN7
IN8
COM 5-8 12COM
12VCOM
+12VDC
GPIO4D Board
IN9
IN10
IN11
IN12
COM 9-12
IN13
IN14
IN15
IN16
COM13-16 12COM
12VCOM
+12VDC
X- Limit
X+ Limit
Y- Limit
Y+ Limit
Z- Limit
Z+ Limit
W- Limit
W+ Limit
EStop +12VDC