CNCroom MachBob2 User manual

MachBob2 (MB2)
Owner’s manual
Doc E1.5 (7/27/2016)
for PCB Ver1.3 and 1.5
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Introduction
It is known that the environment in the industry often have interference from electrical power
such as motors, welding machines, magnetic contactor, etc. These signals interfere personal
computer and control board. Bringing personal computer to this environment is a challenge.
We can improve the environment by placing the devices in the control cabinet in the correct
manner. Including installing noise reduction, such as installing Noise filter, Isolated transformer,
etc. However, using computers and control board designed for industrial applications is more
important.
MachBob2 (MB2) is designed for industrial applications. MB2 is designed to work with ESS the
excellent motion controller for Mach3 and Mach4.
Specification and Features
•With ESS, Ethernet connection helps controller and drives located away from PC and has more
noise resistant than USB and parallel port connection.
•Run on Mach3 / Mach4 with Windows XP, Win7, Win8 both 32 and 64 bit, on both desktop
and notebook computers.
•New! Utilizes All 3 ports of ESS.
•New! Motion command signal can be selected between Pulse/Sign, CW/CCW, and Quadrature.
Frequency can be selected from 32 kHz to 4 MHz.
•New! Differential line driver for motion signals makes a longer wiring with more resistant to
interference when comparing to TTL open end.
•New! Single 24Vdc Power supply is needed. On the board consist of 5Vdc isolate and non-
isolate dc2dc converter, thus saving installation space and wiring.
•New! OSSD outputs and safety circuit are implemented. When a peripheral device such as
servo motor drive and/or spindle VFD causes alarm. Safety Circuit will disengage OSSD output.
This method is used in big CNC machine to cut power out off the drives.
•New! LED status for all inputs and outputs including motion control signals. Makes it easy to
diagnose the problem.
•Isolated power and ground between PC, ESS, I/O, which eliminates crossover noise and ground
loop problem.
•New! Polarity and over voltage protection (in conjunction with fuse) for 24Vdc power supply.
•AnaSpeed circuit is implemented - the circuit is isolated from MB2 itself, But be a part of VFD
inverter and acts as a digital VR. High voltage noise of inverter cannot interfere through this
connection.
•A charge-pump signal is provided. This helps users to form a safety interlock condition among
controller and devices.
•22 isolated input points, consist of 17 points of NPN and 5 points of PNP type.
•14 NPN isolated output points, sinks current up to 100mA for each channel (up to 500 mA per
group).
•New! MB2v1.5, 2 relay with both NO, NC contact and off delay time, can be to be used in z-
drop protection application. (MB2v1.3 does not have off delay time).
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•Spring terminal for quicker connecting and disconnecting cable and resistant to vibration. No
more screws loose and tightening forgotten.
Precaution
•Take static discharge before touching any part of ESS/MB2. Grounding your body by
wearing grounding strap or frequent touching the metal chassis of earthed to release
electrostatics.
•Make sure that no high voltage leak from solder iron when soldering solder-bridge –
the safe way is to unplug solder iron off the power socket when it builds up enough
heat for melting lead solder. Hi voltage leaking of most cheap solder irons can
potentially damage the integrated circuit (IC) on MB2 board.
•Beware of Fragile, do not drop electronics board.
•Heat could build up if many of inputs and outputs are on at same time. In some
circumstances a cooling fan is needed to ventilate heat to the ambient air.
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Quick Reference
L L L L L
L L L L L L L L L
24Vdc
Power Supply
24Vdc
VFD Inverter
Analog vi
Foward
(b)Single end
connection
(a)Differential
connection
Drive
Drive
Ports and Pins meaning
X110 = input, port 1, pin 10
Y301 = output, port 3, pin 01
Figure 1 MB2 Overview Connection
Figure 2Summary Tables for Ports and Pins
Quick Reference is a summary for experience users. Figure 1 is a shrinkage view of MB2 board. It
shows a connection of inputs/outputs, power supply, analog output for VFD and axis signals including
differential and single end connection. Suggest that you should try figure (a) first, the differential
connections are more noise resistant than single end connection, figure (b) – Figure 2 is summary
tables of ports and pins reference number. For example X110 meaning X is input, first digit is port
number, last 2 digits is pin number.
Precaution,Heat could build up if inputs and outputs are turned on at the same time. In some
circumstances a cooling fan is needed to ventilate heat to the ambient air.
Pin I/O Term N ame Description Pin I/O Te r m Name Description Pin I/O Ter m N ame Description
1 O SPD Sink output 1 O NO1 Relay 1 O Y301 Sink output
2 O XS Axis step 2 I - OSSD feedback 2 O Y302 Sink output
3 O XD Ax is dire ct ion 3 I X203 NPN input 3 O Y303 Sink output
4 O YS Axis step 4 I X204 NPN input 4 O Y304 Sink output
5 O YD Ax is dire ct ion 5 I X205 NPN input 5 O Y305 Sink output
6 O ZS Axis step 6 I X206 NPN input 6 O Y306 Sink output
7 O ZD Ax is dire ct ion 7 I X207 NPN input 7 O Y307 Sink output
8 O AS Axis step 8 I X208 NPN input 8 O Y308 Sink output
9 O AD Ax is dire ct ion 9 I X209 NPN input 9 O Y309 Sink output
10 IX110 NPN input 10 IX210 NPN input 10 IX310 PNP input
11 IX111 NPN input 11 IX211 NPN input 11 IX311 PNP input
12 IX112 NPN input 12 IX212 NPN input 12 IX312 PNP input
13 IX113 NPN input 13 IX213 NPN input 13 IX313 PNP input
14 OCP ChargePump 14 ONO2 Re la y 14 OY 314 Sink output
15 IX115 NPN input 15 IX215 NPN input 15 IX315 PNP input
16 OBS Axis step 16 OCS Axis step 16 OY316 Sink output
17 OBD Ax is dire ct ion 17 OCD Ax is dire ct ion 17 O AO Analog output
Port1 (output)
Port2 (Pins 2-9 as input)
Port3 (Pins 2-9 as output)
*Output can sink current up to 100mA
and up to 500mA per group of 8 pins
Shrinkage part
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MB2 Layout.
MB2V1.3
MB2V1.5
Figure 3 MB2 V1.3 and V1.5 Board Layout
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8–9mm
18-24 AWG
Input (CN1) – Input terminals, consist of 18 channels of NPN type and 5 channels of PNP type
Axis (CN2) – Axis signal terminals, consist of 6 axes, naming X, Y, Z, A, B, C
Output (CN6) – Output terminals, consist of 14 NPN sink outputs, Analog signal, 2 Relay’s
NO/NC and inlet for 24Vdc power supply
LPT1-3 (CN3-5) – Connectors for ESS
JP1 – Charge Pump override
RJ-45 – Communication connector, part of ESS board
ESS and MB2 piggyback
ESS board will get 5V power from MB2 by close all jumpers and no need external 5Vdc.
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MB2 Connection Diagram
Figure 4 Connection Diagram
Hardware
Connecting the SmoothStepper to Your PC
This part is taken from
http://www.warp9td.com/index.php/documentation/doc-ess#Connecting
The best way to connect your ESS to your PC is to use the Direct Connect method: hook the
Ethernet cable directly from your ESS to the network adapter in your PC. This will make trouble
shooting easier since there are no switches or routers between the ESS and your PC. (A switch
should be fine since it only operates in the lower 3 layers of the TCP/IP stack, but why add extra
equipment if you don't need it. A router should be fine if you only have your ESS and PC
connected to it, but this will require more work to configure and setup. As a result we highly
recommend the direct connection, which is what the SCU [System Configuration Utility]
expects.)
If you don't have an Ethernet Adapter on your PC, we recommend using a a PCI or PCI Express
Ethernet Adapter -OR- a USB 2.0 or USB 3.0 Ethernet Adapter. Quite a few people use these
alternatives successfully, including myself.
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We STRONGLY discourage using a wireless connection to communicate with your ESS. There can
be much more latency or delay involved with wireless communications, along with a much
higher risk of dropped packets. The ESS needs a fast, stable, and consistent link to your PC.
Many people use a second Ethernet connection or their wireless connection on the PC so they
may easily connect to the internet, which is fine.
While you are running Mach and your CNC system, we recommend that you refrain from
browsing the internet, gaming or streaming music or videos. This can cause your computer to
take too much time away from Mach which could cause lost communications with your ESS
(which can ruin your project).
We also recommend that you disable power saving options (monitor sleep and power off timers,
hard drive sleep timers, and computer sleep timers); these have been know to cause lost
communications with your ESS.
We also recommend that you set Windows Update to notify you that there are updates available
instead of automatically installing them on its own.
We also know of cases where antivirus and anti-malware software have caused problems. We
recommend that you disable them while you are running Mach, IF your PC is not connected to
the internet.
Note that you do not need to assign a static IP address to your computer if you program the ESS
to use an address that is in the same subnet as your computer. The subnet is the same if the first
3 groups of numbers in the IP addresses are the same. Quite often Internet routers will assign
addresses in the 192.168.0.x or 192.168.1.x ranges. If you wish to use a DHCP server for your
computer, you can do that but the ESS still needs to use a static IP address in the same subnet. A
direct connection to the ESS is the preferred way to go because there is no question as to
whether there is enough bandwidth available to run your machine reliably.
We STRONGLY RECOMMEND THAT YOU DO NOT hook your ESS up to the same Ehternet adapter
that you connect to the Internet with. There is no telling how much CPU and Ethernet bandwidth
is being used up by other applications or other devices on the network. It is therefore officially
discouraged. You are on your own if you wish to mix the Internet with your CNC data. However,
if you wish to change the IP address of the ESS, you may do so with the Configurator Utility.
If the remainder of this section confuses you, don't worry. The SCU in the next section will do all
of the work for you in just a few mouse clicks! The remainder of this section is just to document
what the ESS uses and needs, you may skip to the SCU section.
The ESS comes configured from the factory with a default static IP address of 10.9.9.9 With your
ESS at 10.9.9.9, you will need to assign your network adapter to use 10.9.9.2 or another valid
and unused address in the subnet. We recommend that you keep the 10.9.9.9 IP address
assigned to your ESS, since all of our documentation and videos will use that value. In fact MOST
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users keep this value assigned to their ESS. However, if there is a need to change it, you may do
so with the Configurator Utility.
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Axis Connection X, Y, Z, A, B, C
AXIS CN2 terminal supplies motion command for drives.
VCC
Dir+
Step+
Dir-
Step-
optocoupler
XD-
XS-
(a) differential connection
(b) single end connection
XD+
XS+
Dir+
Step+
Dir-
Step-
*grounding at drive side
XD-
XS-
Line Reciever
XD+
XS+
Dir+
Step+
Dir-
Step-
Optocoupler
XD-
XS-
*grounding at drive side
Figure 5 Axis command terminal and various connection mode
There are two modes to make connection to CN2.
(a) Differential mode is best noise immunity. Recommended to use differential mode if
possible.
(b) Single end mode is used if drive is not compatible with differential mode. There are two
points of VCC to share with all axes.
MB2
Cable Drive Input
Twisted pair
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Inputs
Figure 6 Input terminal
Figure 6 shows 22 points of inputs. There are 17 points of NPN type which are X110-X115,
X203-X215 and 5 points of PNP type which are X310-X315.
There are solder-bridges underneath of MB2 board for user to bridge input status of X203 –
X210 to safety circuit. The OVR input is override signal for the circuit.
Safety circuit will form AND logic for all involved signals. This helps user to eliminate extra
effort to build separately circuit.
0V
X211
24V
Figure 7 Connection of NPN inputs, it references to 0V
Figure 7, shows conventional way to connect a switch to NPN input, X211 with 0V
MB2 NPN inputs connect to 0V
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X310
24V
0V
X310 24V
0V
0V
24V
(a) external supply
(b) internal supply
COM-
COM-
24V
0V
Figure 8 Connection of PNP inputs, it refer to 24V
Figure 8, (a) shows the way we connect PNP input to external source. This connection is
totally isolated from any part of MB2 circuit. The external circuit is maybe fault output of VFD
drive or servo drive.
Figure 8, (b) shows conventional way we connect PNP input to internal source.
0V
X211
24V 24V
X310
24V
COM-
0V
0V
(a) NPN connection
(b) PNP connection
0V
24V
Figure 9 Sensors connection
MB2 NPN type connection
Brown
Black or white
Blue
MB2 PNP input connect to external source
MB2 PNP inputs connect to internal source
MB2 PNP type connection
Brown
Black or white
Blue
Jumper wire connect to nearby terminal
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Figure 9, (a) shows connection of NPN type of sensors. This connection is applied for X110-
X115 and X203-X215 inputs only.
Figure 9, (b) shows connection of PNP type of sensors. This connection is applied for X310-
X315 inputs only.
X203
X204
Y Home Z HomeX Home
X+ Limit X- Limit Y+ Limit Y- Limit Z+ Limit Z- Limit
E-Stop
X211
0V
Figure 10 an example of E-STOP, LIMIT and HOME connection
Figure 10, shows conventional way to connect Estop, Limit and Home switches. This will form
a AND circuit. Notice that all use NC contact (normally close).
Output
Transistor Sink Output
Figure 11 Output terminal
Figure 11, show 14 points output, each output can sink current up to 100mA and cannot sink
more than 500 mA per one group of 8 as shown in Figure 1.
นอื มสเ ทุ พ์ ทา อเ ร จง ว
VCC
100 mA (max)
L
หรือ
L*
0V
24V
Ynnn
Figure 12 Connecting various load to Y output
MB2 external circuit
External power supply
5-30Vdc
* a diode is needed to
parallel with coil
MB2 External circuit
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Relay
Analog
MB2
AH
AO
AL
CM2
NO2
K2
+
-
AnaSpeed
circuit
Figure 13 VFD connection
AnaSpeed circuit converts PWM signal into analog signal. The maximum voltage level is
depending upon external power supply. For example connect to 0-10V analog input of VFD, it
demands 10Vdc from VFD as well.
AnaSpeed has about ±0.2V top and bottom margin. It is able to generate voltage up to 9.8V
only (10V-0.2V) when given external power supply at 10V. Compensation of this margin can
be done in VFD’s parameter.
Normally, VFD need forward command to rotate the motor. Thus, any NO contact of K1 or K2
can be used for this purpose.
OSSD Output and Safety Circuit
MB2 has an OSSD (Output Signal Switching Device) output for users to form a simple safety
circuit in their system. MB2 energizes OSSD output if there is no any error feeding in and it
will de-energize OSSD output if there is an error occurred.
Most drives will give an OK signal or “Servo Ready” or similar meaning by energizing its
output and external devices will take this status. In this case, MB2 collects OK signals from
various devices thru X203-X210 inputs and send out OK signal to the next device.
However, if there an error feeding in, MB2 will send out “Not OK” signal by de-energize OSSD
output and external safety circuit will stop the hazard.
It is simply to use magnetic contactor as external device to disconnect power supply from
drives or VFD. Override input also provided for temporary energizing the magnetic contactor
which lets machine operator to recover the error.
Connect to Analog
Input of VFD
Connect to Forward
input of VFD
5V or 10 V
Analog Output
0V
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Figure 14 shows safety circuit block and relevant I/O including, inputs, solder-bridge, an
override input and outputs
Warning. MB2 has used a simple safety circuit. There is no guarantee of failure. Thus, users
MUST always check the functioning of the circuit.
Safety
Circuit
X203
X204
X205
X206
X207
X208
X209
X210
Safety OVR (override)i202
OSSD
Figure 14 On board safety circuit
Power Supply
MB2 needs only single 24Vdc power supply to operate the board. The Figure 15 shows input
terminal for 0V and 24V.
There is a non-isolate step down switching regulator converts 24V (12-24Vdc) down to 5V to
power most parts of circuit including inputs and output. However, there is also a special
isolated DC2DC convertor generates 5V for only ESS board.
On board has a small fuse protection against over voltage and polarity reversal.
Figure 15 Power supply connection
24Vdc
0V
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Modification
MB2 has a number of places where users can conduct modification. Instead of using pin
jumper, the solder-bridges are implemented to save cost and space. Users need to solder or
de-solder these bridges to archive their purpose.
*1. Safety circuit inputs; primary function of X203-X210 are normal inputs just like the others.
But these inputs are chose to be inputs for the safety circuit by soldering the bridge.
*2. Pin for PWM Analog, let users choose between Y101 and Y317 (set to Y317 by default)
*3.DC converter – Soldering the bridge to use onboard 5V isolated DC2DC converter
(default). In some cases there are necessary to use external 5V power supply instead of using
a tiny converter. This bridge has to be de-soldered then connect external 5V power supply to
VCC channel at AXIS CN2 terminal.
*4. Free terminal – In some circumstances, users need few extra terminals for their work.
User needs to free terminal by de-solder the bridge. These free terminals are meant to use
with low voltage signal only, not over than 24V.
*7. Off Delay Relay (MB2v1.5) – This feature can be used in applications where off delay is
needed, such as z-drop protection which allows mechanical brake to be engaged before
motor loss its holding torque which happen after control signal or main power is cut off from
its drives. Close the bridge to enable off delay 220 ms for K1 and 440 ms for K2. The delay
time can be extended by adding more capacitors to the provided pads underneath the board.
MB2v1.3
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MB2v1.5
Figure 16 underneath layout of MB2
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Software
Users can obtain up to date software, plugins and tutorials from following link.
http://warp9td.com/index.php/sw
http://www.youtube.com/channel/UCpg3EROtW8xA_KzrFHgn4ZQ
User also can obtain MB2 pre configuration file from product link below.
http://www.cncroom.com/index.php?main_page=product_info&cPath=7&products_id=209
Mach3 Configuration
Users can obtain pre configuration XML file and copy to their system. However, there are
some value needs to be set to suite for user’s application.
After downloading and extracting pre configuration profile. You will find MB2.xml that need
to be copied and pasted into C:\Mach3 which is shown in picture below. Run Mach3 Loader
and choose MB2 profile.
Figure 17 Copy and Paste MB2 pre-configuration
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Figure 18 Mach3 first screen
Menu Config > Ports and Pins
Figure 19 Mach3 Ports and Pins dialog
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Figure 20 Motor output tap
Specify value as shown in the picture.
Figure 21 Mach3 Input tap
Users need to set suitable value by themselves
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