Digital Dream DDCS V2.1 User manual

Standalone Motion Controller
DDCS V2.1
User’s Guide
Digital Dream CNC Co,. Ltd.
www.ddcnc.com

1 DDCS V2.1 Controller Introduction
1) 16 opto isolated digital inputs
2) 3 opto isolated digital outputs
3) Analog spindle control 0-10V spindle control (can be modified as PWM output)
4) 4 axis motor control, max 500KHz per axis
5) ARM9 main control chip
6) FPGA core algorithm chip
7) 4.3 inches TFT screen, resolution ratio: 480x272
8) 17 operation keys
9) 18V-32V power input, minimum 0.5A
10) USB flash disk support for G code file input
11) 1GB internal memory
12) MPG port for our MPG with digital display. Many other MPG’s also supported
13) Jog function for each axis (continuous, step, defined distance
14) Support the operation of quickly specify the running position
15) Support for “Power Cut” recovery. Data is automatically saved.
Digital Dream has a 20 years history in the numerical control industry, specializing in the research, devel-
opment and production of various CNC (Computer Numerical Control) systems. Digtital Dream aims to
combine high quality and high reliability with affordability. We produce 1 axis to 6 axes CNC system.
The DDCS V2.1 is a 4 axis motion controller for stepper and servo systems. We are very proud of this
product, it combines great power with a tiny footprint and is easy to use. After a very short time you will be
familiar with the functions and this manual will help you. The highest output pulse per axis is 500KHz. The
pulse width is adjustable (refer to driver manual). The control period of each position is only 4 milliseconds.
This provides high control precision for stepper motors and servo motors.
The DDCS V2.1 numerical control system adopts the ARM+FPGA design framework. ARM controls the
human-computer interface and code analysis and the FPGA provides the underlying algorithms and creates the
control pulse. This guarantees reliable control and easy operation. The internal operating system is Linux based.
The panel layout structure of the DDCS V2.1 is very rational to save space. All operations are controlled
by only 17 keys and a comprehensive G code set is supported.
The DDCS V2.1 can be used for many styles and types of CNC machines. Lathes, Routers, Pick&Place and
Mills are just a few examples. The DDCS V2.1 operates as a Stand Alone system without the need of a comput-
er. This guarantees high precision, accuracy and reliability. The interface, even very comprehensive, can be
learned in a very short time.
1.1 Introduction of Product
1.2 Performance parameter of the Digtital Dream DDCS V2.1
Page -1Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The DDCS V2.1 is a small box that can fit in a window of a small control box or control cabinet. Two
locking hooks fix this controller from the inside. The dimension you find in picture 1-1 and picture 1-2.
The front panel is 163mm*102mm*5mm；
The main body is 156mm*93mm*45mm；
To mount the unit in an equipment cabinet, cut the hole156mm*93mm
1.3 Appearance, Structure and Size of Product
Picture 1-1 DDCS V2.1 Front external view and dimensions
Picture 1-2 DDCS V2.1 Rear view and dimensions
Page -2Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual
5 mm
163 mm
102 mm

The front panel consists of 17 user keys and the 4.3’’ (480*272) LCD. The rear side provides screw termi-
nals for power (18-32V), input signals, spindle control, pulse and direction for 4 stepper/ servo drives, MPG,
four programmable interfaces as well as an USB input. Please see the reference picture 1-3 and picture 1-4 in
detail.
Picture1-3 Front panel
Picture 1-4 Rear view
4.3'' Screen
17 user’s keys
Input Ports
Spindle&output Ports
Stepper/
Servo Ports MPG Ports
Power Supply
18~24VDC
USB Port
Page -3Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

When operating the DDCS V2.1, the users will come across some English abbreviations. Here a list with
explanations
FRO: Feed Rate Override
SRO: Spindle Rate Override
SRJ: Jog Speed Setting
F: Feed rate, unit is mm/min
S: Spindle Speed, unit rev/min.
X: The coordinate code of the X axis.
Y: The coordinate code of the Y axis.
Z: The coordinate code of the Z axis.
A: The coordinate code of the A axis
BUSY: The system is busy. You still can adjust FRO and SRO
READY: READY mode, any operation can be done
RESET: Reset mode, controller is in “OFF” mode, no operation can be performed
CONT: Continuous mode, each axis can be manually jogged with the arrow keys
Step :Manual Step Mode，each axis can be jogged in defined steps
MPG: MPG mode. Operate the machine with the MPG (Manual Pulse Generator)
AUTO: Run G code. Auto is showing when file is processing
Keep away from exposure to moisture or water. This product contains sophisticated electronics
and must not get wet.
Wiring warning: the IO input terminal of this controller supports equipment with source power (such as
Inductive Proximity Switch ). When using this kind of equipment, pay attention to the polarity. Avoid the
+terminal to be connect with GND. This controllers has analog output for spindle control (0-10V). Please avoid
this terminal to ever connect with GND as damage to the controller may occur.
Operation warning. Please observe all security measures when operating the machine. The ESTOP
must be connected and properly labelled. In case of a problem, press the E-stop at once to avoid
damage to humans, animals and the equipment.
High voltage danger. The DDCS V2.1 is connected to18-32V DC. Obey and follow the electricity safety
rules of your country when connecting this equipment.
1.4 Explanation of Abbreviations
1.5 Notes and Warnings
Page -4Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

2 Wiring
In general, the power supply of industrial control’s equipment products are complex. They have many
different ground levels. The internal power structure of this product is as follows:
See picture 2-1. The Master Power input and MPG module and stepper control module have the same
ground. Limit,ESTOP and other input modules as well as the spindle speed control output /M3/M8/M10 and
other output modules have the same ground, which use optical isolation. The Limits, E-STOP and other input
modules are connected with the same positive. The controller provides 12V as the common + port, without the
requirement of the external power source. As for the spindle port, take the output ground for references and the
0-10V adjustable voltages to adjust the spindle speed (refer to spindle VFD manual). The M3/M8/M10 digital
output ports pull to ground. You can connect an external relay with up to 50mA direct to 12V+ and the M
connector (Solid State relays usually pull between 15 and 20mA)
As the picture shows, the wiring section of the controller has Input Ports,Spindle&Output Ports,tepper/Ser-
vo control step and direction output,MPG Port, USB Port and Power supply Port.
2.1 Power supply explanation
2.2 Product Wiring
Picture 2-1 Power supply structure
Picture 2-2 Wiring and Ports
Input Ports
Spindle&output Ports
Stepper/
Servo Ports MPG Ports
Power Supply
18~32VDC
USB Port
Page -5Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

As Picture 2-3 shows, the power interface, a 5.08mm screw terminal. The right terminal is the positive
power, the left wiring terminal is the negative power.
Use 18V-32V±0.5V. The current must be equal or >0.5A
2.2.1 Power Supply Wiring
This USB port is the standard USB A-type. A 50cm USB extension cord with installation plug is supplied
with the controller. See sketch diagram picture 2-4 for reference.
2.2.2 USB Wiring
Picture 2-3 Power supply Wiring
Picture 2-4 USB interface extension cord
+-
DC 18V~32V
be equal or >0.5A
Page -6Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The MPG port picture is shown in Picture 2-5. It is the 8+9 double row screw terminals next to the
USB port.
The MPG port has 17 screw terminals, see Table 2-1 for reference. See Table 2-2 and table 2-3 for the wiring.
2.2.3 MPG Port
Picture 2-5 MPG port
Table 2-1 Cr8-500’s MPG Port
Pin Mark Definition Notes
ESTOP of MPG Connect with GND,ESTOP is in effect.Open indicates Estop is invalid
Select switch 1 X Connect with GND, indicates selecting1 X, open indicates no pulse
Select switch 10 X Connect with GND, indicates selecting10 X, open indicates no pulse
Select switch 100 X Connect with GND, indicates selecting100 X, open indicates no pulse
MPG Ground MPG power supply ground, so it is the switch signal reference ground
MPG B phase negative MPG B phase differential input negative terminal
MPG A phase negative MPG A phase differential input negative terminal
MPG power supply 5V output Exclusive use supply terminal of MPG, which can restore the fuse
connection with a 200MA of the system power supply.
MPG serial communication input Used for digital display of theMPG communication
Select switch of X axis Connect with GND, indicates selecting X axis, open indicates no selecting
Select switch of Y axis Connect with GND ,indicates selecting Y axis, open indicates no selecting
Select switch of Z axis Connect with GND, indicates selecting Z axis, open indicates no selecting
Select switch of A axis Connect with GND, indicates selecting A axis, open indicates no selecting
MPG B phase positive MPG B differential input positive terminal
MPG A phase positive MPG A phase differential input positive terminal
MPG ground MPG power supply reference ground.
MPG serial communication output Used for digital display of the MPG
ESTOP
X10
X100
Ground
B phase-
A phase-
+5V-W
RXD
X select
Y select
Z select
A select
B phase+
A phase+
ground
TXD
X1
ESTOP X1 X10 X100 GND WHB- WHA- +5V-W RXD
X-IN Y-IN Z-IN A-IN WHB+ WHA+ GND TXD
Page -7Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

Note: It you want to use the single-terminal MPG (there is no A-B-MPG), please refer to table 2-3 for reference.
As for the unlisted MPG, please take the differential MPG wiring mode.
DDCS V2.1 Wiring Pin MPG Pin Mark and Color
C Light blue
X1 Grey
X10 Black/Grey
X100 Orange
X Yellow
Y Black/Yellow
Z Brown
4 Black/Brown/
A+ Green
A - Purple
B+
B-
White
Purple/Black
0V/CN/COM Black;Black/Light Blue;Black/Orange
Red
X1
X10
X100
X Select
Y Select
Z Select
A Select
A phase+
A Phase-
B phase+
B Phase-
Ground
+5V-W
ESTOP
+5V
Table 2-2 Differential MPG and DDCS V2.1 wiring mode
Table 2-3 Single-terminal MPG and DDCS V2.1 wiring modeh
A+ Green
0V Black
B+ White
0V Black
DDCS V2.1 Wiring Pin Mark MPG Pin Mark and Color
A phase+
A phase-
B phase+
B phase-
Page -8Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

Picture 2-6 shows the stepper/servo control output screw terminals (second group of screw terminals from
the right). As for the connection between system and stepper motor drive, please refer to Table 2-4.
2.2.4 Stepper/Servo control output
Picture 2-6 Stepper/servo control output terminal
GND Dir X Dir Y Dir Z Dir A
+5V-S Step X Step Y Step Z Step A +5V-S
Stepper/servo control interface wiring reference table 2-4
Table 2-4 DDCS V2.1 stepper/servo control interface definition
Pin Mark Definition Note: positive+common wiring method
Note: Strictly avoid to directly connect +5V to GND
+5V-S
Ground
Pulse X -
Direction X-
Pulse Y-
Direction Y-
Pulse Z-
Direction Z-
Pulse A-
Direction A-
5V+ positive terminal
GND
X axis pulse
X axis direction
Y axis pulse
Y axis direction
Z axis pulse
Z axis direction
A axis pulse
A axis direction
Common terminal for Step+ and Dir+
Not used
X axis pulse signal negative terminal
X axis direction signal negative terminal
Y axis pulse signal negative terminal
Y axis direction signal negative terminal
Z axis pulse signal negative terminal
Z axis direction signal negative terminal
A axis pulse signal negative terminal
A axis direction signal negative terminal
Page -9Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The spindle control output terminal offers connections for Start and Stop of the Spindle (M3/M5),
Start/Stop of Cooling (M8/M9) and Start/Stop of Lubrication (M10/M11). These three output terminals are
signals open to ground. The highest electric current can be absorbed is 50mA. The speed controlling output
terminal can output 0-10V. It can adjust the speed of the spindle motor by sending the voltage between 0 and
10V to the VFD according the the Spindle Speed Setting.
Controlling the speed of a spindle with a VFD (variable frequency drive) only needs the Start/Stop signal
and the 0-10V signal to control the frequency.
M3/M5 is connected to FWD (sometimes called FOD,Forward),
GND-0 is connected to CM (also called DCM),
VSO connects to Speed adjustment which defined by voltage 0-10V,
GND-0 connects to CM (also called ACM).
Many VFD’s have DCM and ACM in common so only one needs to be connected. In case they are not in
common, both need to be connected.
As the picture 2-7 shows, the third group of screw terminal blocks from the right are the spindle control
output terminals. As for the definition, please see Table 2-5.
2.2.5 Spindle control output
Picture 2-7 Spindle control output terminal
VSO M3/M5 M8/M9
M10/M11GND
DDCS V2.1 wiring pin SUNFAR E300
AI
FWD
CM
Speed output（0-10V）VSO
Start and stop of spindle (open ground)
Output ground
Output ground Note: Some VFD’s have the ground for 0-10V
and the input signal FWD separate. In those
cases both grounds need to be connected.
Table 2-5 DDCS V2.1 VFD wiring
Page -10Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

This screw terminal block contains three kinds of input signals. The external switches for Start and Pause,
Probe, Limit/Home and E-Stop. Home and Limit switches can be NO or NC, the parameters can be set accord-
ingly in the Parameter Page.
As picture 2-8 shows, the far left terminal block is the Input Port.See pictures for reference
2.2.6 E-STOP, Limit, Home and Probe Inputs
Picture 2-8 Input Port terminal
Start Estop +12V Limit X- Limit Y+ Home Y Home Z- Limit A+ Home A
+12V Pause Probe Limit X+ Home X Limit Y- Limit Z+ Home Z Limit A- GND
Picture 2-9 ESTOP, LIMIT and PROBE input signal circuit
Page -11Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The following picture 2-10 shows the wiring of the external Start, Pause and E-Stop
Picture 2-10 Wiring diagram of the external Start, Pause and ESTOP
Picture 2-11 Wiring of Limit X+ switch
E-Stop Start Pause
External Buttons
-+ -+ -+
Start Estop
Pause+12V
Start Estop +12V Limit X- Limit Y+ Home Y
+12V Pause
Probe Limit X+ Home X Limit Y-
+
-
+12V Limit X+
Start Estop +12V Limit X- Limit Y+ Home Y Home Z-
+12V Pause Probe Limit X+
Home X Limit Y- Limit Z+
Page -12Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

Picture 2-12 Wiring of Limit X+ switch
Picture 2-13 Wiring of Limit X+ switch
Home Z- Limit A+ Home A
Limit Z+ Home Z Limit A- GND
Limit A+ Home A
Limit A- GND
Start Estop +12V Limit X- Limit Y+ Home Y Home Z- Limit A+ Home A
+12V Pause Probe Limit X+ Home X Limit Y- Limit Z+ Home Z Limit A- GND
+12V Limit X+ GND
Page -13Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

Picture 2-14 Wiring of the Probe
Limit/home general micro switch or wiring mode of 2-line Inductive proximity switch:
Picture 2-15 Inductive proximity switch wiring mode
+12V Probe
Start Estop +12V Limit X- Limit Y+ Home Y
+12V Pause Probe
Limit X+ Home X Limit Y-
Page -14Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The picture 3-1 shows the Main page of the DDCS V2.1. It is divided into status column, coordinate
display column, basic parameter column, and notification column. In total, it is divided into 18 sections in
detail. Here the detailed description of the 18 sections :
1、X Coordinate
This column shows the current coordinate value of X. The display range is -99999.999~+99999.999, the
minimum JOG value is 0.001.
2、Y Coordinate
This column shows the current coordinate value of Y. The display range is -99999.999~+99999.999, the
minimum JOG value is 0.001.
3、Z Coordinate
This column shows the current coordinate value of Z. The display range is -99999.999~+99999.999, the
minimum JOG value is 0.001.
4、A Coordinate（This section has no definition in the 3-axis）
This column shows the current coordinate value of A. The display range is -99999.999~+99999.999, the
minimum JOG value is 0.001.
5、Current Operation
When the controller runs the G code file, it will show the current operation line number and coordinates.
When the operation state is READY, it will show nothing
6、Page
The page shows the current page. This controller has 3 pages, Main Page, File Page and Configuration
Page. Press Page button to move between the Pages.
7、Operation Window
This message window switches between 3 displays. It shows the prompt message of several keys and the
2nd (second function)
3 Software Operation and Parameter Settings
3.1 Interface description
The software interface contains 3 pages. Main page, File page and Configuration page.
Picture 3-1 Main page
3.1.1 Main page
1
7
8
9
10
11
12
13
14
18 17 16 15
2
3
4
5
6
Home Z- Limit A+ Home A
Limit Z+ Home Z Limit A- GND
Page -15Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The message displayed while in normal state is: Normal Mode.
The message displayed of the 2nd function status is:
X-: goto, Y-: zero, Z-: home, A-: probe, Start: goto break
If you now click X-, the machine will move to Zero. If you click A-, the probe function will be activated.
If you click Y-, all coordinates will be set to Zero. If you click Z-, the machine will home. If you click Start, the
Start Line window appears and you can enter the G-code line you want to start from. Click on Pause to enter the
breakpoint CONT Callback Function.
Tip:
You need to click these functions twice to activate them (first click is “select”, second click is “activate”.
Tip:
When you are in an Editing Window, you can insert values by using the following keys:
X-: moves the cursor left
X+: moves the cursor right
Y-: decrease the value
Y+: increases the value
Z-: Enter
Z+: Cancel
8 Coordinate System
With the DDCS V2.1 control panel it is very easy to control your Machine Coordinates and Work Offset
Coordinates. Click FRO/SRO/SJR (from now on only called FRO) 6 times until the coordinate system is
highlighted. Here you can display G54 to G59 and MACH (Machine Coordinates) by clicking A+ and A-
Tip
After selecting a function with the FRO key you use the A+ button to Select and the
A- button to Modify the value.
If the function can be edited, the Editing Window will open and you can edit with:
X-: moves the cursor left
X+: moves the cursor right
Y-: decrease the value
Y+: increases the value
Z-: Enter
Z+: Cancel
9、Status of M3/M5,M8/M9 or M10/M11
M3/M5: Start/Stop Spindle
M8/M9 : Start/Stop of Cooling
M10/M11: Start/Stop of Lubrication
10、Speed of spindle
S stands for Spindle Speed. Click FRO till S is highlighted,click A- to modify and edit the value you want.
The display shows two values. The left value is the real time Spindle Speed, the right value shows the
default Spindle Speed. The Default Spindle Speed can be changed, use the A- key to modify.
11、Feed speed
F stands for Feed Speed. Click FRO till F is highlighted, click A- to modify and edit the value you want.
The display shows two values. The left value is the real time Feed Speed, the right value shows the default
Feed Speed. The Default Feed Speed can be changed, use the A- key to modify and edit.
Page -16Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

12、SJR
SJR controls the jogging of the machine. Click FRO till SJR is highlighted.
First Option: MODE
Check window 18 and you can see what Jog Mode you are in. By clicking MODE you can change Jogging
to Continuous, Step or to MPG, Window 18 will display this function.
When in Cont Mode, A+ and A- can adjust the speed in 10% increments
When in Step Mode, A+ and A- can change from 0.01mm to 0.1mm to 1mm and to 10mm
When in MPG mode you can use the MPG to jog the machine
Second Option: Jog a defined distance
13、SRO
SRO controls the Spindle Speed. Click FRO till SRO is highlighted, use A+ and A_to adjust the Spindle
Speed in 10% increments
14、FRO
FRO controls the Feed Speed. Click FRO till FRO is highlighted. Use A+ and A- to adjust the Feed Speed
in 10% increments
15、Working time
This column shows the processing time of the G code operation. Time keeping is halted during Pause
16、Processing file
This column shows the name of the processing files. In the formal situation, it only shows the filename.
Under the situation of CONT adjust, it will also show the content of the file.
17、Operating Status
This column shows the operating state. The status and implications can be displayed as follows:
Busy: Operation is running
Reset: Reset flashing = controller not active. To activate the controller click Reset
READY: Ready state. Controller is ready and all operations can be performed
18、Feed status
This window shows the feed status of Jogging and File Processing.
AUTO: displayed while processing and executing the G code file
CONT: indicates Jog CONTINUOUS. You can Jog manually with the “-”or “+” keys of X Y Z and A. A
short click will move the axis in the defined step, a long click will move the axis till you let go
Step: Jogging in Step Mode
Page -17Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

Click the Page button once and the File Management Page will open
As the picture 3-2 shows, the file management page can be divided into 5 columns
1、Change Directory
2、Subfolder list of current Directory
3、File list of current Directory
4、Files size column Shows file size in byte
5、Modification time and date
As the picture 3-3 shows, the configuration page can be divided into 4 columns:
1. Parameter Number
Each parameter has a specific number, the parameter can be modified .
2. Parameter Name
The definition of the Parameter is listed in the Parameter Name column. All Parameters are divided into
groups according to their function.
Click the Page button once and the File Management Page will open:
Picture 3-2 File management page
3.1.3 Configuration Page
Picture 3-3 Configuration page
3.1.2 File Management Page
1
2
3
4 5
Page -18Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual

The picture 3-4 shows the key layout of the DDCS V2.1. The Controller DDCS V2.1 has 17 keys. Please
see table 3-1 for reference.
Picture 3-4 Keys Layout
3.2 Definition of Keys
Keys Icon Function No. Definition Notes
3. Parameter Value
The Parameter Value column lists the value of each Parameter. This value can be configured
4. Parameter Unit
The Parameter Unit lists the unit of each parameter.
1
1
Start operation
After loading the G code file, please press this key
to start the operation. In case of Pause Status,
press this key to continue the processing operation.
Pause operation Press this key to Pause the operation.
1 Reset and E-STOP If Reset is blinking, press this key to activate the
controller. Press this key to stop processing urgently.
1Page switch
Toolpath display switch
Switch through File Management Page, Processing
Main Page and Parameter Configuration Page.
1Switch the display between Coordinate Display or
Tool Path Tracking display.
1Spindle manual start/close
Press this key to manually switch the spindle on or
off. Can not be used if Reset is blinking and while
processing an operation (Busy)
Page -19Digtital Dream 4 Axis Motion Controller DDCS V2.1 User’s Manual