Flashcut CNC 401A Installation instructions

™
Control Made Simple
Model 401A
Signal Generator
Hardware Guide
3
2
1 4
LIMIT
ON
OFF
RXD TXD POWER
West Coast Office
1263 El Camino Real
Menlo Park, CA 94025
Phone [phone] ♦Fax [phone]
www.flashcutcnc.com
Midwest Office
444 Lake Cook Road, Suite 17
Deerfield, IL 60015
Phone [phone] ♦Fax [phone]
www.flashcutcnc.com
Revised 5-28-03
© 1998-2003 FlashCut CNC, Inc.

Table of Contents
1. GETTING STARTED .......................................................................................................................................1
ABOUT THIS MANUAL ................................................................................................................................................ 1
SAFETY AND USAGE GUIDELINES...............................................................................................................................2
2. HARDWARE GUIDE .......................................................................................................................................3
OVERVIEW OF THE SIGNAL GENERATOR .................................................................................................................... 3
FRONT PANEL............................................................................................................................................................. 3
REAR PANEL ..............................................................................................................................................................3
JUMPER SETTINGS ...................................................................................................................................................... 7
JP1 AND JP2 .........................................................................................................................................................7
JP3........................................................................................................................................................................8
JP4, JP5 & JP6 .....................................................................................................................................................8
TURNING OFF THE CONTROLLER ................................................................................................................................8
3. SAMPLE WIRING DIAGRAMS..................................................................................................................... 9
TYPICAL MOTOR SIGNAL CIRCUIT FOR HALF-STEPPING AND MICROSTEPPING DRIVES ..........................................10
TYPICAL MOTOR SIGNAL CIRCUIT II........................................................................................................................11
MOTOR SIGNAL CIRCUIT FOR GECKO DRIVES .........................................................................................................12
TYPICAL OUTPUT LINE CIRCUIT............................................................................................................................... 13
TYPICAL INPUT LINE CIRCUIT ..................................................................................................................................14
I/O CONNECTOR AND HEADER SCHEMATIC ............................................................................................................. 15
SIGNAL GENERATOR BOARD LAYOUT ..................................................................................................................... 16

FlashCut CNC Section 1 Getting Started 1
1. Getting Started
About this Manual
FlashCut CNC is a unique application involving hardware and software, so you’ll
need some instruction to get started.
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.
Section

FlashCut CNC Section 1 Getting Started
2
Safety and Usage Guidelines
When running an automated machine tool, safety is of utmost importance.
For proper and safe use of the FlashCut CNC program and your CNC
machine, the following safety guidelines must be followed:
1. Never let the machine tool run unattended.
2. 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.
WPI, 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. WPI supplies this
product but has no control over how it is installed or used. Always be
careful!
WPI, Inc. is 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.

FlashCut CNC Section 2 Hardware Guide
3
2. Hardware Guide
Section
Overview of the Signal Generator
The Signal Generator provides a flexible interface that controls up to 4 stepper or
digital servo motor drivers, 8 output lines and 8 input lines. It works in
conjunction with the FlashCut CNC software. Please note that there are several
software and hardware settings that affect the use of the Signal Generator. These
settings are described in this manual and in the software User’s Guide.
Front Panel
The front panel of the signal generator has the power on/off switch and 8 LED’s
with the following functions:
3
2
1 4
LIMIT
ON
OFF
RXD TXD POWER
Limit – Turns red when any limit/input switch is open when using
normally closed (NC) switches, or when any limit/input switch is closed
when using normally open (NO) switches. For proper operation of this
LED, JP3 must be shorted for NO switches and open for NC switches.
1, 2, 3, 4 (or X, Y, Z, A) – Turns green when the respective motor is
stepping. Note that the polarity of these lights will be reversed depending
on the Step Signal setting in the Motor Signals Setup dialog box. Also
note that these lights appear brighter or dimmer depending on the Step
Pulse Width setting. A small pulse width will make them very hard to see
in a well lit room.
RXD – Turns yellow when receiving data from the host PC serial port.
TXD – Turns yellow when transmitting data to the host PC serial port.
Power – Turns green when the power switch is turned on.
On/Off Switch – Turns the unit on and off. If there is ever a
communications error while running FlashCut CNC, turn the switch off
and on to reset the internal microprocessor.
Rear Panel
The rear panel has connectors for input and output signals as described below.

FlashCut CNC Section 2 Hardware Guide
4
Model No. 401A
S.N.__________
WPI
Menlo Park, CA
POWER
RS-232
INPUT OUTPUT
MOTOR SIGNALS
FUSE
DC IN – Receptacle for the power supply. The unit is shipped with a 9V
DC, 800-1000mA wall transformer power supply.
Fuse – Cartridge for the fuse. If the fuse blows, replace it with a 3AG,
1.5A slow-blow fuse.
RS-232 – Serial port connector for communication with the host PC (9 pin
female). Most PC’s have 9 pin male or 25 pin male. Use either a 9 Pin
Male - 9 Pin Female or a 9 Pin Male - 25 Pin Female cable depending on
the serial port on your PC.
INPUT – The connector 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
CMOS-compatible inputs. When a switch is open, its input signal is high
(+5V). When the switch is closed, its input signal is grounded low (0V).
The 401A is wired for all normally closed (NC) or all normally open (NO)
switches. When in NC mode, each line that is not connected to a switch
must be wired directly to its ground. When any of the input lines are
open, the red Limit light will illuminate and a signal will be sent to the
host PC to indicate which input line(s) went high. When in NO mode,
each line that is not connected should remain open. The red limit light will
illuminate when any of the switches close. To change between NO mode
and NC mode, set jumper JP3. When JP3 is shorted, it is in NO mode,
when JP3 is open, it is in NC mode. If you are not using any limit
switches, you should set JP3 to NO mode.
If you are using version 1.61 or earlier, and you are using normally closed
switches, make sure the Signal Generator Model 401A option is selected
in the System Options Setup dialog box. If you are using normally open
switches, make sure the Signal Generator Model 401 option is selected in
the System Options dialog box. All input lines must be properly defined
in the Input Lines Setup dialog box. If you are using Version 2 and higher,
go to the Configuration…Input Lines menu and make sure the NC or NO
option is chosen properly for the wiring you are using.
The input lines are also TTL/CMOS-compatible. The FlashCut CNC
display reflects a logic "1" or "OPEN" for a high-level input voltage, or
open switch and a logic "0" or "CLOSED" for a low-level input voltage or
closed switch. Short jumper JP3 if your switches are normally open or
your normal input status is logic high. Leave JP3 open if your switches
are normally closed or your normal input status is logic low. Note that all
switches and input lines should have the same normal state.

FlashCut CNC Section 2 Hardware Guide
5
The input lines are all optically isolated. This means that a 5V power
source must be provided to power the external end of the optical couplers.
There are two ways to do this listed below. Note that you must use only
one of the two options below. If you use more than one, you can cause
severe damage.
1. Use the internal power source on the signal generator by shorting JP1
and JP2 on the circuit board. This is the most convenient option and
works well for most applications, but negates some of the signal
isolation. OR
2. For the best noise immunity, connect an external 5V power supply
through pins 23 (OPT 5V) and pin 25 (OPT GND) of the Motor Signal
Connector (CON5).
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE SIGNAL GENERATOR.
Input lines 1, 2, 3 & 4 are also connected through pins 15, 16, 17 & 18
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 your motor
driver box, such as limit lines or servo position error signal, back to the
Signal Generator through the DB25 cable without the need of 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. Also,
if the Input connector is wired as normally closed, then the signal coming
in through the Motor Signal connector must be normally LOW.
Alternatively, if the Input connector is wired as normally open, then the
signal coming in through the Motor Signal connector must be normally
HIGH. If you are not using input signals through the Motor Signal
connector, then don’t connect them to anything.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit
Jr. Series 16 pin receptacle (part number 39-01-2160), with female pins
(part number 39-00-0039 or 39-00-0047 for 22 gauge or thinner wires).
The input lines as seen from the back of the box are arranged as follows
(all of the ground connections denoted by “G” are optically isolated
ground.):
GGGG
GGGG
8642
75 31
OUTPUT – The connector for up to 8 output lines. These lines are all
compatible with TTL/CMOS level outputs. They are all driven by HCT
family logic. Output logic high is normally 5V and can go down to 3.9V

FlashCut CNC Section 2 Hardware Guide
6
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 20mA of current.
Two additional pins are provided for your output lines: ground and +5V.
If the signal generator has a serial number of 102300 (Rev J) or below,
these are connected to OPT GND and OPT +5V. To make these lines
operational, jumpers JP1 and JP2 must be shorted, or external power can
be provided directly to them. If these lines are shorted, you cannot
provide external power through the OPT GND and OPT 5V pins on the
DB25 Motor Signal Connector.
If the signal generator has a serial number of 102301 (Rev K) or higher,
these are connected to GND and +5V and are not optically isolated.
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 1, 2, 3 & 4 are also connected through pins 1, 2, 3
& 4 respectively of the Motor Signal connector. This makes it convenient
to connect up to 4 output signals to your motor driver box to drive devices
such as solid-state relays that might be in your motor driver box.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit
Jr. Series 10 pin receptacle (part number 39-01-2100), with female pins
(part number 39-00-0039 or 39-00-0047 for 22 gauge or thinner wires).
The output lines as seen from the back of the box are arranged as follows:
8 6 4 2
7 5 3 1
GND
+5
V
MOTOR SIGNALS – The DB-25 male connector for all signals going out
to the stepper or digital servo motor driver(s). If you are using one of the
FlashCut CNC motor drivers, connect this to the DB-25 female connector
on the motor driver using a DB25 M-F interface cable.
The cable used must be a DB-25 Interface Cable with all 25-pins
wired straight through.
The main use of this connector is to provide step and direction signals to
the motor drivers. Each of these signals can provide up to 20mA of
current.

FlashCut CNC Section 2 Hardware Guide
7
Two input pins are provided for optical ground (pin 25) and optical VCC
(pin 23) to power the optical couplers on the input lines (see above). You
can place a 5 VDC power source across these two pins. If you are
powering input lines internally using JP1 and JP2, do not connect
these input pins.
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE MOTOR SIGNAL GENERATOR.
Two pins are directly connected to ground (pin 24) and +5V (pin 22) from
the internal power supply. These are provided to power simple, external,
5V electronics associated with your motor driver. They can source up to
50mA.
The motor signal lines as seen from the back of the box are arranged as
follows:
113
14 25
DB25
Pin
Signal DB25
Pin
Signal
1 OUTPUT 1 14 ENABLE ALL
2 OUTPUT 2 15 INPUT 1
3 OUTPUT 3 16 INPUT 2
4 OUTPUT 4 17 INPUT 3
5 INPUT 5 18 INPUT 4
6 INPUT 6 19
ΑDIRECTION
7 INPUT 7 20 Z DIRECTION
8 INPUT 8 21 Y DIRECTION
9 X DIRECTION 22 Internal VCC +5V
10 ΑSTEP 23 OPT VCC (INPUT)
11 Z STEP 24 Internal GND
12 Y STEP 25 OPT GND (INPUT)
13 X STEP
Jumper Settings
JP1 and JP2
These two jumpers enable you to use the internal power of the Signal Generator to
provide power to the external side of the optically isolated input lines. When JP1
is shorted, OPT VCC gets its power from the Internal VCC. When JP2 is shorted,
OPT GND is directly connected to the Internal GND. If you are providing an
external 5V through pins 23 and 25 of the DB25 Motor Signal connector,
then you must leave JP1 and JP2 open.

FlashCut CNC Section 2 Hardware Guide
8
JP3
This jumper configures the Signal Generator for all normally closed (NC) or all
normally open (NO) switches. When in NC mode, JP3 should be open. When any
of the input lines are open the red Limit light will illuminate. When in NO mode,
JP3 should be shorted. Each line that is not connected should remain open. The
red limit light will illuminate when any of the switches close. If you are not using
any limit switches, you should set JP3 to NO mode (shorted). If you are using the
FlashCut CNC Limit Switch Kit, you should set JP3 to NC mode (open).
JP4, JP5 & JP6
These switches are for FlashCut CNC Personnel use only and should always be
open.
Turning off the Controller
Always turn off the Signal Generator when it is not in use.

FlashCut CNC Section 3 Sample Wiring Diagrams
9
3. Sample Wiring Diagrams
Section

FlashCut CNC Section 3 Sample Wiring Diagrams
10
Typical Motor Signal Circuit For Half-Stepping and Microstepping Drives
Signal Generator Model 401 A
DB25-22
11
U2D
74LS32N
ENA
STEP
COM
EN
DIR
A+
A-
B-
B+
VDC+
VDC-
32VDC
Shielded Cable
The above schematic shows a typical connection of a single axis motor driver to the motor signals of the Signal Generator.
Each of the step and direction signals have a 22 ohm resistor in series with their outputs. This is to reduce any “ringing” at
the transient switching points. This resistor pack (RP5) is socketed so that you can change the value if needed for your
application.

FlashCut CNC Section 3 Sample Wiring Diagrams
11
Typical Motor Signal Circuit II
Signal Generator Model 401 A
DB25-24
11
U2D
74LS32N
ENA
Step Clock
Logic
Ground
Enable
Half/Full
CW/CCW
0.1 F
µ
0.1 F
µ
Phase A
Phase A~
Phase B~
Phase B
V+
Ground
40VDC
Shielded Cable
Current
Adjust
2K Ω
The above schematic shows a typical connection of a single axis motor driver to the motor signals of the Signal Generator.
Each of the step and direction signals have a 22 ohm resistor in series with their outputs. This is to reduce any “ringing” at
the transient switching points. This resistor pack (RP5) is socketed so that you can change the value if needed for your
application.
In this example a 0.1uF capacitor was placed between the step signal and ground and between the direction signal and
ground. This filters out any transient noise in the signals. It is better to place these capacitors on the drive unit rather than
the Signal Generator.

FlashCut CNC Section 3 Sample Wiring Diagrams
12
Motor Signal Circuit For Gecko Drives
Signal Generator Model 401 A
DB25-22
11
U2D
74LS32N
ENA
STEP
COMMON
DISABLE
DIR
Phase A
Phase B
Phase C
Phase D
V+
Ground
40VDC
Shielded Cable
The above schematic shows a typical connection of a single axis motor driver to the motor signals of the Signal Generator.
Each of the step and direction signals have a 22-ohm resistor in series with their outputs. This is to reduce any “ringing” at
the transient switching points. This resistor pack (RP5) is socketed so that you can change the value if needed for your
application.

FlashCut CNC Section 3 Sample Wiring Diagrams
13
Typical Output Line Circuit
Signal Generator Model 401 A
Solid State Relay
Continental Industries
S505-0SJ610-000
+ 3
Load
1
2
AC Power
Fuse
3.3K
4
OPT
GND
Output1
The above schematic shows a typical connection of one solid state relay controlled by output line 1 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 S505-0SJ610-000. It takes a 3 to 32VDC input and has an output of 24-330VAC.
Each of the output signals has a 22-ohm resistor in series with their outputs. This is to reduce any “ringing” at the transient
switching points. This resistor pack (RP6) is socketed so that you can change the value if needed for your application.
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.

FlashCut CNC Section 3 Sample Wiring Diagrams
14
Typical Input Line Circuit
Signal Generator Model 401 A
OPT
GND
Short
Short
DB25 Pin22
DB25 Pin23
DB25 Pin24
DB25 Pin25
DB25 Pin 8
DB25 Pin 7
DB25 Pin 6
DB25 Pin 5
DB25 Pin 18
DB25 Pin 17
DB25 Pin 16
DB25 Pin 15
OPTGND
The above schematic shows a typical connection of 5 normally closed switches.
These switches are connected between input lines 1-5 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. Since these
switches are normally closed, JP3 should be open.
The input lines are all optically isolated. In this example, JP1 and JP2 are shorted
using the internal power to source the external side of the optical couplers. However,
for the best isolation, JP1 and JP2 should be open, and power should be provided
through pins 23 and 25 of the DB25 Motor Signal connector. Input lines 1-4 and 5- 8
are internally connected to pins 15-18 and 5-8 respectively of the DB25 Motor Signal
connector.
Note that the FlashCut CNC limit switch kit has the same wiring as shown in this
example.

FlashCut CNC Section 3 Sample Wiring Diagrams
15
I/O Connector and Header Schematic

FlashCut CNC Section 3 Sample Wiring Diagrams
16
Signal Generator Board Layout