Vital Systems DSPMC pn7762 User manual

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 1 www.vitalsystem.com
Table of Contents
License Agreement........................................................................................................................................ 2
I. Introduction ............................................................................................................................................... 3
Package Contents...................................................................................................................................... 3
II. Setup ......................................................................................................................................................... 4
Setting up the Vital CNC Control............................................................................................................... 4
Integrating the Vital CNC Control with your machine .............................................................................. 6
Internal Layout...................................................................................................................................... 6
Digital I/O Signals .................................................................................................................................. 7
Drive Connection with Maxsine AC Servo Drives and 7736 Board ....................................................... 8
Drive Connection Without Using the 7736 Board ................................................................................ 9
Mach3 and Software Setup..................................................................................................................... 11
Configuring the Default Profile ........................................................................................................... 11
Creating your own Mach3 profile ....................................................................................................... 16
III. Operation ............................................................................................................................................... 19
Front Panel Controls ............................................................................................................................... 19
MPG Handwheel Controls....................................................................................................................... 21
TroubleShooting..........................................................................................................................................22

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 2 www.vitalsystem.com
License Agreement
Before using the Vital CNC Control and any accompanying software tools, please take a moment to
review this License agreement. Any use of this hardware and software indicate your acceptance to this
agreement.
It is the nature of all machine tools that they are dangerous devices. In order to be permitted to use the
Vital CNC Control on any machine you must agree to the following license:
I agree that no-one other than the owner of this machine, will, under any circumstances be responsible,
for the operation, safety, and use of this machine. I agree there is no situation under which I would
consider Vital Systems, or any of its distributors to be responsible for any losses, damages, or other
misfortunes suffered through the use of the Vital CNC Control and its software. I understand that the
Vital CNC Control is very complex, and though the engineers make every effort to achieve a bug free
environment, that I will hold no-one other than myself responsible for mistakes, errors, material loss,
personal damages, secondary damages, faults or errors of any kind, caused by any circumstance, any
bugs, or any undesired response by the board and its software while running my machine or device.
I fully accept all responsibility for the operation of this machine while under the control of the Vital CNC
Control, and for its operation by others who may use the machine. It is my responsibility to warn any
others who may operate any device under the control of the Vital CNC Control of the limitations so
imposed.
I fully accept the above statements, and I will comply at all times with standard operating procedures
and safety requirements pertinent to my area or country, and will endeavor to ensure the safety of all
operators, as well as anyone near or in the area of my machine.
WARNING: Machines in motion can be extremely dangerous!
It is the responsibility of the user to design effective error
handling and safety protection as part of the system. VITAL
Systems shall not be liable or responsible for any incidental or
consequential damages. By using the Vital CNC Control, you
agree to the license agreement.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 3 www.vitalsystem.com
I. Introduction
Package Contents
Before proceeding to setup your Vital CNC Control, please take a moment to verify that all necessary
components are present within the delivery.
The Vital CNC Control Package should contain the following items:
-Vital CNC Control
-Vital CNC Control Stand (optional)
-MPG handwheel (optional)
-Operator’s Keys
-Backup Software disc (Windows 7)
NOTE: The Vital CNC Control may contain either the HiCON Integra (pn7766) or DSPMC (pn7762)
motion controller depending on the purchase.
Vital CNC Control
with optional stand
MPG Handwheel
(Optional)

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 4 www.vitalsystem.com
II. Setup
Setting up the Vital CNC Control
NOTE: It is recommended to mount your Vital CNC Control or assemble the optional stand before
proceeding with the setup phase.
1. Plug in the power cable to the Vital CNC Control and connect the other end to an outlet. If you
intend setup any wiring, such as inputs, it is recommended that you keep the power switch at
“0”.
IMPORTANT: Before powering up the unit, make sure that all
packing material is properly removed from the inside of the
Vital CNC Control unit.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 5 www.vitalsystem.com
2. Your Vital CNC Control should now be operational and can be turned on with the ON/OFF
Button. The next steps will cover integrating the Vital CNC Control with your machine. During
this phase, the unit must be turned off and unpowered.
Unit is ON

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 6 www.vitalsystem.com
Integrating the Vital CNC Control with your machine
For these next steps, you will need to open your Vital CNC Control to inspect the internal components.
Internal Layout
Below is an image of the contents of the Vital CNC Control. Please use this image as reference while
continuing with the next setup procedures.
NOTE: Some Vital CNC Controls may contain different parts as requested by the user before shipping.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 7 www.vitalsystem.com
Digital I/O Signals
NOTE: Please verify the model of your 7535 Digital I/O Breakout Board before continuing as they can
be provided in PNP (7535P) and NPN (7535N) versions.
Wire the required Digital I/O signals of your machine to the provided Digital I/O Breakout Board. This
breakout board allows the use of 16 Inputs and 8 Outputs, as well as the use of 24V for said Digital I/O.
Detailed Wiring instructions for PNP and NPN versions can be found in their respective sections
See “Internal Layout” section for location of the I/O Breakout Board.
PNP Digital I/O Wiring
NPN Digital I/O Wiring
NOTE: You must also wire your 3-
phase contactor supplying power to
your Servo Drives to the Estop button
contact located inside the Vital CNC
Control to achieve a true hardware E-
Stop.
The Red Disarm Button located on your MPG
Handwheel (if you have purchased it) only
disarms the motion controller.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 8 www.vitalsystem.com
Drive Connection with Maxsine AC Servo Drives and 7736 Board
AC Servo Motor and Drive Packages purchased from the Vital Systems website come with additional
components, for a simple and quick plug-and-play wiring setup.
Said components are:
-1x Drive Interface Board (EPx-DIB) plugs on the servo drive
-1x Blue RJ45 Drive cable
-1x Green RJ45 Encoder cable
-7736 Differential Encoder and StepGen Board
NOTE: the 7736 board works with both DSPMC and HiCON Integra motion controllers. However, this is
only used for the Step/Dir Outputs with the DSPMC.
Setting up the drive connection is simply a matter of plugging the colored cables to the corresponding
colored and labeled RJ45 Ports on the 7736 board and the Drive Interface Board.
The Blue RJ45 cables connect to the drive ports while the green cables connect to the encoder ports.
Connection on 7736 Differential Encoder and StepGen
Board
NOTE: You may also view a video tutorial for this
connection method.
link: http://www.youtube.com/watch?v=xDHRH0ZVeow
Connection on Maxsine AC Servo Drives
WARNING: NEVER interchange the Blue Drive cables with the
Green Encoder cables. Doing so may damage your drives and the
Vital CNC Control.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 9 www.vitalsystem.com
Drive Connection Without Using the 7736 Board
This method is used in case the 7736 Board is not installed or interfacing with non-Maxsine AC Servo
Drives.
NOTE: The 7736 Board uses RJ45 ports for Encoders. For wiring differential quadrature encoders to the
7736 Differential Encoder and Step/Dir Board, please refer to the 7736 Wiring Guide.
NOTE: With this method, it is highly recommended to read the User Guide for the DSPMC Ethernet
Motion Controller. Encoders 8 through 15 are only accessible via the 7736 Differential encoder and
Step/Dir Board on internal ports J11 and J12.
J2 Pin Assignments (Analog Outputs and Inputs):
Pin#
Function
Pin#
Function
1
+12V, 100mA max
20
Analog Input 0
14
+5V, 500mA max
8
Analog Input 1
2
-12V, 50mA max
21
Analog Input 2
15
Analog Output 0
9
Analog Input 3
3
Analog Output 1
22
Ground (return)
16
Analog Output 2
10
Analog Input 4
4
Analog Output 3
23
Analog Input 5
17
Ground (return)
11
Analog Input 6
5
Analog Output 4
24
Analog Input 7
18
Analog Output 5
12
Ground (return)
6
Analog Output 6
25
Ground (return)
19
Analog Output 7
13
+5V, 500mA max
7
Ground (return)

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 10 www.vitalsystem.com
J6 Pin Assignments (Encoder Channels 0 –2):
Pin#
Function
Pin#
Function
1
Encoder Channel 0 A+
8
+5V 500mA
14
Encoder Channel 0 A-
21
Ground (Return)
2
Encoder Channel 0 B+
9
Encoder Channel 2 A+
15
Encoder Channel 0 B-
22
Encoder Channel 2 A-
3
Encoder Channel 0 Z+
10
Encoder Channel 2 B+
16
Encoder Channel 0 Z-
23
Encoder Channel 2 B-
4
+5V 500mA
11
Encoder Channel 2 Z+
17
Ground (Return)
24
Encoder Channel 2 Z-
5
Encoder Channel 1 A+
12
+5V 500mA
18
Encoder Channel 1 A-
25
Ground (Return)
6
Encoder Channel 1 B+
13
Reserved
19
Encoder Channel 1 B-
7
Encoder Channel 1 Z+
20
Encoder Channel 1 Z-
J7 Pin Assignments: (Encoder Channels 3 –5):
Pin#
Function
Pin#
Function
1
Encoder Channel 3 A+
8
+5V 500mA
14
Encoder Channel 3 A-
21
Ground (Return)
2
Encoder Channel 3 B+
9
Encoder Channel 5 A+
15
Encoder Channel 3 B-
22
Encoder Channel 5 A-
3
Encoder Channel 3 Z+
10
Encoder Channel 5 B+
16
Encoder Channel 3 Z-
23
Encoder Channel 5 B-
4
+5V 500mA
11
Encoder Channel 5 Z+
17
Ground (Return)
24
Encoder Channel 5 Z-
5
Encoder Channel 4 A+
12
+5V 500mA
18
Encoder Channel 4 A-
25
Ground (Return)
6
Encoder Channel 4 B+
13
Reserved
19
Encoder Channel 4 B-
7
Encoder Channel 4 Z+
20
Encoder Channel 4 Z-

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 11 www.vitalsystem.com
Mach3 and Software Setup
Configuring the Default Profile
After the digital I/O and the drives have been properly wired, it is now time to switch ON your Vital CNC
Control.
NOTE: Your Vital CNC Control may be password protected on the windows log in. The default
password is “CNC”. It is recommended that the user change this to their own password.
NOTE: Although the purchase of a Vital CNC Control along with Maxsine Motors and Drives allows
Vital Systems to make several configurations within the factory, Digital I/O will have to be wired
manually and configured by the user to suit the target machine.
For a more detailed guide on using DSPMC with Mach3, please refer to the DSPMC User Guide.
Open Mach3 using the default profile provided. You should then see this window popup at the start of
Mach3. Select “M3dspMC” as shown in the picture.
A message like the one below should appear in the Mach3 Status Bar indicating that communication has
been established between Mach3 and the DSPMC.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 12 www.vitalsystem.com
Digital I/O can be configured by going to the Ports and Pins Menu, then the “Input Signals” and Output
Signals tab.
Digital I/O Signals on the DSPMC can be mapped by using setting the Port as 1, and pins 0 –63. Below is
a table showing the physical pin layout and its corresponding Mach3 pin layout.
Inputs
DSPMC Port
Mach3 Ports and Pins
J4
Port 1, pins 0 –15
J5
Port 1, pins 16 –31
J11
Port 1, pins 32 –47
J12
Port 1, pins 48 –63
Outputs
DSPMC Port
Mach3 Ports and Pins
J4
Port 1, pins 0 –7
J5
Port 1, pins 8 –15
J11
Port 1, pins 16 –23
J12
Port 1, pins 24 –31
The image below shows an example for X Home and Limit switches connected to J4 and the Y homing
and limit switches connected on J5. Both must be wired using the 7535 I/O Board.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 15 www.vitalsystem.com
The I/O mapping can also be checked from the Mach3 Diagnostic Tab.
If the Mach3 signals do not correctly activate in response to the state of the Digital Input, then you may
need to check the “Status Window” to see if the Digital I/O state works (or is wired) correctly. If the
signal polarity is incorrect, the active low setting can be changed in the Ports and Pins Config.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 16 www.vitalsystem.com
Creating your own Mach3 profile
Should you want to create your own Mach3 profile, you would need to perform these steps to get your
profile working correctly with the Vital CNC Control.
NOTE: This method requires a better understanding of Mach3, as well as experience with the HiCON or
DSPMC plugin config. It is always recommended to use one of the default profiles.
Open the Mach3 application which can be found in C:\Mach3\Mach3.exe. The profile selection screen
will show up when you open Mach3.
1. Click on Create Profile
2. Type a new profile name. You can either
start with default profile values or clone an
existing profile.
3. Your new profile should now be useable.
4. You may also create a shortcut to your
new profile by creating a shortcut of the
“Mach3.exe”file then right-click to
“Properties”

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 17 www.vitalsystem.com
After creating your own profile, you must perform these additional steps.
1. Copy the macropump.m1s file from the macros folder of any default profile
(Mach3\macros\<profile>\macropump.m1s) and paste it into the macros folder of your new
profile(Mach3\macros\<yourNewProfile>\macropump.m1s).
2. After Mach3 is opened. Go to the general config to enable the macropump.

Vital CNC Control User Guide
© 2014 Vital Systems, Inc. 19 www.vitalsystem.com
III. Operation
Front Panel Controls
Control
Function
Wiring Location
1. Operator Key
Slot
Enables the use of motion control or system enable.
DSPMC:
[J5, Input 6]
2. CPU LED
Indicates the current status of the internal motion controller.
NOTE: If the HiCON motion controller is used, a heartbeat blink
pattern indicates that the motion controller is operational. This LED
will turn off during firmware upgrade by the user.
If using the DSPMC motion controller, the CPU LED will blink slowly
to indicate operational status.
DSPMC:
[J5, Output 0]
3. Estop Button
Disarms the current system and stops all motion. The button can be
twisted clockwise after being pressed to remove the system from
the Estop state.
DSPMC:
[J5, Input 7]
4. Error LED
Turns on when the internal motion controller incurs an error.
DSPMC:
[J5, Output 2]
5. User
Programmable
Function
Buttons
These buttons are wired to specific inputs on the HiCON or DSPMC
and can be mapped to execute custom commands or macros in
Mach3.
DSPMC:
FN1 –[J5, Input 0]
FN2 –[J5, Input 1]
FN3 –[J5, Input 2]
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