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MPU11-AC/DC-GPIO4D

Centroid MPU11, AC/DC, GPIO4D Install Manual

AC/DC servo drive based CNC control system step by step installation instructions

Chapter 1: Whats Included

Chapter 2: Bench Test Hardware

Chaper 3: Software Installation

Chapter 4: Bench Test Software

Chapter 5: In cabinet Installation

Chapter 6: Final Software Conguration

Appendix A/B: Windows 8/7 conguration

Appendix C: General Troubleshooting

Appendix D: AC/DC TroubleShooting

87/99

114

123

Appendix E: Stock Centroid Encoders

Appendix F: Manual conguration of AC/DC servo drive motor parameters

Appendix G: Compatible Servo Motors

www.centroidcnc.com

126

128

136

DRIVE WARRANTY DOES NOT COVER DAMAGE BY FAULTY MOTORS OR WIRING.

The information provided by CENTROID relating to wiring, installation, and operation of CNC components is intended only as a guide, and in all cases a qualified technician and all applicable local codes and laws must be consulted. CENTROID makes no claims about the completeness or accuracy of the information provided, as it may apply to an infinite number of field conditions.

As CNC control products from CENTROID can be installed on a wide variety of machine tools NOT sold or support by

CENTROID, you MUST consult and follow all safety instructions provided by your machine tool manufacture regarding

the safe operation of your machine and unique application.

Servo Motor Handling

When working with servo motors:

· NEVER pick up or carry the motor by the cables or the shaft. (Always carry by the frame.) Use a crane or lift to move

the motor when necessary.

· NEVER drop or subject the motor to impact. The servo motor is a precision device.

· NEVER set heavy or sharp objects on the motor or cables. Do not step or sit on the motor or cables.

· NEVER use a metal hammer on any part of the motor. If it is absolutely necessary to use a hammer, use a plastic

hammer.

Keep the motor properly secured and away from the edge of the work area when servicing the motor, as a dropped motor could cause personal injury or destroy the motor.

Page 2 of 138

Basic Safety Procedures and Best Practices

For Motors

Be safely dressed when handling a motor. Wear safety shoes and gloves. Avoid loose clothing which can get caught on the

motor. Be careful not to let hair get caught in the rotary section of the motor. Do not handle the motor with wet hands.

Shut off the power before working on a motor. Wait at least 5 minutes after the motor is shut off before touching any power terminals.

Ensure that the motor and motor related components are mounted securely. Ensure that the base or frame to which the motor is mounted to is strong enough.

Do not touch the rotary section of the motor when it is running unless instructed to.

When attaching a component having inertia to the motor, ensure any imbalance between the motor and component is minimized.

Be sure to attach a key to a motor with a keyed shaft.

Use the motor in appropriate environmental conditions. Do not store flammables in close proximity to the motor. When not in use, store the motor in a dry location between 0° to 40° C.

Do not remove the nameplate from a motor.

For Circuit Boards

Minimize handling circuit boards as much as possible. If you must hold a circuit board, grab it by the edges as shown below in figure 2. Avoid touching any of the circuits, components, or component leads. Improper handling lead to ESD (electrostatic discharge) which can damage the PCB, and shorten the operational lifespan.

Figure 1.

Improper PCB Handling

Keep the work are free from static generating materials such as Styrofoam, vinyl, plastic, and fabrics.

Page 3 of 138

Figure 2.

Proper PCB Handling

CONTENTS

INTRODUCTION......................................................................................................................................................................................... 6

CHAPTER 1 WHAT'S INCLUDED

1.1 MPU11............................................................................................................................................................................ 7

1.2 Crimpers.......................................................................................................................................................................... 8

1.2 GPIO4D.......................................................................................................................................................................... 9

1.3 AC/DC........................................................................................................................................................................... 10

CHAPTER 2 BENCH TEST SETUP

2.1 Introduction................................................................................................................................................................... 11

2.2 Power Supply Configuration......................................................................................................................................... 12

2.3 Communication Configuration...................................................................................................................................... 14

2.4 Encoder Setup.............................................................................................................................................................. 17

2.5 MPU11 Accessories...................................................................................................................................................... 19

2.6 Powering On and Verifying LED States........................................................................................................................ 21

CHAPTER 3 SOFTWARE INSTALLATION

3.1 Software Preinstallation................................................................................................................................................ 25

3.2 CNC11 and PLC Installation......................................................................................................................................... 26

3.3 AC/DC Setup Wizard.................................................................................................................................................... 30

CHAPTER 4 BENCH TEST

4.1 Software Configuration.................................................................................................................................................. 36

4.2 Bench Testing the AC/DC............................................................................................................................................. 41

4.3 Bench Testing the GPIO4D and MPU11....................................................................................................................... 43

CHAPTER 5 ELECTRICAL CABINET INSTALLATION

5.1 Introduction to Electrical Cabinet Layout...................................................................................................................... 45

5.2 Electrically Configuring Inputs on the GPIO4D............................................................................................................. 48

5.3 Wiring Motors................................................................................................................................................................ 50

5.4 Wiring AC/DC Brake Resistor....................................................................................................................................... 51

5.5 Wiring E-Stop............................................................................................................................................................... 52

5.6 Wiring Limit Switches................................................................................................................................................... 54

5.7 Wiring Lube Pump........................................................................................................................................................ 56

5.8 Wiring Coolant Pump.................................................................................................................................................... 57

5.9 Wiring Spindle.............................................................................................................................................................. 58

Page 4 of 138

CHAPTER 6 FINAL SOFTWARE CONFIGURATION

6.1 Introduction................................................................................................................................................................... 60

6.2 Confirm AC/DC Communication................................................................................................................................... 60

6.3 Confirm Encoder Communication................................................................................................................................. 61

6.4 AC Encoder Alignment.................................................................................................................................................. 62

6.5 Jogging and Motor Direction......................................................................................................................................... 67

6.6 Coarse Adjustment of DRO Position............................................................................................................................. 70

6.7 Homing the machine..................................................................................................................................................... 72

6.8 Calculating Maximum Feed Rate.................................................................................................................................. 74

6.9 Tuning your AC/DC

6.9.1 A Basic Introduction to Tuning and PID......................................................................................................... 75

6.9.2 Tuning Software Setup.................................................................................................................................. 76

6.9.3 Acceleration Tuning...................................................................................................................................... 77

6.9.4 Inertia Tuning................................................................................................................................................ 78

6.9.5 Kp Tuning...................................................................................................................................................... 79

6.9.6 Kd Tuning...................................................................................................................................................... 80

6.10 Fine Adjustment of DRO Position............................................................................................................................... 81

6.11 Removing backlash..................................................................................................................................................... 84

6.12 Deadstart.................................................................................................................................................................... 86

6.13 Other Misc Tuning Information.................................................................................................................................... 86

6.14 Performing a System Test........................................................................................................................................... 86

APPENDICES

Appendix A – Windows 8 Preinstallation.............................................................................................................................. 87

Appendix B – Windows 7 Preinstallation............................................................................................................................. 99

Appendix C – General Troubleshooting............................................................................................................................. 114

Appendix D – AC/DC Troubleshooting............................................................................................................................... 123

Appendix E – Stock Centroid Encoders............................................................................................................................. 126

Appendix F – Manual Configuration of the AC/DC Motors Parameters.............................................................................128

Appendix G – Compatible Motors...................................................................................................................................... 136

Page 5 of 138

Introduction

This manual describes how to install the Centroid CNC (Computer Numerical Control) system with an AC/DC servo drive. The

PC based system provides up to eight axes of closed loop servo interpolated motion, controlled by industry standard G-Codes.

Ours can be used for the CNC control of milling machines, routers, lathes, flame cutters, plasma cutters, laser cutters, water

jet cutters, drill presses, grinders, and other specialized applications.

This installation manual covers the most common AC/DC hardware setups. Specifically, this manual will focus on the following equipment:

• Centroid AC/DC drive,

• Centroid GPIO4D PLC (programmable logic controller)

• Centroid MPU11 (motion processing unit)

• Installation of Centroid Software on a Computer

This manual does not cover an AC/DC drive used with a Centroid RTK4 PLC or Centroid PLCADD1616 PLC, but users of those products will benefit from the information in this manual.

Before You Begin

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. 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. Additional troubleshooting is included in the appendices.

Motor Compatibility

The AC/DC supports over 60 different motors. Including over 50 different Fanuc motors, 6 SEM motors, and 4 Mecapian motors. The easiest way to install an AC/DC is with motors provided by Centroid. Users should only use motors on the list of motors found in Appendix E. What if your motors not on the list? For an evaluation fee, Centroid can evaluate your motor and provide you with the correct software parameters.

In the future, Centroid plans on bringing an advanced set of features to the Centroid CNC11 software allowing users to calculate their own software parameters without the need to have Centroid evaluate their motors.

The First Steps

The first step is to visually inspect everything that came with your kit. Use the charts on the following pages to check for any missing parts and to familiarize yourself with the hardware.

Page 6 of 138 Introduction

CHAPTER 1

WHAT'S INCLUDED

1.1 MPU11

The MPU11 stands for “motion processing unit (version) 11”. The MPU11 is a motion control card that will act as the “brain” for your CNC system. The MPU11 provides the link connecting your computer to all of your drives, PLC, and accessories.

The following components are included with your MPU11:

1. MPU11 ........................................................................................................................... Part Number 11012

2. Power supply.................................................................................................................... Part Number 1331

3. Power supply AC input cable............................................................................................ Part Number 3952

4. Power supply DC output cable ........................................................................................Part Number 3951

5. Twenty four pin MPG connector....................................................................................... Part Number 5984

6. Ten Pin Probe connector.................................................................................................. Part Number 5918

7. Twelve Pin Jog panel Connector...................................................................................... Part Number 5919

8. Twenty six crimp pins for MPG connector ........................................................................ Part Number 5983

9. Twenty four crimp pins for jog panel connector and probe connector ..............................Part Number 5511

Page 7 of 138 1.1 MPU11

1.2 Crimpers

Crimp Pin Part Number 5511 (Used for making jog panel and probe cables)

The appropriate hand crimping tools are available from TE Connectivity as “PRO-CRIMPER III Hand Tool Assembly 91387-1 with Die Assembly 91387-2 (26-22 AWG)” or “PRO-CRIMPER III Hand Tool Assembly 91388-1 with Die Assembly 91388-2 (22-18 AWG)”. These tools are sold separately and can be purchased from most major electronics components distributors such as Digi-

Key.

Fully assembled cables for jog panels and probes can be bought through Centroid.

Crimp Pin Part Number 5983 (Used for making MPG cables) The appropriate hand crimping are available from JST as “YRS-245”. These tools are sold separately and can be purchased from most major electronics components distributors such as Digi-Key.

Fully assembled cables MPG cables can bought through Centroid.

Page 8 of 138 1.2 Crimpers

1.3 GPIO4D

The GPIO4D stands for “General purpose input / output (for up to) four drives”. The GPIO4D is a PLC, meaning it is a “programmable logic controller”.

Essentially the GPIO4D is a set of computer controlled inputs and outputs. On an AC/DC system, the GPIO4D will provide I/O (“input / output”) for subsystems such as lubricant, coolant, and the spindle drive.

The following components are included with your GPIO4D:

1. GPIO4D.......................................................................................................................... Part Number 11018

2. Power supply.................................................................................................................... Part Number 1331

3. Power supply AC input cable............................................................................................ Part Number 3952

4. Power supply DC output cable.........................................................................................Part Number 3951

5. Optic fibers labeled “1” and “3”....................................................................................... Part Number 10018

6. 2 twenty position terminal blocks ..................................................................................... Part Number 3450

7. Twelve position terminal block ......................................................................................... Part Number 1551

8. 4 seven position terminal blocks ...................................................................................... Part Number 2611

9. 2 ten position terminal blocks...........................................................................................Part Number 3904

10. 5 five volt SIPS (color and appearance may vary)............................................................Part Number 3956

11. 5 twelve volt SIPS (color and appearance may vary).......................................................Part Number 4152

Page 9 of 138 1.3 GPIO4D

1.4 AC/DC

Your motors will be controlled by an AC/DC drive. AC/DC stand for “alternating current / direct current” because the drive works with both AC and DC motors.

The following components are included with your AC/DC:

1. AC/DC Drive...........................................................Part Number 12854 (30A) or Part Number 12855 (60A)

2. Fibers labeled “4” and “5”............................................................................................... Part Number 12832

3. Jumper.............................................................................................................................. Part Number 1761

4. Seven position terminal block........................................................................................... Part Number 2611

5. Power Resistor(s) (2 per drive for a 60A drive, 1 per drive for a 30A drive)......................Part Number 7352

6. Power Supply (1 per every 3 drives).................................................................................Part Number 7384

7. Power supply DC output cable...............................................................................Drawing Number S13352

8. Each additional AC/DC will contain the same parts except instead of having a fiber optic cable, a drive wired

communication cable (Part Number 11146) will be included instead.

Page 10 of 138 1.4 AC/DC

CHAPTER 2

BENCH TEST

2.1 Introduction

The first step in installing your new system is performing a bench test. A “bench test” is connecting all of the electronics together to test them before installing the system in a machine. This test is usually done on a work bench, hence the name. A bench test allows you to:

• Troubleshoot hardware and software problems early on, before they can cause permanent damage to the system.

• Identify missing or defective hardware before installing the system

• Allows for greater visibility when troubleshooting than an electrical cabinet.

• Should a serious issue arise, it gives the user a knowledge base that allows Centroid Technical Support to more quickly

and efficiently solve problem.

The bench test ALWAYS needs to be performed BEFORE applying HIGH VOLTAGE to the drive. Applying high voltage to an improperly configured system could cause permanent damage to the hardware and physical harm to the technician or operator. Figure 2.1.1 below shows an example of an AC/DC system set up for a level test. In the following pages we will guide you stepby-step through the setup and execution of a bench test.

Tools and Equipment Needed

• Picking a good location - A bench test needs to be performed on a large table or desk with good lighting and easy access to electrical outlets. The surface should NOT be made out of metal or contain metal scraps or shavings, as we will be resting powered circuit boards on the surface. Do not use fabric covered surfaces because they put the PBC high risk for ESD (electrostatic discharge) damage. Anti-static mats are normally conductive, and make a poor surface for powered boards. Plastic is acceptable, but could put the board at risk for static damage. A wooden surface is an ideal test

bench location.

• Some method of powering multiple 120 VAC devices off and on simultaneously. An outlet strip with an “on/off” switch and some 120VAC power cords is the easiest method. For the remainder of this document, I will assume an outlet strip with power cords is being used.

• A PC with an internet connection, or a Centroid console unit (comes with CNC11 already installed). The PC must meet the specifications listed in Technical Bulletin 273, which can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb273.pdf)

• Some method of splicing wires such as crimp terminals or a terminal block.

• Small screw driver set

• Wire strippers

Figure 2.1.1

Example of equipment set

up for a board level test.

Page 11 of 138 2.1 Introduction

2.2 Power Supply Configuration

1. Connect AC/DC to the power supply

1. Connect AC/DC logic power cable (Dwg No. S13352) to the power supply (PN 7384) as shown in below Figure 2.2.1.

Up to three AC/DC's can be powered with a PN 7384 supply.

1. Connect the shield (bare metal), 5V ground (black), and the 12V ground (green) to the common terminal as

shown in Figure 2.2.1.

2. Connect +5V to +V1 and +12V to +V2.

3. Connect your 120VAC line cord to the corresponding live, neutral, and chassis ground screw. Connect the other

end to your outlet strip (keep your outlet strip turned off until instructed to turn it on).

2. Plug the connector on the other end of the power cable to the “Logic Power” input of the AC/DC as shown in figure

2.2.2.

1. NOTICE: Do NOT construct a longer or lighter gauge cable. Do NOT daisy chain logic supply connections. This can produce a voltage drop which can cause the AC/DC to operate incorrectly.

Figure 2.2.1

Power Supply Wiring Diagram For AC/DC

Power Supply Connected to AC/DC

2. Connect MPU11 to the power supply

1. Plug the power supply AC input cable (PN 3952) and DC output cable (PN 3951) to the power supply (PN 1331).

2. Splice your power cord to the power supply AC input cable. Connect the power cord to the outlet strip.

3. Connect the power supply input cable to rectangular plug labeled “power” in the MPU11 as shown in figure 2.2.3

Figure 2.2.3

Power Supply Connect to MPU11

Figure 2.2.2

Page 12 of 138 2.2 Power Supply Configuration

3. Connect GPIO4D to the power supply

1. Plug the power supply AC input cable (PN 3952) and DC output cable (PN 3951) to the power supply (PN 1331).

2. Splice your power cord to the power supply AC input cable. Connect the power cord to the outlet strip.

3. Connect the other end of the power supply DC output cable to the twelve pin terminal block connecting to header H6

as shown below in Figure 2.2.4. and in Figure 2.2.5

Figure 2.2.4

Power Supply Connected to GPIO4D

Figure 2.2.5

Power Supply Wiring Diagram For GPIO4D

Page 13 of 138 2.2 Power Supply Configuration

2.3 Communication Configuration

4. Configure AC/DC communication

1. AC/DCs need to be chained together with wire or fiber optic cables to allow them to communicate. The AC/DC that is furthest away from the MPU11 in the communication chain will be the first axis. The drive closest to the MPU11 will be your last axis. An example set up is shown in Figure 2.3.8.

2. On the last axis, connect fibers 5 and 4 (PN 12832) from AC/DC to the MPU11. When connecting fibers match the

colors and numbers. (Ex. gray connector to gray socket, fiber 5 to socket 5) as shown below in Figures 2.3.6 and Figure 2.3.7.

3. On the last axis remove or offset the wired input jumper (PN 1761) so that it does not connect both pins as shown in

Figure 2.3.8. The wired input jumper will not disable the wired output, only the wired input.

4. Connect the drive communication cable (PN 11146) from the “drive communication out” last axis to the “drive

communication in” of the next drive in the communication chain as shown in 2.3.8

Figure 2.3.6

Connect drive communication

fibers 4 and 5 to the AC/DC.

Figure 2.3.7

Connect drive communication

fibers 4 and 5 to the MPU11

Page 14 of 138 2.3 Communication Configuration

5. For rest of the drives in the communication chain, the wired input jumper needs to be connected to both pins as shown. Connect the drive communication cable (PN 11146) from the output of one drive to the input of the next drive as shown below.

Wired Input Jumper Disabled

Last Axis

Remove or offset the jumper so that it does not connect to

both pins to disable the wired communication inputs and

enable the fiber optic inputs labeled “4” and “5”.

Wired Input Jumper Enabled

First Axis

Jumper enabled. This will disable the fiber optic inputs

and enable the wired input.

Figure 2.3.8

AC/DC Communication diagram

Page 15 of 138 2.3 Communication Configuration

5. Configure MPU11 Communication

1. Connect a shielded Ethernet cable from your MPU11 device to the PC. A shielded Ethernet cable will have a metal

clip around the RJ-45 connector it as shown by the blue cable in Figure 2.3.9 Centroid recommends using snagless patch cables from StarTech. StarTech ID# S45PATCH25BL. This information is outlined in Technical Bulletin #251, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb251.pdf)

1. NOTICE: An unshielded cable can cause intermittent PC Data receive errors in the software due to electronic

noise and interference.

Figure 2.3.9

Unshielded Ethernet cable (gray) compared to Shielded Ethernet cable (blue)

6. GPIO4D Communication and setup

1. Connect PLC communication fibers labeled “3” and “1” (PN 10018) from the GPIO4D to the MPU11 as shown in

Figures 2.3.10 and 2.3.11.

Figure 2.3.10

Connect PLC communication

fibers to the GPIO4D.

Figure 2.3.11

Connect PLC communication

fibers to the MPU11.

Page 16 of 138 2.3 Communication Configuration

2.4 Encoder Set-up

7. Connect the motor encoders. A table of supported Centroid encoders with part numbers is provided in Appendix C, Stock Centroid Encoders.

1. The encoder cables MUST be shielded cables. The shield wire of the encoder cable needs to be grounded to the

metal shield of the DB-15 connector as seen in figure 2.4.1. Centriod recommends using a twisted pair cable.

1. NOTE: Failure to do so can cause encoder differential errors in the software.

2. Connect the motor encoders to the AC/DC. Do not use the encoder connectors on the MPU11 (encoders 1-6) when

connecting a motor to a AC/DC. Use the encoder connection on the front of the AC/DC as shown in Figures 2.4.2 and

2.4.3.

3. AC/DC accepts incremental quadrature encoders and BiSS serial protocol encoders. The type of encoder will be

automatically detected when logic power is applied. The encoder must be connected before applying power, or the AC/DC will report an encoder type of “none” and be unable to control a motor. Wiring diagrams for supported encoders are shown below in 2.4.4

1. Incremental quadrature encoders Encoders must have RS422 type differential outputs to work with AC/DC. The outputs have additional voltage level requirements described in the table below:

Characteristic Min. Typ. Max. Unit

Encoder channel low level 0.0 0.3 0.5 V

Encoder channel high level 3.0 3.5 5.0 V

1. AC Incremental Quadrature Encoders Commutation encoders for use with AC brushless (PMSM) motors

have commutation channels (U, V, W) in addition to the position channels (A, B, Z) as shown on the next page. These additional channels are used to indicate rotor position for smooth initial start up. Commutation channels must be aligned using the “move sync” functions in CNC11 when mounting a new encoder. This is detailed later in this document in section “6.4 AC Encoder Alignment”.

2. DC Incremental Quadrature Encoders These encoders for DC brush motors require only A, B, and Z

position channels as shown on the next page. Notice that the A and B channels are swapped for DC encoders to reverse the count direction and maintain backward compatibility with older Centroid DC systems.

3. BiSS protocol encoders: These encoders communicate all needed information over only two differential

pairs. This type of encoder is available in single and multi-turn absolute versions. The more advanced protocol allows for a very high number of counts per revolution, which enables very smooth motion and high accuracy. For the purpose of a bench test, the encoders do not need to be connected to a motor. If you did not purchase an encoder cable, wire the DB15 connector that connects your encoders to the AC/DC as shown on the next page.

Figure 2.4.1

Cable shield grounded to the metal

shield of the D-sub connector.

Figure 2.4.2

Do not use the encoders on the MPU11

when connecting motors to the AC/DC!

Page 17 of 138 2.4 Encoder Set-up

Use the encoders connection on the

Figure 2.4.3

front of the AC/DC.

Figure 2.4.4

All drawings are shown from

the perspective of the mating

end of the encoder cable

( As opposed to the end

containing the soldered or

crimped connections. )

Encoder Type

Incremental

10 +W - 11 0V 0V 0V 12 +5V +5V +5V 13 -U - -Clock 14 -V - 15 -W - -

Case Shield / Drain Shield / Drain Shield / Drain

Quadrature

1 +A +B 2 +B +A 3 +Z +Z +Data 4 +V - 5 - - 6 -A -B 7 -B -A 8 -Z -Z -Data 9 +U - +Clock

Incremental

Quadrature

BiSS

Protocol

Page 18 of 138 2.4 Encoder Set-up

Count Directions

Motor

Brushless PID screen Abs Pos increases

Brush PID screen Abs Pos decreases

(while turning shaft clockwise, looking at mounting flange)

Encoder Count Direction

2.5 MPU11 Accessories

8. Connect additional accessories

1. If a jog panel/pendant or MPG was ordered, please connect it to the MPU11 as seen in Figures 2.5.1 and 2.5.2.

Figure 2.5.1

Jog Pendant

9. Connect any additional PLC I/O.

1. The use and operation of additional PLC I/O (Such as PLCADD1616) is beyond the scope if this document and will

not be covered in detail. If you have any additional PLC I/O, you should consult the appropriate documentation and hook it up accordingly for the bench test.

Figure 2.5.2

MPG

Page 19 of 138 2.5 MPU11 Accessories

Depending on the number drives and accessories, each customers bench test setup will look a little different. When you are finished, it should look somewhat similar to the picture shown below.

Figures 2.5.3

AC/DC, MPU11, GPIO4D connect for a bench test.

Page 20 of 138 2.5 MPU11 Accessories

2.6 Powering On & Verifying LED States

Before powering on, perform a visual inspection of what you have set up so far. Check to make sure no metal object can short against the circuit boards. Check to make sure all wiring is firmly in place.

Switch the outlet strip on, powering on the AC/DCs, MPU11, GPIO4D, and any accessories if applicable.

GPIO4D LED States: Just like the MPU11, the LED's are next to the power connector as shown in Figure 2.6.1. After 15 to 30 seconds all LEDs should initialize to solid green. Make sure that all light are on, indicating the GIO4D has proper power and is communicating with the MPU11.

Figure 2.6.1

LEDs on the GPIO4D

GPIO4D LED States

LED Name LED Function Nominal State

PLC OK Indicates that the PLC is communicating with the MPU11 Solid Green

3.3V The PLC has 3.3 volt power. Solid Green

5V The PLC has 5 volt power. Solid Green

+12V The PLC has +12 volt power. Solid Green

-12V The PLC has -12 volt power. Solid Green

Page 21 of 138 2.6 Powering On & Verifying LED States

MPU11 LED states: While powering up, there are 4 LED's next to the power connector on the MPU11 that flicker while the MPU11 is initializing as shown in Figure 2.6.2. After 15-30 seconds the LED's should initialize to the state shown in the table below.

Figure 2.6.2

LEDs on the MPU11

MPU11 LED Nominal LED States

LED Name LED Function Nominal State

FPGA-OK The FPGA is working correctly Solid green

DSP-DEBUG Flashing indicates drive detected. Flashing ~1 per second

DSP-OK The DSP is working correctly Solid Green

+5V The board has 5 volt power. Solid Green

LED Symptiom Possible Cause Corrective Action

FPGA-OK not lit

DSP-OK not lit MPU11 is booting up Wait for the MPU11 to start and enter run mode

DSP-DEBUG LED

flashing twenty times per second

DSP-DEBUG and DSP-OK LED flashing

alternately eight times per second

DSP-DEBUG and DSP-OK LED both on

continuous

MPU11 LED LED Troubleshooting

MPU11 Not Ready Wait for the MPU11 to start and enter run mode

Internal hardware Fault Return for repair

MPU11 is detecting hardware Wait for MPU11 to detect hardware and start run mode

FPGA memory test failed Return for repair

DSP Failed to initialize Return for repair

Page 22 of 138 2.6 Powering On & Verifying LED States

1. AC/DC LED States: The AC/DC is different from the MPU11 and GPIO4D in the fact that it uses both a seven segment display and LEDs to provide the user with information. Always wait 15 to 30 seconds for the drive to initialize for checking the LED states.

The LEDs on the AC/DC are hidden on the side of the drive opposite of the fan as seen in Figure 2.6.3. You do not need to remove the cover to view the LED's, but for your reference a picture of the logic board with the cover removed is provided in Figure 2.6.4. Make sure the FPGA OK, +5V, and +12V LEDs are solid green. The DSP OK light should flash.

Encoder

Power

Board

Figure 2.6.3

LEDs on the side of the drive.

Logic

Board

Drive Fault

FPGA OK

DSP Debug

DSP OK

Drive Enable

+5V

+12V

Figure 2.6.4

LEDs on the Logic board

ACDC Logic LED States

LED Name LED Function Nominal State

Drive Fault Status of the drive fault relay. Turns on when communication is

established with the software and all drive

faults are cleared.

FPGA OK The FPGA is working correctly. If this light is off, it indicates a

possible hardware failure.

DSP Debug Should never be on, not used. Off

DSP OK The flashing once per seconds means the DSP is working

correctly. If this light is off, it indicates a possible hardware failure.

Enable Axis Indicated when the drive is enabled by the software. Turns on when the drive is enabled by the

+5V The drive has 5 volt power. Solid Green

+12V The drive has 12 volt power. Solid Green

Page 23 of 138 2.6 Powering On & Verifying LED States

Solid Green

Flashing ~1 per second

software.

2. AC/DC LED1 (Seven Segment Display) States: Approximately 15-30 seconds after starting LED1 will display a number. If the seven segment display is displaying a solid number without a decimal point it indicates the drive axis number as seen in Figure 2.6.5. If LED1 is flashing with a decimal point it indicates an error as shown in Figure 2.6.6.

If you have a blinking 4, that means the AC/DC is not seeing the limit switches. Since we have not hooked up limit switches, you can disable them by switch SW1 to the down position as shown in Figure 4.2.7. If done correctly, the drives will all be displaying their drive axis number. A table of other drive errors and their definitions is provided below.

Limits Switches Enabled

Limit Switches Disabled

Figure 2.6.5

Drive Number

(Please note the decimal point)

Figure 2.6.6

Drive Error

Figure 2.6.7 Switch SW1

ACDC Seven Segment States

Error

Number

1 Communication Error "Wired Input" Jumper set incorrectly or

4 Limit Tripped any limit switch is tripped Use the limit defeat switches to disable hardware limits

5 Drive Error A serious fault has caused the drive to

Meaning Cause Corrective Action

Set jumper properly and check communication cables. fiber 4 or cable connection not working properly

Check HSC Screen for error cause <F7>, <F9>, <F5> shut down

Page 24 of 138 2.6 Powering On & Verifying LED States

CHAPTER 3

SOFTWARE INSTALLATION

3.1 Preinstallation

1. If you have purchased a console unit or computer from Centriod, it already comes with Windows properly configured and the CNC11 software already installed. Please skip to section “3.3 AC/DC Setup Wizard”.

2. If you have a computer with the Microsoft Windows 8 operating system, please skip to Appendix A, Windows 8 preinstallation.

3. If you have a computer with the Microsoft Windows 7 operating system, please skip to Appendix B, Windows 7 preinstallation.

4. Microsoft Windows Xp, Vista, and older versions of Windows are not supported. Mac OS and Linuix are also not

supported.

5. Before installing CNC11, all anti-virus and 3rd party firewall software should be uninstalled (not disabled) and your computer rebooted.

1. Nearly 100% of all communication problems between CNC11 and the MPU11 are caused by anti-virus and 3rd

party firewall software. Virus software works by stopping unusual or suspicious behavior in software, and will

almost always detect the interaction between the MPU11 and the PC as unusual/suspicious and interfere with operation of CNC11. Firewalls work by blocking certain communication ports, and often these ports are needed for operation of CNC11. The default firewall built into Microsoft Windows will work fine with CNC11 if you allow access as specified in this manual.

2. If your corporate policy requires anti-virus software, a third party firewall, or that certain Windows security features be

enabled to connect to the network, then Centroid recommends that you keep any computers with CNC11 installed disconnected from the network.

Page 25 of 138 3.1 Preinstallation

3.2 CNC11 and PLC Installation

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 (http://www.centroidcnc.com/usersupport/support_files/latest_release/cnc11_latest.zip)

2. Copy the downloaded file to your desktop. Depending on your Windows 7 settings, the file you downloaded will be displayed as either cnc11_win7_current.zip or cnc11_win7_current. 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 centroidcnc11-v312-D, your version maybe newer but the name will be the same other than the “v312” which signifies the CNC11 version number as shown below in Figure 3.2.1.

Figure 3.2.1

Copy to desktop

4. Double click the install folder and double click setup to begin CNC11 install as seen in Figure 3.2.2

Figure 3.2.2

Double click “Setup”

5. On a Windows 7 or 8 computer if “User Account Control” is enabled, Windows will ask “Do you want to allow the following program from an unknown publisher to make changes on this computer?”. Click “Yes”.

Page 26 of 138 3.2 CNC11 and PLC Installation

6. Select CNC11 Mill and WinPcap for a Mill installation as shown in Figure 3.2.3. Select CNC11 Lathe and WinPcap for a Lathe installation. For the remainder of this document we will assume the system is being installed on a mill. Click “Next”, accept default installation drive and directory (c:\) and click “Install” as seen in Figure 3.2.4. The software will extract as shown in Figure 3.2.5.

Figure 3.2.3

Selecting CNC11 and WinPcap

Figure 3.2.4

Select the C drive

7. Install WinPcap Click “Next” in the WinPcap Setup Wizard window as circled in Figure 3.2.6. Check the “Automatically start the WinPcap at boot” box when prompted.

Figure 3.2.5

Software installation

Figure 3.2.6

Installation complete

8. Click “Next” to continue. After the WinPcap installation has finished, click “Next” in the “Installation Complete” window to continue.

Page 27 of 138 3.2 CNC11 and PLC Installation

9. 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 as circled in Figure 3.2.7. Click “Next” to continue. When asked if you would like to change the IP address for the adapter selected, click “yes”.

1. NOTE: Centroid recommends using a computer with two Ethernet ports. That way one Ethernet port is used for the

MPU11, and the second Ethernet port can be used to access the internet.

2. NOTE: Your IP address will differ from those shown in the picture. If you only have the MPU11 hooked up (and are

disconnect the internet/network), only the MPU11 will be detected.

Figure 3.2.6

Select the network adapter that is connected to the MPU11

10. 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 and GPIO4D. Click on “acdc-basic”, then click “Install” as shown in Figure 3.2.7.

Figure 3.2.7

Install the PLC program

Page 28 of 138 3.2 CNC11 and PLC Installation

11. Click “Finish” to complete CNC11 software installation. After the PLC program installation has completed, click “Finish” to complete the installation.

12. Power off the computer, MPU11 and GPIO4D and restart.

13. 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, see Appendix A for troubleshooting.

Figure 3.2.8

Make a firewall exception

14. Confirm that CNC11 start up correctly. Close CNC11 and continue on to the next step.

1. NOTE On wide screen monitors, CNC11 will only take up 2/3rds of the monitor screen while running in “full screen”.

Page 29 of 138 3.2 CNC11 and PLC Installation

3.3 AC/DC Setup Wizard

Centroid has a motor configuration tool to simplify setting up an AC/DC. This same information is found in Technical Bulletin TB277. The latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb277.pdf)

The Centroid AC/DC Setup Wizard simplifies setting up an AC/DC. Alternatively, an AC/DC can be setup without using the tool by referring to the tables listed in Appendix B

1. Download the latest version of the AC/DC Motor Setup Wizard. Click on the link below to download the latest version of CNC11 software: AC/DC Motor Configuration Tool (www.centroidcnc.com/usersupport/support_files/acdc/acdc_setup_wizard.zip).

2. Extract/Decompress the downloaded file. Double click on the downloaded file. Extract the compressed file. On Windows 8 extraction is done by clicking on the “Extract all” button as shown below in Figure 3.3.1.

Figure 3.3.1

Extracting the AC/DC setup wizard

3. Copy and Paste into the CNCM / CNCT directory.

1. Select the extracted files “ACDC Setup Wizard (.exe)” and “pwm_parameters (.xml)”

2. Copy both files as demonstrated in Figure 3.3.2.

3. Right click on your CNC11 desktop shortcut.

4. Select properties as seen in Figure 3.3.3

5. In the shortcut tab, click on “Open File Location” as shown in Figure 3.3.4.

6. Windows explorer will open up in a new window showing the contents of your CNC11 directory (The directory will be

called “CNCM” or “CNCT” depending on weather you have a mill or a lathe). Paste both files into your CNC11 directory.

Figure 3.3.2

Steps 1 & 2. Select and copy the extracted files.

Figure 3.3.3

Step 3 & 4. Right click on

your CNC11 software

selecting properties

Page 30 of 138 3.3 AC/DC Setup Wizard

Figure 3.3.4

Step 5. Click “open file

location”

4. Create a desktop shortcut.

1. Highlight just the ACDC Setup Wizard (.exe) inside your CNC11 directory.

2. Right click on the application. A drop down menu will come up.

3. Select “Send To” on the drop down menu

4. Select “Desktop (Create Shortcut)” as shown in Figure 3.3.5

5. Exit Windows File Explorer. On your desktop you should now have a shortcut to CNC11 and to the ACDC Setup

Wizard.

Figure 3.3.5

Creating a desktop shortcut for an application

Page 31 of 138 3.3 AC/DC Setup Wizard

5. Using the Centroid AC/DC Setup Wizard

1. On your desktop, double click on the ACDC Setup Wizard. The tool should looks like the figure 3.3.6 shown below. If

Windows Smart Screen tries to block this program, click “more info”, then “run anyways”.

1. NOTE: Some of the information provided in the wizard is used for calculating values for unknown/unapproved

motors. In this manual we will not be covering these advanced uses of the tool and can ignore the extra information.

2. Motor Configuration

1. Click the large “select motor” button in the center of the screen circled in Figure 3.3.6

2. A new window will pop up. Click on the motor you are using for this axis.

3. With your motor highlighted, click “select motor” at the bottom of the screen to finalize your selection as shown in

Figure 3.3.7.

Figure 3.3.7

Figure 3.3.6

Motor selection menu

Selecting a motor

Step 1

Step 2

Page 32 of 138 3.3 AC/DC Setup Wizard

3. Drive parameters

1. Under “Drive Parameters” use the “Drive Type” dropdown box to select your model of AC/DC as circled below in

Figure 3.3.8.

2. Under “Drive Parameters” set the “Drivebus Number (LED1)” and the “Axis Number” as circled below. For the first axis, set the Drivebus Number to 1 and the Axis Number to 1. If you have multiple AC/DCs connected together, the first axis is defined as the AC/DC that is farthest away from the MPU11. For most applications you want the drive bus number to be the same as the axis number.

3. Under “Drive Parameters” enter the motor voltage supply value in the “Bus Voltage (Vm) (VDC)” field as circled below. This is set by the output of your DC rectifier.

4. Under “CNC11 Parameters” enter your brake resistor wattage into “p284 Brake Resistor Wattage” as circled below. In most systems an AC/DC 30 will use 300 watts, and an AC/DC 60 will use 600 watts. The brake wattage is usually printed directly on the resistor.

Step 1

Step 2

Step 3

Step 4

Figure 3.3.8

Entering the parameters into the AC/DC Wizard

Page 33 of 138 3.3 AC/DC Setup Wizard

4. Motor Parameters and General Information

1. Under “Motor Parameters” enter your encoder counts in the “Encoder Counts/Rev” box as circled in Figure

3.3.9.

2. Under “General Information” enter your brake resistor resistance in “Brake Resistor (ohms)” as circled below.. For most systems an AC/DC 30 is 15 Ω and an AC/DC60 is 7.5 Ω.

3. Click “Calculate Parameters” as circled below.

Step 1

Step 3

Step 2

Figure 3.3.9

Final parameters

5. Take a few seconds to review what the tool calculated. Look over all the boxes to make sure all values seem reasonable. Check for errors in any of the boxes.

1. Troubleshooting and Tips

1. If the box labeled “ACDC Current Setting (%)” says “Over 100%” the drive will still work with the AC/DC.

Your motor will not run at maximum performance due to the AC/DC not being able to provide maximum power to the drive.

2. In the unlikely event that the Wizard does encounters a “Data Missing” error, there is a box with missing information. If you get this error, contact technical support.

3. If you click on the “Window” button on the top left of the screen a menu will come up with some additional motor related tools. These tools are provided by Centroid for your convenience and are intended for advanced users.

1. “Estimate Motor Performance” will graph your motor's estimated performance using the data provided.

The tool will create a graph of motor power and torque. This estimate may not be accurate on all motor types.

2. “Conversions” will convert from one unit to another

Page 34 of 138 3.3 AC/DC Setup Wizard

6. With CNC11 closed, click “Write change to CNC11 Setup Files” and as shown circled below in Figure 3.3.10.

Figure 3.3.10

Writing parameters to CNC11

7. If multiple drives are being used, repeat this procedure.

1. For the second drive, select 2 for the Drivebus number and axis number. For the third drive, use 3 and so forth.

2. If all the axes are the same drive model / motor model keep the other parameters the same and continue to the

next step. Otherwise, update any other parameters that need changing (such as a different motor for the second axis.)

3. Recalculate parameters again.

4. Write changes again to CNC11 setup files.

5. Repeat until all drives axes have been set up.

8. After all drives have been setup close the AC/DC setup wizard.

Congratulations! Your AC/DC(s) have been configured to work with your motors.

Page 35 of 138 3.3 AC/DC Setup Wizard

CHAPTER 4

BENCH TEST

4.1 Software Configuration

Start the CNC11 Software

Troubleshooting

If you clicked on the CNC11 icon to start the software and you are getting “Timeout: MPU11 not responding” errors, you most likely didn't have the MPU11 connected to the PC when you installed the software. Check your Ethernet card to make sure it is configured properly.

Go to “Control Panel”, select “Network and Internet”, and then “Network and Sharing Center”. Click on “change adapter

settings” on the upper left corner of the window, right click on the network icon, select “Properties”. Highlight “Internet Protocol Version 4 (TCP/IPv4)”, then click “Properties” again.

Select “Use the following IP address” then set the IP address and Subnet mask to:

IP address: 10.168. 41.1 Subnet mask: 255.255.255.0

Click Ok and then try to start the CNC11 software again.

For more in troubleshooting see Appendices C and D.

If your software has 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”.

1. Enter your Software Unlock Demo Code To enter a software unlock press F1-Unlock Option. In “Enter Unlock #:” enter 297 for demos or 298 for permanent unlocks as shown on your unlock sheet. This will display the Unlock Value window as shown in Figure 4.1.1. Look at the value in the “Software Unlocks” sheet that shipped with control. Enter the value next to the unlock number.

2. Repeat the process to unlock other options, such as Intercon or DXF import. To get back to the Software Add-Ons menu screen from the main menu press F7 – Utility → F8-Option → F1-Unlock Option.

Figure 4.1.1

Unlocking Options

Page 36 of 138 4.1 Software Configuration

From now on when using CNC11, you can always go up one menu level by pressing the escape key (ESC). Tapping escape multiple times from any menu will eventually take you back to the main menu.

To do the bench testing temporarily disable the fault protection logic built into CNC11 and the PLC program as specified in the following pages. CNC11 monitors the signal levels of hardware as jog panels and encoder inputs, and will generate a fault if any hardware does not respond as expected. In addition, the ACDC-basic PLC program contains default logic that monitors the inputs for Limit Switches (inputs 1-8), Lube Fault (input 9), Spindle Fault (input 10), Estop (input 11), and Axis Drive Faults (inputs 17-20). If ANY of these inputs are open a fault will be issued.

3. Change Machine Home Type To navigate to the “Control Configuration” screen. From the main screen press press F1-Setup → F3 -Config. The password is 137. Then press F1 Contrl. Using the keyboard spacebar change “Machine home at power up” to “Jog”.

1. TIP If you can not save any of your changes in CNC11, close CNC11. Right click on CNC11 desktop shortcut. Select

properties. Click on the Compatibility tab. Check the box labeled “Run this program as an administrator”. Click

“Apply”. Click “OK”. Start CNC11 again.

Figure 4.2.2

Changing machine home at powerup to disable limit switches

4. Disable Jog Panel Communication Faults (If you have a jog panel or pendant connected, skip this step.) If the optional Jog Pendant is not connected for bench testing, disable Jog Panel communication faults. Use the arrow keys to select “Jog Panel Required” in the Control Configuration and press the space bar to toggle to “No”.

Figure 4.1.3

Disabling jog panel

Press F10-SAVE to save. After Saving, Press escape to go back to the Main Screen. Press F10-Shutdown, → F2 Power Off, and then power off the MPU11 and GPIO4D via switching of your outlet strip. Wait 30 seconds and power everything back up.

Page 37 of 138 4.1 Software Configuration

5. Disable PLC faults for Limit Switches, Lube, Spindle, Estop and Axis Faults. At the main screen press the alt and i keys to bring up the real-time I/O display as shown in Figure 4.1.4. Using the arrow keys, move the selection box to the top left of the inputs. The screen should read “INP1 Ax1_MinusLimitOk” as circled below. 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.

1. NOTE: Using alt + I to disable I/O only works for those using the default Centroid provided PLC programs. On a

custom PLC program, this feature may need to be added to the PLC code.

Figure 4.1.4

Disabling inputs using alt + i

6. Label the Axes: From the main menu, press F1-Setup → F3 -Config. The password is 137. Press F2 Mach. → F2 Motor. Under “Label” configure the software for the correct number of axes and label them appropriately. Any unused

axes should be set to “N” to disable the axis as seen in Figure 4.1.5.

Figure 4.1.5

Labeling the axses and verifying the spindle axis.

Page 38 of 138 4.1 Software Configuration

7. Verify Spindle Axis: Your spindle axis will have an “S” next to it in the motor parameters as shown in Figure 4.1.5. The default is axis 6.

1. Reassigning Spindle Axis: If the spindle axis is set incorrectly, it will have to be fixed by changing parameter 35 in

the machine parameters menu as shown in Figure 4.1.6. The machine parameter menu can be reached by pressing F1-Setup → F3 -Config from the main menu. The password is 137. Press F3-Parms. Use the arrow keys to navigate to the field labeled “35”. Click enter to edit the field. Type in a whole number for the axis that corresponds to yours spindle. Typing in a zero will disable the spindle. Press enter, then F-10 save. Verify the spindle is set up by going back into the Motor Parameter menu and looking for the S as shown in Figure 4.1.5.

Figure 4.1.6

Setting the spindle axis

8. Zero out any unused axes Axis can be turned off in the motor menu, but still be assigned axis numbers in the parameters menu. Go into the parameters menu. The machine parameter menu can be reached by pressing F1-Setup → F3 -Config from the main menu. The password is 137. Press F3-Parms. Pres F8-Next Table repeatedly until parameters 300-307 are displayed. Set any unused axes to zero. If you need to zero out any axis, the machine will need to be restarted before you can continue.

9. Clear 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” as demonstrated below in Figure 4.1.7. 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. During the bench test we will trick the software into thinking we cycled the E-stop (not connected yet), by toggling the input 11 using alt + I.

Figure 4.1.7

Software Ready Fault

Page 39 of 138 4.1 Software Configuration

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)” as shown below in Figure 4.1.8. Press the ctrl-alt-i keys simultaneously to toggle the EstopOK input to red, and press the crtl-alt-i keys again to toggle it back to green.

Figure 4.1.8

Toggling E-stop

Status window showing the emergency

Figure 4.1.9

stop clearing faults.

Notice that as you toggle the EstopOk input to red “406 Emergency Stop Detected” is displayed in the status window as shown above in Figure 4.1.9. When the emergency stop is pressed notice how “2099 Message Cleared” is displayed, referring to clearing the “9039 stop fault”. Toggling EStopOK back to green displays “335 Emergency Stop Released”.

10. Clear Any Existing Faults Before Beginning Bench Testing. To confirm that all faults have been cleared before continuing, press F3 MDI from the main menu. If all faults have been cleared correctly, the screen should look like Figure

4.1.10.

If the screen shown in Figure 4.1.10 is not displayed, there is an existing fault. Please check the status window to determine the cause of the fault and then clear it as shown in Figure 4.1.8. Confirm that all parameters are set as required and that all inputs (1-11 & 17-20 green) are in the correct state.

All faults shown in Figure 4.1.11 (as well as other faults) are “Stop Faults”. Stop faults cancel existing jobs, prevent new jobs from being started, stop the spindle, prevent motion, and require that the E stop PLC input be cycled (opened and closed) in order to clear the fault before continuing.

If you have any stop faults, they will have to be removed then E-stop will have to be toggled as shown in the previous step.

Figure 4.1.10

MDI Command Mode

Figure 4.1.11

Faults detected

Page 40 of 138 4.1 Software Configuration

4.2 Bench Testing the AC/DC

Since the AC/DC is a drive, there is not a lot of I/O testing we can do. Primarily we want to test drive communication with the MPU11 and encoder communication with the drive.

1. From the main menu press F7 Utility → F9 Logs → F5 HSC. The HSC menu is the most powerful software tool for troubleshooting an AC/DC. More details about how to use this menu and what each box means is contained in Appendix B. This screen is organized by DriveBus channels, therefore the channel number at the top of a column matches LED1 on the AC/DC. The columns are not reorganized by axis according to the drive mapping done in the parameters.

If everything is connected correctly:

1. the “Debug counter” should be counting in hexadecimal for each drive connected to the system as circled below in

Figure 4.2.1. This indicates that the drive is talking to the MPU11.

2. Make sure the “Encoder OK” as circled below is set to a one as shown below.

3. Turn each of the motor shafts clockwise by hand. If using an AC motor, ErrorUVWInvalid, ErrorUVWBadTransition,

and ErrorUVWBadSize should all be zero. CommutationZone should count 1-6. If not using a BiSS encoder, ignore BissRecptionErrors. If using a DC motor, ErrorUVWInvalid, ErrorUVWBadTransition, ErrorUVWBadSize, and CommutationZone have no meaning and should be ignored.

1. NOTE: A value of “0” for the debug counter means communication was not correctly established between the MPU11 and the AC/DC. Go back and double check your wiring and jumper settings. Give the system a reboot and see if the problems still occurs. If it still is not communicating, consult Appendix A and B for troubleshooting.

2. NOTE: The menu is labeled “AC1 Status” on the top left. AC1 was the original code name of the AC/DC drive. AC/DC and AC1 are the same thing.

Figure 4.2.1

The HSC screen

Page 41 of 138 4.2 Bench Testing the AC/DC

2. Press the Estop button in keep it depressed. Go back to the main menu. From the main menu press F1 -Setup → F3 Config. The password is 137. Press enter → F4 PID. This will display the PID menu screen below and allow you to

monitor the encoder counts by watching the values in “Abs Pos” field (circled below in Figure 4.2.2) for each axis.

Figure 4.2.2

Watching absolute position of the PID menu

7.5 To confirm that each encoder is wired correctly, rotate the motor shaft Clockwise (as seen while looking at the face of the motor as shown below) and confirm that the counts displayed in the ABS Pos column of the PID menu change. For a DC brushed motor the absolute position value should decrease. For a brushless motor the absolute position should increase.

Record how much the motor counts during one revolution. Go into the motor parameters menu. From the main menu, press F1-Setup → F3 -Config. The password is 137. Press F2 Mach. → F2 Motor. The encoder counts/rev field (circled below in Figure 4.2.4) should approximately match how much the encoder counted when it was turned one revolution.

Figure 4.2.4

Encoder counts per revolution

Figure 4.2.3

Rotate the motor clockwise

Page 42 of 138 4.2 Bench Testing the AC/DC

4.3 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 spindlebenchtest.cnc: From the main menu press F2-Load. Use the arrow keys to select the file spindlebenchtest.cnc

1. If spindlebenchtest.cnc is not present in the c:\cncm\ncfiles directory it can be downloaded here:

spindle benchtest.cnc (http://centroidcnc.com/usersupport/support_files/benchtest/ spindle benchtest.cnc)

2. Download spindlebenchtest.cnc. If your web browser does not provide an option to download spindlebenchtest.cnc

and instead displays a bunch of code, copy the code from your web browser into your default text editor (such as notepad++). Save the file as spindlebenchtest.cnc.

3. Copy spindlebenchtest.cnc to your CNC11 root directory.

1. Right click on your CNC11 shortcut

2. Click properties as shown in figure 4.3.1.

3. A window will pop up, go to the “shortcut” tab and click “open file location” as shown in Figure 4.3.2.

4. Open the folder labeled “ncfiles”. Paste spindlebenchtest.cnc into the ncfiles directoy.

5. In the load menu of CNC11 press F8-refresh.

2. With spindlebenchtest.cnc highlighted, press F10 Accept. If the DRO does not display when you press alt-s, you likely

encountered a fault. See clearing faults is covered in section 4.3.3

Figure 4.3.1

Right click on

CNC11 and click

“properties”

Figure 4.3.2

Select the “shortcut”

tab and click “Open

File Location”

Figure 4.3.3

Selecting

Benchtest.cnc

Page 43 of 138 4.3 Bench Testing the MPU11 and GPIO4D

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 (variable frequency drive). The default maximum spindle speed specified in the Control Configuration is 3000rpm. 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.

1. Set a digital voltage meter to VDC as shown in Figure 4.4.4.

Probe Terminals Here

2. Insert the digital voltage meter leads into H6 as shown in Figure

3.9.4. Tighten down the screw terminals to firmly grip the probes.

3. 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)

4. Enter the voltage readings as pictured, and press Cycle start to continue.

Figure 4.3.4

Selecting

Benchtest.cnc

Page 44 of 138 4.3 Bench Testing the MPU11 and GPIO4D

CHAPTER 5

ELECTRICAL CABINET INSTALLATION

5.1 Introduction to Electrical Cabinet Layout

Now that you are finished with the board level test it is time to think about electrical cabinet installation. In this chapter of the manual we will go into detail about how to wire the various systems into your cabinet. Below is a sample AC/DC electrical cabinet from Centroid in the final stages of wiring. (Note: some of the wiring in the picture below is in the process of being added). During cabinet wiring it is important that you follow the schematic provided by Centroid. The following page and the picture below outline some basic best practices.

Leave two inches of space

Label all wires, devices, relays, etc.

Single grounding bar

High voltage AC power lines kept away from low voltage signal lines.

Figure 5.1.1

Sample Electrical Cabinet

Page 45 of 138 5.1 Introduction to Electrical Cabinet Layout

• Minimize Noise and Interference

◦ Keep sensitive electronics away from noisy equipment. Install high voltage drives, rectifiers, transformers,

contactors, and other electrically noisy equipment as far away from low voltage circuit boards (such as the MPU11 or GPIO4D) as practical.

◦ Keep high voltage power lines far away from low voltage signal lines. Keep the high-voltage AC power lines and

motor power lines as far away from low voltage logic signals as practical.

◦ Grounding Principle. Wire the incoming chassis ground lug directly to a single ground bus bar as shown in the

picture on the previous page. Wire all cabinet doors, AC/DC chassis grounds, power supply chassis ground, and other equipment chassis ground to one single ground bus bar. What you should NOT do is have several different grounding points throughout the cabinet, as this could increase electrical noise and interference.

◦ Leave plenty of space between wire ducts and components. Keep wire ducts at least 2” away from components

when practical.

◦ Use Snubbers on Contactors. Contactor blocks and relays need a snubber across the coil. Centroid recommends

using Quencharc snubber networks (Centroid PART# 1819). This reduces electrical noise. If you are new to using snubbers more information can be found in Technical Bulletin #206, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb206.pdf)

• Keep the cabinet maintainable and easily serviceable. Centriod can provide electrical cabinet materials such as contactors blocks, time delay contactor blocks, relays, fuse blocks, din rails, overload relay with fuses, din rail end stops, terminal blocks, etc. Call Centroid for details.

◦ Wire management Use PVC wire ducts (such as Panduit Panduct) to keep your wires neat and organized.

◦ Use DIN Rails Use DIN rails for mounting relays, contactors, terminal blocks, circuit protection blocks, disconnects,

etc.

◦ Leave a little bit of slack in the wire. Take all corners in the wiring ducts as wide as possible. Always leave a little

bit of slack in the wires.

◦ Keep all the wiring in neat horizontal and vertical lines.

◦ Label EVERYTHING. Label everything so that it matches the labels on your schematic. This includes labeling each

individual wire at both ends, circuit boards, relays, contactors, etc.

◦ Don't lose the schematic. Keep the schematic attached to the cabinet somewhere so it doesn't get lost.

• Use the correct AWG Below is the minimum AWG for the AC/DC.

Minimum Wire Gauge (AWG)

Motor Power Cable Vm+, Vm- Brake+, Brake- Logic Power

AC/DC-30 16 14 16 16

AC/DC-60 12 10 12 16

1. Recommendations for typical applications – cable lengths, drive current setting, and motor loads may change requirements. Always follow the electrical code.

[1]

Page 46 of 138 5.1 Introduction to Electrical Cabinet Layout

Common Wiring Problems

The following information is also covered in Technical Bulletin #78 which can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb078.pdf)

Figure 5.1.2

Common Wiring Problems

Page 47 of 138 5.1 Introduction to Electrical Cabinet Layout

5.2 Electrically Configuring Inputs on the GPIO4D

The inputs of the GPIO4D can be configured for either 5, 12, or 24 volts DC. The input voltage is changed by changing the resistance of the SIP (single inline package) resistor. By default the GIO4Ds come with SIPs for 24VDC installed. If you are using a voltage other than 24VDC, the SIPs need to be changed.

The SIP resistance is the defined by the last three numbers of the manufacturers part number as shown in Figure 5.2.1. Of the last three numbers, the first two digits signify the value of the resistance. The last digit signifies the number of zeros after the value. For example if the manufacturers part number is “4308R-102 LF – 222”, the values 222 define the resistance. The resistance is 22 plus two zeros, so the final value is 2200 Ohms. The chart next to Figure 5.2.1 defines which resistors are needed for which voltages.

Voltage Level Centriond SIP

Part #

5VDC 3950 470 Ohm(471)

12VDC 4152 1K Ohm(102)

24VDC

(default)

Looking closely at the GPIO4D, the silkscreen is labeled “SIP1, SIP2, SIP3, and SIP4” as shown in Figure 5.2.2. Each SIP controls a group of I/O as demonstrated by the table below.

1548 2.2K Ohm(222)

SIP Value

Figure 5.2.1

Reading SIPs

Input Group SIP Number

Inputs 1-4 4

Inputs 5-8 3

Inputs 9-12 2

Inputs 13-16 1

Figure 5.2.2

Location of SIPs

Page 48 of 138 5.2 Electrically Configuring Inputs on the GPIO4D

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 four with a common shared by each input in a group.

There are two ways to wire I/O on the GPIO4D:

• Sourcing Connecting the inputs to power is sourcing. The netagive lead of the power supply must be connected to common. This is demonstrated on inputs 1-4 in Figure 5.2.3.

• Sinking By connecting the inputs to ground is sinking. The positive lead of the power supply must be connected to common. This is demonstrated on inputs 5-8 in Figure 5.2.3

+12VDC

Figure 5.2.3 Wiring Limit

Switches

GPIO4D Board

IN1 IN2 IN3 IN4

COM 1-4

IN5 IN6

IN7 IN8 COM 5-8

12VCOM 12VCOM

+12VDC

Page 49 of 138 5.2 Electrically Configuring Inputs on the GPIO4D

5.3 Wiring Motors

The AC/DC supports over 60 different motors. Including over 50 different Fanuc motors, 6 SEM motors, and 4 Mecapian motors. The easiest way to install an AC/DC is with motors provided by Centroid. Users should only use motors on the list of motors found in Appendix G. What if your motors not on the list? For an evaluation fee, Centroid can evaluate your motor and provide you with the correct software parameters.

In the future, Centroid plans on bringing an advanced set of features to the Centroid CNC11 software, allowing users to calculate their own software parameters without the need to have Centroid evaluate their motors.

Motor Installation Procedure

1. On the motor, check for >100 MΩ between the motor chassis, and the motor power terminals.

2. On the AC/DC drive, check for >100 MΩ between the motor chassis and the power terminals.

3. Wire the motors to the drive.

1. 16 AWG minimum is required for the AC/DC 30. 12 AWG minimum is required for the AC/DC 60.

2. For AC motors connect the U, V, and W to the corresponding terminals of the AC/DC. For DC motors connect the

negative wire to the V terminal and the positive wire to the W terminal as shown below in Figure 5.3.1.

3. Ground the motor power cable to the AC/DC Chassis as shown below in Figure 5.3.1.

Figure 5.3.1

AC and DC motor Wiring

4. With the motors connected, confirm continuity between motor chassis and the AC/DC chassis using a DVM/multimeter.

1. DANGER An ungrounded motor is an electrocution hazard. Always confirm continuity with a multimeter!

Page 50 of 138 5.3 Wiring Motors

5.4 Wiring AC/DC Brake Resistor

A motor acts like a generator when it is trying to slow down. The AC/DC slows the motor by converting unwanted electricity into heat using a brake resistor. Therefore, the brake resistor gets extremely hot and can run over 65C or 150F.

Centroid recommends installing the brake resistor outside the electrical cabinet, but always consult with your local electrical code first and be sure to follow any safety requirements. Care must be taken to ensure that the brake resistor gets adequate air flow, and does not overheat the electrical cabinet or pose a burn hazard. Always keep the electrical cabinet below 40°C (104°F). A guard can be fabricated around the brake resistor if needed to prevent accidental burns.

Brake resistors are NOT polarity sensitive.

Centroid recommends using two 300 watt 15 ohm brake resistors (Part Number 7352) in parallel for an AC/DC60, and one 300 watt 15 ohm brake resistor (Part Number 7352) for an AC/DC 30. 12 AWG minimum is required for an AC/DC60, and 16 AWG minimum is required for an AC/DC-30.

Page 51 of 138 5.4 Wiring AC/DC Brake Resistor

5.5 Wiring E-Stop

(refer to the picture on the next page)

1. E-Stop Wiring The E-stop is a safety mechanism used to shut off the machine during an emergency. The switch should be closed when the machine is in it's operational state. Wiring E-stop in a normally open configuration is dangerous as it will not stop the machine in the event that a wire breaks. It also prevents noise from causing spurious faults because the signal is being electrically held at the operational level.

1. E-Stop Switch – Use a double pole single throw (DPST), normal closed, twist to release, emergency stop switch.

Such as Centroid part number #1009 used with #5934.

2. GPIO4D E-Stop - Input 11 needs to be routed through your E-stop switch so the PLC knows if the E-stop is engaged.

The coil voltage that controls the Estop contactor is routed through two sets of fault relays on the GPIO4D. The Estop switch and fault relays are wired in series so that, if any of the circuits is opened the Estop contactor is dropped out.

1. The first relay, Output1, is controlled by the PLC program. It can be used to drop the Estop contractor based on any PLC event.

2. The second relay, Output17, is used to drop the Estop contractor in the event that a fault occurs that the PLC is not be able to recognize – such as a hardware communication error between the GPIO4D and the MPU11.

3. AC/DC E-Stop - Wire the AC/DC E-stop relay in series with the GPIO4D E-stop relay as shown on the next page. Treat CN1 (pin 2) as your E-Stop input for the AC/DC, and CN2 (pin1) as your E-stop output for the AC/DC. This allows the AC/DC to cut the power to the motors in the event of a fault, even if they have lost communication with the MPU11 and GPIO4D.

4. Contactor – A snubber needs to be placed across the contactor(s). Centroid recommends using Quencharc snubber networks (Centroid PART# 1819). This reduces electrical noise when the motor power is cycled on and off.

5. Voltages

1. GPIO4D Inputs – The example on the next page uses +12VDC for input 9. This voltage can be 5 to 24 VDC

depending on the SIPs used in the GPIO4D as demonstrated in section 4.2

2. GPIO4D and AC/DC Relay Outputs – In the example on the next page 24VAC is used for the relays. The relay

outputs on the AC/DC and GPIO4D are rated for up to 30 VDC @ 5 amps OR up to 125 VAC @ 10 Amps. It is best practice to use lowest practical voltage with your relays, as higher voltages create more electrical noise and interference.

2. Testing E-Stop Wiring

1. Power up your system.

2. Start CNC11 and press F10 to continue to the main screen

3. Enable the E-stop (which was inverted during board level testing). In the main menu press alt + I to bring up the real time I/O display.

4. Click on input 11.

5. Press the ctrl-alt-i keys simultaneously to remove the bar over the input in the display, enabling your E-stop.

6. Toggle the E-stop. Confirm that input 11 is green when the E-stop is released (not tripped).

Page 52 of 138 5.5 Wiring E-Stop

Example E-Stop Wiring

Figure 5.5.1

E-Stop Wiring

Page 53 of 138 5.5 Wiring E-Stop

5.6 Wiring Limit Switches

All inputs used for Limit switches must be wired in normally closed configuration. The switch should be closed when the machine is in its operational state. Wiring any of these inputs in a Normally Open configuration is dangerous as the machine will not stop in the event that a wire breaks. 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 4.2 match the voltage levels for your devices.

Failure to install the proper SIPS to match the voltage levels being used will damage the GPIO4D. Do not use the limit switch I/O on the AC/DC. At the time of this writing, they are not supported.

Connect your limit switches as shown below in Figure 5.6.2.

+12VDC

GPIO4D Board

IN1 IN2 IN3 IN4

COM 1-4

IN5 IN6

IN7 IN8 COM 5-8

IN9

IN10

IN11

IN12

COM 9-12 IN13

IN14

IN15

IN16 COM13-16

Figure 5.6.2

AC/DC limit switches.

X- Limit X+ Limit

Y- Limit Y+ Limit

Z- Limit

Z+ Limit W- Limit W+ Limit

12COM

12VCOM

12COM

12VCOM

+12VDC

Figure 5.6.1

Do not use AC/DC limit switches.

Testing Limit Switch Wiring

1. Power up your system.

2. Start CNC11 and press F10 to continue to the main screen

3. Invert the limit switches (which were inverted during board level testing). In the main menu press alt + I to bring up the real time I/O display.

4. Click on limit switch inputs (input 1 - 8), and press the ctrl-alt-i keys simultaneously to remove the bar over the input in the display. This will enable your limit switches.

5. Confirm that all limit switches are are green when nothing is tripped. Confirm that the correct input turns red when the switch is tripped.

Page 54 of 138 5.6 Wiring Limit Switches

5.7 Wiring Lube Pump

(refer to the picture on the next page)

The typical lube pump circuit consists of two parts: The first part is the control of the lube pump itself which is controlled by output 2 sending 110VAC to the lube pump. The second part is the low lube alarm signal which gets wired to input 9. The low lube

signal tells the control to produce a “405 Low lube” alarm which inhibits the control from starting a new job until the lube pump is refilled and the alarm is cleared.

Keep in mind that the GPIO4D output relay is rated for up to 5 amps DC or 10 Amps AC. If your lube pump draws more current you will need to install a contactor.

When wiring your lube pump it is important to know which type of lube pump you have so that you configure it correctly. Typically lube pumps come in one of 3 types:

• Mechanical Cam Actuated Lube Pump: This pump is based on a simple mechanical plunger riding on a clock motor driven cam. The advantage of this type of lube pump is that it is reliable and it remembers where it was and how much run time has been accumulated even between power cycles. So that you actually get lube every 10 minutes for 5 seconds of machine use.

• Electronic Lube Pumps: These pumps try to imitate the mechanical cam pumps but often forget where in sequence they were when powered off. There are two types of Electronic lube pumps, “lube first” which pumps lube immediately after power on. Which typically results in too much lube. The second type is “lube last”, this type waits a set amount of time before lubing the machine. The problem with this type is on small jobs your machine may never get any lube, therefore possibly damaging the machine. To avoid this some people wire the lube last type to get power all the time which then results in too much lube.

• Direct controlled lube pumps: These pumps are controlled by the control via the PLC program and the software. With this type the lube pump is not responsible for the timing of the pump actuation. This method is the best for reliable, even lubing of your machine. Centroid Users see Tech Bulletin #171 and Parameter 179 in the operators manual for further explanation.

Enabling Lube Inputs

1. Power up your system.

2. Start CNC11 and press F10 to continue to the main screen

3. Invert the lube fault input (which was inverted during board level testing). In the main menu press alt + I to bring up

the real time I/O display.

4. Click on input 9, and press the ctrl-alt-i keys simultaneously to remove the bar over the input in the display. This will

enable your lube fault input.

5. Confirm that lube fault is green when nothing is tripped. Confirm that the correct input turns red when the switch is

tripped.

Page 55 of 138 5.7 Wiring Lube Pump

Figure 5.7.1

Sample Lube Pump Circuit

Page 56 of 138 5.7 Wiring Lube Pump

5.8 Wiring Coolant Pump

By default GPIO4D output 3 is the coolant flood pump output and output 4 is the default output for a coolant mist pump. If you have a custom PLC program your I/O may be different.

This sub-circuit shows how to hook up a 3 phase Flood Pump. Because the pump in this example draws more power than the GPIO4D is rated for, a Flood Contactor (Centroid PART# 3959) is needed.

All contactors need a snubbers. Centriod recommends using the Quencharc snubber network (Centroid PART# 1819) on the coil of the contactor. This reduces electrical noise when flood coolant is cycled on and off. A thermal overload is also shown, this part protects the motor by opening the circuit if it stalls for any reason, such as metal chips in the pump.

Centroid recommends a thermal overload protector. The example below diagram depicts the 24VAC wired through the NC contacts on the overload section of the contactor. The overload protection circuit on your existing contactor may be labeled differently or there may be no overload protection.

Figure 5.8.1

Sample Coolant Pump Circuit

Page 57 of 138 5.8 Wiring Coolant Pump

5.9 Wiring Spindle

More information on spindle can be found in Technical Bulletin #152, which can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb152.pdf)

STOP: Before wiring up the spindle make sure that you already tested the spindle as directed during the board level tests.

There are two methods of wiring a spindle:

1. Connect three phase directly to an induction motor (shown on the next page). Hooking the three phase directly saves costs, but prevents the Centriod CNC software from being able to control the speed of the spindle. The spindle speed will have to be controlled by mechanical methods such as pulleys.

2. Use a spindle controller (not shown). The terms “inverter” (short for power inverter), “AC Drive”, and “VFD” (Variable Frequency Drive) can all refer to the spindle controller. Centroid does not provide spindle controllers and recommends using Delta Products VFDs, Automation Direct GS2 and GS3 AC drives, as well as Yaskawa VS (Varispeed) Inverters. It is the responsibility technician installing to consult their spindle controller manufacturer for support. However, Centroid does provide Technical Bulletins with detailed installation instructions and troubleshooting for a few select models of spindle controllers.

With the default PLC program, several of the I/O are decided for use with a spindle. Input 10 is the spindle fault input. Output 7 is the spindle fault output. Output 5 is the inverter fault reset. Output 8 is the inverter direction. Output 10 is for a spindle cooling fan. Always refer to your schematic.

In the example below the thermal overload protector is wired directly to the spindle fault. If your spindle controller has a fault condition it should be wired in series with the thermal overload protector.

All contactors need snubbers. Centriod recommends using the Quencharc snubber network (Centroid PART# 1819) on the coil of the contactor. This reduces electrical noise when the spindle is turned off and on.

Enabling Spindle Fault Inputs

1. Power up your system.

2. Start CNC11 and press F10 to continue to the main screen

3. Invert the spindle fault input (which was inverted during board level testing). In the main menu press alt + I to bring up

the real time I/O display.

4. Press the ctrl-alt-i keys simultaneously to remove any bars over the input in the display. This will enable the spindle

inputs.

Page 58 of 138 5.9 Wiring Spindle

Figure 5.9.1

Sample Spindle Wiring

Page 59 of 138 5.9 Wiring Spindle

CHAPTER 6

FINAL SOFTWARE CONFIGURATION

6.1 Introduction

This chapter assumes that you have completed the board level test, and have built up a level of confidence with the hardware and software. PID settings and parameters for the AC/DC need to be entered into the software as described during the board level test before continuing with chapter 6.

6.2 Confirm AC/DC Communication

The very first time the AC/DC is switched on after being wired up, check to see if the AC/DC is detecting any errors or problems with your system.

Use the HSC screen to check for any AC/DC communication problems exactly as you did during the board level test. From the main menu press F7 Utility → F9 Logs → F5 HSC. More details about how to use this menu is contained in Appendix B.

If everything is connected correctly:

1. The “Debug counter” should be counting in hexadecimal for each drive connected to the system. This indicates that

the drive is talking to the MPU11.

2. The “Encoder OK” is set to a one.

3. Fatal Error and Warning should be zero. If the AC/DC has any errors, use Appendix B to troubleshoot the drive.

Figure 6.2.1

AC/DC HSC menu

Page 60 of 138 6.2 Confirm AC/DC Communication

6.3 Confirm Encoder Communication

1. DANGER: DISCONNECT THE MOTORS FROM THE MACHINE. The motors need be able to move freely. Failure to

disconnect the motors from the machine could result in personal injury or damage to the machine.

2. Confirm Encoder Feedback on all axes

1. From the main menu, press F1-Setup → F3-Config. Password is 137. Press F4 PID

2. With the Estop pushed in, manually rotate each motor while watching the abs pos field (circled below) for that axis as

seen in Figure 6.3.1. Confirm that you have smooth feedback on all axes and that X updates the X DRO, Y updates Y DRO etc.

3. Confirm that the absolute position increases for an AC motor (decreases for a DC motor) while rotating the shaft

clockwise.

1. NOTICE: The AC/DC servo drive needs the encoder correctly connected/wired before attempting a move. If the encoder is not detected upon start up, you will need to restart both the AC/DC drive and the CNC11 software before trying to test the encoder again. Users can troubleshoot drive errors through the HSC bit screen definitions in Appendix B.

Figure 6.3.1

Confirm encoder rotation

Users with AC Motors Continue to Section 6.4 AC Encoder Alignment

Users with DC Motors Skip to Section 6.5 Jogging and Motor Direction

Page 61 of 138 6.3 Confirm Encoder Communication

6.4 AC Encoder Alignment

Introduction

This same information can be found in Technical Bulletin #166, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb166.pdf)

AC drives rely on knowing the motor position in order to stay synchronized while driving the motor. Before the motor is mounted on a machine, the motor's encoder commutation tracks are aligned with the motor phases. During the “Move Sync” procedure, the drive applies sinusoidal voltages to rotate the motor shaft to a starting position. Typically, four “Move Sync” cycles will rotate the motor shaft one revolution.

The drive looks at the commutation lines from the encoder to give it a coarse position of the shaft for smooth movement on power up. These commutation signals are interpreted by the drive as zones 1 through 6. As the motor turns clockwise looking at the output shaft the commutation zone count should increase. Centroid AC motors use a differential, 8 pole, 5V, quadrature encoder with an index pulse. The encoder resolution depends on the motor and the drive (see below).

This procedure can also be repeated if you suspect the encoder alignment is incorrect. An incorrect alignment will show the following symptoms:

1. Axis is jumping.

2. Motor is running roughly.

3. Motor runs better in one direction than the other.

4. Motor has an uneven amount of current draw in one direction than the other.

5. Large current draw with a light load.

Prerequisites

• If connecting a motor to a drive for the first time, please complete the following steps: ◦ Check for >100 MΩ between the motor chassis and power terminals. ◦ With the motor connected to drive, confirm continuity between the drive chassis and motor chassis. ◦ On the drive terminal, check for >100 MΩ between your power and shield terminals. ◦ Check VM wiring for correct polarity ◦ Additional information on motor testing can be found in Technical Bulletin 155.

Tools and Equipment for Encoder Alignment

◦ A set of metric and SAE hex keys. ◦ A small Philips head screw driver set. ◦ Loctite Blue 242 (Optional) ◦ If removing the motor from the machine, a set of clamps such as Irwin Quick Grips. ◦ If there is any contamination or debris inside the end cap, basic cleaning supplies such as a paper towel and all-

purpose cleaner.

◦ If there is not a rubber O-ring or gasket between the end cap and motor, a non-corrosive RTV sealant (such as Dow

Corning 3165) is needed.

◦ If changing the encoder, the correct replacement encoder and pigtail (see chart on next page).

Page 62 of 138 6.4 AC Encoder Alignment

The motor must be disconnected from the machine or have the machine drive belt removed for the alignment process. This procedure is best performed on a sturdy bench where you have good lighting and easy access to the encoder. If the motor is removed from the machine, the motor frame must be firmly secured to the bench using clamps or some other attachment method. The motor may try to jump around during the procedure (especially if something goes wrong during the alignment). Before starting the alignment procedure, the drive software must be configured correctly.

Alignment Procedure

DANGER: Do not jog the axis until instructed!

1. Remove the motor end cap.

1. NOTICE: Any dust, dirt, coolant, or other contamination inside the motor end cap can get inside the sensitive internal

components of the optical encoder and cause a premature failure. Make sure the inside of the motor end cap and encoder mounting plate are clean before continuing with encoder alignment.

If there is a large amount of contamination inside the end cap, there is a high probability that the existing encoder will work unreliably and need to be replaced. If there is liquid inside the end cap, there may also be liquid inside the motor. A motor with liquid inside is a serious safety hazard, and will have to be replaced.

2. If installing a new encoder, remove the old encoder. Attach the new encoder. Snug the encoder set screws and encoder ears so that the encoder counts when the motor spins.

1. TIP: Nylon washers between the encoder ears and the mounting bolts makes the motor much easier to align as

shown below.

Figure 6.4.1

Parts of an encoder

3. Connect power cable and encoder cable from the drive to the motor.

4. Power up your drive and control system running Centroid CNC software

5. Go to the drive configuration menu. From the main menu press F1-Setup → F3-Config. Password is 137. F4 PID → F8-Drive as shown below in on the next page. Do not home the motor.

Page 63 of 138 6.4 AC Encoder Alignment

Figure 6.4.2

Drive Configuration Menu

Figure 6.4.3

Toggle Axis

6. Press F2-Move Sync as circled in Figure 6.4.2. The axis selected is shown underneath PWM Kp as circled in Figure

6.4.3. If you are not on the correct axis, press F1-Toggle Axis until the correct axis label is on the screen. Finally press F10-GO. The shaft should rotate. The first move sync rotation may cause the motor to jerk or move roughly. Move sync a few more times by pressing F2-Move Sync then F10-GO repeatedly. All move syncs after the first sync should cause the shaft to rotate smoothly. If the motor oscillates wildly, moves erratically, or makes loud unusual noises, kill the

motor power immediately!

1. DANGER: An incorrectly wired or configured motor may move violently or unpredictably when attempting move sync.

Keep your body (and others) away from the motor when move syncing for the first time, and be prepared to hit the emergency stop.

2. DANGER: Large motors may have a tendency to oscillate during a move sync due to nature of the current feedback

loop. It is recommended for 3KW and larger motors that you adjust the motor current to half of the recommended value in the current feedback menu while move syncing. After the encoder alignment process is complete, set the current back to the recommended setting.

3. NOTICE: If no motor movement occurs, an error was encountered. AC/DC users can troubleshoot drive errors

through the HSC bit screen definitions as described in Appendix D.

4. TIP: If the motor slightly oscillates after move syncing or continues to move a little rough while move syncing, grab the

motor on the shaft carefully with your hand while wearing a leather glove. Move sync the motor while gently squeezing the motor shaft. If the oscillations and/or jerky movements go away after manually applying a small amount of load to the shaft, this is normal. This problem is caused by not enough load on the motor shaft during alignment and will not occur during normal motor operation. Do not fight with the motor! If a small amount of pressure on the shaft does not stop the oscillations, stop the motor. Double check your PID values. If PID values are correct try reducing the current to the motor and trying again.

5. TIP: If the motor moves out of control, double check your PID settings and encoder counts per revolution. Make sure

the encoder is not wired backwards.

Page 64 of 138 6.4 AC Encoder Alignment

Figure 6.4.4

Encoder Alignment

Figure 6.4.5

Encoder Alignment

7. Keep running the move sync operation until the point where the encoder reading is closest to 0 or its maximum encoder count. The “Encoder Reading” is circled in above in Figure 6.4.4.

8. Loosen the encoder collar set screws as shown in Figure 6.4.5.

9. Move the encoder until the encoder reading is as close to zero as reasonably possible.

10. Tighten the encoder collar set screws. The encoder collar usually has two set screws on most encoders; make sure both

are tight if applicable.

11. Loosen up the encoder ears and use them to fine tune the adjustment. When the encoder is within specifications, a red message will appear on the control saying “*** Tighten Encoder Now ***” as circled in Figure 6.4.4. For a 40,000 count encoder, it needs to be aligned with +/- 25 counts of zero. Tighten the encoder ears. The encoder mounting plate is usually made out of aluminum, so DO NOT OVERTIGHTEN! Loctite blue (242) or similar may be used to prevent loosening without over-torquing the screws.

12. Press F2-Move Sync and F10 - Go to rotate the motor shaft several full revolutions. Verify that the software still displays “*** Tighten Encoder Now ***” when closest to the zero position. Some encoder re-adjustment may be needed. Observe the commutation count goes 1 through 6 consecutively. The commutation count is displayed below the encoder reading as circled in Figure 6.4.4. At rest position the commutation zone should be either a 1 or a 6 only. A 0 or a 7 commutation value indicates a bad encoder or wiring problem. If the motor is stopping on a commutation zone other than 1 or 6 your phases are in the wrong order or the encoder is wired incorrectly.

13. Tighten the end cap onto the motor. Be careful placing the encoder cable in the end cap. If the cable is causing any strain or pushing on the encoder, it will twist the encoder out of alignment.

14. Reboot the drive and control system.

Page 65 of 138 6.4 AC Encoder Alignment

15. After a reboot, jog the motor in each direction to verify correct operation.

1. Disable increment mode, by making sure the “incr cont” button on your jog panel is NOT lit up.

16. In the drive configuration menu, do a final move-sync check to verify that the motor is still aligned correctly. Look for the red message saying “*** Tighten Encoder Now ***” when the motor is closest to zero.

17. If there is not a rubber O-ring or gasket between the motor and the end cap, remove the end cap again. Apply a bead of

non-corrosive RTV sealant (such as Dow Corning 3165) onto the end cap mounting surface as shown below in Figure

6.4.6. Reinstall the end cap. This step is necessary for any motor bought from Centroid, but may be needed when performing retrofits to older systems.

Figure 6.4.6

Sealing the motor endcap

The motor is ready for normal operation after the system has been rebooted again.

You are done aligning the encoder!

Page 66 of 138 6.4 AC Encoder Alignment

6.5 Jogging and Motor Direction

1. Release E-stop to clear all errors and provide power to the motors.

2. Set the feedrate to around 10%

3. Jog each motor while it is disconnected from the machine if you have not already done so. Disable increment mode while

jogging by making sure the button on your jog panel labeled 'Incr Cont” is not lit up.

1. DANGER: The first time jogging the motor it must be disconnected from the machine! (Either by physically removing

the motor, or disconnecting a gear or drive belt.) This way if something goes wrong these is a minimal risk of damage

to the machine.

2. NOTE: It is normal if the motor is a little noisy or does not move smoothly. This will be fixed during tuning later in this

chapter.

4. Power down the machine

5. Manually move all axes to the center of their travel to provide safe clearance when the motors are tested under power.

6. Reconnect the motors to the machine

7. Power up the machine. Release E-stop to provide power to the motors.

8. Check home configuration During the board level test in Section 4.2 we changed the machine home at power up to jog.

Double check to make sure it is still set to jog as demonstrated in figure 6.5.1.

1. DANGER: Since your limit switches have not been configured correctly yet, homing to limit switches right now could

cause physical damage to your machine.

Figure 6.5.1

Checking home configuration

9. Make sure the feedrate is turned down to around 10%

10. Press the Start button on the jog panel, or Alt+S from the keyboard. This will cause the machine to set home right where

it is.

Page 67 of 138 6.5 Jogging and Motor Direction

11. Configure motors to move in the correct direction It is important to understand that correct motor direction is determined by the motion of the tool relative to the part, this is not necessarily the same as the motion of the table. This procedure is also covered in Technical Bulletin #137, which can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb137.pdf)

For axes that move the table while the tool remains stationary such as the X & Y axes on a typical Bridgeport type knee mill, the table motion is the opposite of the “tool motion”. For axes that move the tool, such as the quill on a knee mill, axis motion is the same as the tool motion. The Figures 6.5.2 and 6.5.3 below describe this concept.

Figure 6.5.2

Difference between table motion and tool on a knee mill.

Figure 6.5.3

Table verses tool movement

In the above illustration 5.5.3, the tool is moving in the X+ direction relative to the part while the table moves to the left.

Page 68 of 138 6.5 Jogging and Motor Direction

Configuring motors to move in the correct direction (continued) Use MDI to move each axis and determine if the axis is moving in the correct direction. To determine this, observe that the DRO counts more positive while moving an axis in the positive direction and that it counts more negative while moving in the negative direction. To correct for an axis that is moving in the wrong direction, from the main menu press F1 -Setup → F3 Config. The password is 137, Press enter. Press F2 Mach → F2 Motor. Use the arrow keys to select the “Dir Rev” field for the axis that needs to be corrected and press the space bar to toggle it's current state as seen in Figure

6.5.4.

Figure 6.5.4

Direction reversal

Page 69 of 138 6.5 Jogging and Motor Direction

6.6 Coarse Adjustment of DRO Position

NOTE: An alternative method is to use math to get a course estimation. This is described in the first part of Technical Bulletin #36, which can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb036.pdf)

The value being displayed the DRO screen is calculated from knowing how much the motor moved, and the motor revolutions per inch/mm (usually controlled by the ball screw). Before we can continue to tuning, we need an estimated number.

Later in this chapter after tuning the motor, we will perform a fine adjustment on the motor revs/in (mm/rev for metric systems) to calculate an exact value.

1. Jog the machine Jog the machine so that the spindle is in the center of the table.

2. Zero the software From the main menu, press F1 – Setup → F1 Part → F10 Set Zero as shown below in Figure 6.6.1.

Figure 6.6.1

Setting Part Zero

3. Set Up a Tape Measure on the Table Set up a tape measure on the table so that 0” is lined up under the center of the spindle.

4. Command the machine to move. The longer the move the more accurate your final calculation will be. It is recommended that you move the machine at least 1 foot. Use the MDI command. From the main menu, press F3 MDI. If we were testing the X axis for example we could type “X 12”.

1. WARNING: Turn the feed rate down and be prepared to hit E-stop. Since your limit switches have not been completely configured it is possible to crash the machine if it moves too far.

Page 70 of 138 6.6 Coarse Adjustment of DRO Position

5. Calculate the value Enter into the motor parameters menu. From the main menu press F1 -Setup → F3 Config. The password is 137, Press enter. Press F2 Mach → F2 Motor.

Figure 6.6.2

Adjusting motor revs/in or mm/rev

1. Imperial Units To calculate the value to be entered in the revs/inch field. Divide the distance moved (DRO value) by

the distance that the axis actually moved (measuring tape). Multiply this result by the current value in the rev/inch field as circled in Figure 6.6.2.. This the new value that you will enter in the revs/inch field. If the axis traveled 6”, but the command was 7.5” 7.5/6 = 1.25, if the current revs/inch is 5.000 * 1.25 = 6.25 is the new value to enter in the revs/inch field.

2. Metric Units To calculate the value to be entered in the mm's/revs field. Divide the distance that the axis actually

moved (measuring tape) by the distance commanded (DRO value). Multiply this result by the current value in the mm's/rev field as circled in Figure 6.6.2. This the new value that you will enter in the mm's/rev field. If the axis traveled 150mm”, but the command was 175mm, 150/175 = .85714, if the current mm's/rev is 5.08 * .85714 =

4.35428 is the new value to enter in the mm's/rev field.

6. Repeat the test as needed until the DRO matches the measuring tape.

7. Repeat the test for each axis.

Page 71 of 138 6.6 Coarse Adjustment of DRO Position

6.7 Homing the Machine

This same procedure is outline in Technical Bulletin #22, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb022.pdf)

1. Creating and Editing the Homing File

Your software comes with a default homing file that will work for most cases. If you have a machine with an

unusual number of axes (such as a rotary table, CNC controlled grinder, CNC controlled drill press, extra lathe axes, etc..) or an unconventional limit switch configuration editing the home file will be necessary.

1. Exit CNC11.

2. Right click on your CNC11 desktop shortcut.

3. Select properties as shown in Figure 6.7.1.

4. In the shortcut tab, click on “Open File Location” as shown in Figure 6.7.2.

5. Windows explorer will open up in a new window showing the contents of your CNC11 directory (The directory will be

called “CNCM” or “CNCT” depending on weather you have a mill or a lathe).

6. If “cncm.hom” (“cnct.hom” for lathes) is present, double click on it. If not the file present, it will have to be created.

To create this file,.right click on cncm folder in the Windows File Explorer. (cnct for lathes). Select “new”, then select “text document”. A file will be created named “New Text Document.txt”. Rename this file “cncm.hom” (“cnct.hom” for lathes).

1. TIP Centroid recommends using Notepad++ as your default text editor. Notepad++ can be downloaded here. (http://notepad-plus-plus.org/)

7. Edit the file as needed as seen in Figure 6.7.3. There should be the correct number of axes defined in this file, and they should be listed in the correct order.

1. Centroid recommends that the Z positive axis is always homed first to prevent damage to the machine!

8. Make sure to save any changes that you make.

Figure 6.7.1

Steps 2 and 3

Figure 6.7.2

Step 4

Figure 6.7.3

Steps 5, 6, and 7

Page 72 of 138 6.7 Homing the Machine

2. Start CNC11

3. Configure Limit Switches

1. NOTE: More information on Limit switches can be found in Technical Bulletin #127, which can be found here.

(http://www.centroidcnc.com/usersupport/support_files/tbs/tb127.pdf)

2. Prerequisite: The motor movement direction mentioned must be configured correctly before testing the limit switches!

3. Enter the motor parameters menu. From the main menu press F1 -Setup → F3 Config. The password is 137, Press enter. Press F2 Mach → F2 Motor.

4. Move the machine so that the spindle is in the center of the table.

5. Manually trip the minus limit switch for the X axis. Try to jog the machine. It should only move in the plus direction. If

it does not, change the limit switch in software as shown below in Figure 6.7.4.

Figure 6.7.4

Reversing limit switches in software

4. Change the home type From the main screen press press F1-Setup → F3 -Config. The password is 137. Then press F3 Parms. Using the keyboard spacebar change “Machine home at power up” to “Limit Switch”.

Figure 6.7.5

Enabling homing off limit switches

5. Restart the Machine

6. Home the Machine: From the main menu press “start” on the jog panel or “Alt+S” to home the machine. The machine

should move slowly towards each jog switch.

1. DANGER: Adjust the feedrate as needed so that the machine moves slowly. Be prepared to press E-stop if anything

unexpected occurs.

2. NOTE: If the machine stops homing and the main menu says “Warning: Machine not homed” a limit switch was

pressed in the wrong order and the machine faulted out. Please check the order of your limit switches as shown above.

Page 73 of 138 6.7 Homing the Machine

6.8 Calculating Maximum Feed Rate

In past Centroid products the maximum feed rate and acceleration was determined by autotune. At the time of this writing, the AC/DC does not support auto tune. Maximum feed rate will have to be found manually.

Use the following equation to get a estimation: (maximum motor rpm / motor revolutions per inch) * 0.85 = maximum feed rate.

Enter the maximum feed rate in the Jog Parameters menu (F1 - Setup, F3 - Config, F2 – Mach., and then F1-Jog.).

The calculated maximum feedrate may be too high due to variations in supply voltage and load. Use MDI commands to test the calculated machine maximum feed rate. Gradually issue faster feed commands until the maximum is determined. If the machine is displaying the following symptoms the maximum feed rate is too fast and should be decreased:

• The load bar graph in the DRO display of the main menu is red, indicating excessive load on the motors

• The software is giving errors such as position errors.

• Motors are overheating.

Figure 6.8.1

Adjusting maximum feed rate

Page 74 of 138 6.8 Calculating Maximum Feed Rate

6.9 Tuning Your AC/DC

6.9.1 A Basic Introduction to Tuning and PID

AC/DC uses a PID loop to control motor movement. PID stands for Proportional, Integral, and Derivative. A PID controller calculates an error value as the difference between a measured process variable (motor position) and a desired set point (expected motor position). The controller attempts to minimize the error by adjusting the power to the motor. The PID controller’s calculation algorithm involves three separate parameters: the proportional, the integral and derivative values, denoted in the software as Kp, Ki, and Kd. Additionally, the motors inertia constant plays a large role in how the PID loop behaves.

The general idea of the tuning process is to minimize the Absolute Error (ErrAbs), which is measured in encoder counts. The inertia of the system varies from machine to machine, and the ideal PID values vary from motor to motor. To achieve optimal performance out of your motor, the inertia, position Kp, and position Kd values will have to be manually adjusted. Under most circumstances, the position Ki values do not need any adjustment. The current feedback Kp, Ki, and Kd (different from the position feedback Kp, Ki and Kd) should be left alone unless otherwise instructed.

Altering the PID values incorrectly could cause DRAMATIC changes in the way the servo system operates, leading to possible machine damage. Be cautious when adjusting the PID values, and be prepared to hit the E-stop as the motor may become unstable or move unpredictably if adjusted incorrectly.

Finally, PID tuning is not a black and white process. What is “good enough” of a value will depend on your accuracy needs and the capabilities of your system. Some experimentation is always required to find the ideal settings.

Centroid recommends using 40,000 counts per revolution encoders. Having lower resolution encoders is allowed, but might make the machine more difficult to tune.

Page 75 of 138 6.9.1 A Basic Introduction to Tuning and PID

6.9.2 Tuning Software Setup

Tuning should be done last once everything else is set up and the motor is connected to the machine. Before tuning, configure the software (and align the encoder if necessary) as discussed in the earlier sections of this manual.

First, home the machine. Move the machine so that the axes are in the middle of their travel. Make sure the real time I/O display is not showing in the main menu (press alt + I to toggle the real time I/O display). Go to the PID configuration menu by pressing F1 - Setup, F3 - Config, F4 – PID, and then F1 – PID Config from the main menu (as shown below). Press F1-Edit Program to bring up PID_Collection_Moves.txt in the default .txt editor. Edit the G-code so that the motor axis matches the axis of the motor to be tuned. For example, changing the line “G1 w0.0” to “G1 x0.0” will change the program to move the X-axis instead of the W-axis. Now you should be looking at the PID configuration menu as shown in Figure 6.9.2.1.

Figure 6.9.2.2

Figure 6.9.2.1

The PID Configuration menu

The colors of the text on the top left match the colors of the graphs on the right. For example, if you have a V abs value written in blue in the top left, the graph for V abs will be displayed on blue in the top right. For the rest of the tuning procedure when referring to motor velocity, we are referring to the V Abs value and the corresponding graph. When referring to position error, we are referring to the Err Abs value and the corresponding graph. The colors used in the graphs in this manual may be different from the colors shown on your screen.

The graph can be manipulated with a mouse by clicking, dragging, and scrolling. The graph can be manipulated with the keyboard by using the F3, F4, F5, F6, and F7 keys. Start by pressing F7-Zoom All, this will adjust the graph. This menu and these settings are covered in more detail in the CNC11 manual. Pressing F8 – Change Axis will toggle the axis being graphed and will change the error information displayed in the top left of the screen. If necessary, press F8 until the selected axis matches the motor to be tuned.

Press F2-Run Program to start the tuning process. The motor should run in a continuous loop and not stop until manually stopped. Values are adjust with the keyboard. If “finished running program” is immediately displayed, an error was encountered. Go back to the main menu, and check the message window for errors. Advanced AC/DC users can troubleshoot drive errors through the HSC bit screen definitions as described in the Appendix D.

NOTE In upcoming sections 6.9.4 Acceleration Tuning, 6.9.5 Kp Tuning, and 6.9.6 Kd Tuning only movement in one direction will be shown in the examples to make it easier to interpret the graphs. Proper tuning involves movement in both directions. In sections 6.9.4 – 6.9.6 compare the positive half of graph to example as shown in Figure 6.9.2.2.

TIP When viewing the live tuning scope (graphs) be mindful of the scale. You can adjust the scale of the graphic. The encoder counts and the overall turns ratio of the machine will determine the counts per inch. Adjust the scale of the graph to a reasonable encoder count amount for the given encoder counts per inch of that axis. In other words, on a high count per inch system you may have errors as high as 100 counts, but 100 counts might only be representing 0.00005” on the machine.

Page 76 of 138 6.9.2 Tuning Software Setup

6.9.3 Acceleration Tuning

Accel is the time for the axis to reach maximum velocity. An accel rate of 0.1 second is very fast, where an accel rate of

1.0 will be considered very slow.

Record the acceleration rate suggested by the software when the maximum feed rate was saved in the jog parameters menu (In Section 5.6). Entered this acceleration rate into the position PID menu (Press F1 - Setup, F3 - Config, F4 – PID, and then F1 – PID Config.) The rate provided is not the ideal acceleration rate, but a baseline number.

Press F1-Edit Program; adjust PID_Collection_Moves.txt so that it runs at the maximum feed rate as calculated in section 5.8 Save changes. Press F2-Run Program. Slowly decrease the acceleration time in 0.05 increments, testing the value in-between each change (Circled in 6.9.3.1). If you see any of the following symptoms the acceleration rate is too fast and needs to be slowed down:

 The acceleration rate is causing shock or vibration as the machine moves.  The machine movement becomes bumpy, rough, or jerky.  The machine creates unusual or loud noises such as thunks or rapping noises.  The software is giving errors such as position errors.

Figure 6.9.3.1

Acceleration tuning

Page 77 of 138 6.9.3 Acceleration Tuning

6.9.4 Inertia Tuning

For Inertia tuning adjust the feed rate in PID_Collection_Moves.txt to the average rate during a typical machine operation.

The parameters in the F8 – Drive menu, with the exception of inertia, do not change based on machine type, and can therefore be set once from the provided charts. Inertia is set to the motor inertia as a starting point. Once the motor is mounted to a machine, the inertia value will need to be increased to compensate for the additional inertia of the mechanical drive components.

Inertia is adjusted in the drive configuration menu. From the PID configuration menu press F10 – Save and exit, F8 – Drive, and then F1 – PID. Throughout the tuning process make changes in the Drive configuration menu, and then go back to the PID configuration menu and run the collection moves program to see how those changes affect the graph. Repeat this process until results are acceptable.

The following plots demonstrate the effect of the inertia setting. The dark blue line is the motor velocity (V abs) and the red line is position error (Err Abs). In the first example, inertia is set to the motor inertia, but a load has been added, so the setting is too low. The error plot shows that the motor is behind the expected position on acceleration. In the second example, the inertia value has been increased too much. The motor moves ahead of its expected position during acceleration. In the third example, inertia has been set to a reasonably accurate value. The motor follows closely at the beginning of the move.

It is best practice to focus on the error around the rising edge of the motor velocity graph. Start adjusting the inertia in increments of 0.05 at a time, later switching to smaller increments as you approach your final value. Your graph will look slightly different than the graphs displayed below due to factors such as motor velocity, encoder count, other PID values being off, etc. The final inertia value should fall in the range of 0.5 to 0.005.

Figure 6.9.4.1

Low Inertia

Figure 6.9.4.2

High Inertia

Figure 6.9.4.3

Inertia set correctly

Page 78 of 138 6.9.4 Inertia Tuning

6.9.5 KP Tuning

The PID Config menu (F1 - Setup, F3 - Config, F4 – PID, then F1 – PID Config) is used to tune the remainder of the motor control parameters. To adjust, either type in a new value, or use the “Page Up” and “Page Down” keys of your keyboard to increment or decrement the existing value. Increase Kp until some oscillation is heard or seen on the PID tuning graph. Reduce the setting below the oscillation point to give some headroom for stability.

The following examples show the effect of Kp. The dark blue line is the motor velocity (V abs) and the red line is position error (Err Abs). In the first example, Kp is set too low. Large error peaks show where the motor is not following the requested path. Increasing Kp leads to the second example, where error is low throughout the move. However, there is an increasing oscillation in the error plot, indicating that the motor will soon become unstable. The third example demonstrates a Kp reduction to improve stability. The error plot has nearly minimal error achieved during tuning and does not have signs of instability.

Start adjusting the Kp in increments of 1.0 at a time, later switching to smaller increments as you approach your final value. Your graph will look slightly different than the graphs displayed below due to factors such as motor velocity, encoder count, motor performance, etc. The final Kp value should fall in the range of 1 to 20.

Figure 6.9.5.1

Low Kp

Figure 6.9.5.2

High Kp (unstable)

Figure 5.9.5.3

Kp set correctly

Page 79 of 138 6.9.5 KP Tuning

6.9.6 KD Tuning

After Kp has been adjusted, continue to tuning Kd. The Kd term adds stability to the effects of Kp. If Kp or Kd have been adjusted far from the default values, a second iteration of the tuning procedure is recommended. Because the two terms are dependent on each other, a better Kd setting may allow Kp to be adjusted for higher performance.

Incorrect Kd settings create oscillations. A low Kd setting creates low frequency oscillations. As Kd is increased, a high frequency oscillation will become noticeable. Often the high frequency oscillation will be audible before it is noticeable on the error plot. The example shows an extreme case of oscillation due to Kd set too high. When Kd is set properly, it will dampen the Kp contribution, giving a smooth error plot.

Start adjusting the Kd in increments of 1.0 at a time, later switching to smaller increments as you approach your final value. Your graph will look slightly different than the graphs displayed below due to factors such as motor velocity, encoder count, motor performance, etc. The final Kd value should fall in the range of 1 to 20.

Figure 6.9.6.2

High Kd

(unstable)

Figure 6.9.6.1

Low Kd

Figure 6.9.6.3

Kd set correctly

Page 80 of 138 6.9.6 KD Tuning

6.10 Fine Adjust of DRO Position

This method is also described in Method 2 of Technical Bulletin #36, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb036.pdf)

For imperial machine configurations the number of motor revolutions required to move 1” must be calculated.

For metric machine configurations the number of mm's travelled during one revolution of the motor must be calculated.

3. Attach a dial indicator: Attach a dial test indicator (also known as a lever arm test indicator or a finger indicator) to the spindle.

1. NOTE: If you purchased a probe from Centroid, there is an easier method of doing this. Use of the probe will not

be covered in this document.

4. Create a Test Fixture: Create an “L” shaped block of material to act as a reference for measurement as seen in Figure 6.10.1. The material should be appropriately 6 inches to 12 inches in length. A longer material will give you better accuracy. The exact length of the “long” part of the “L” needs to be known. A gauge block attached to another gauge block is recommended. An example test fixture is shown below.

The long part of the “L” is from is guage block measuring 12.000”

Figure 6.10.1

Example test fixture

5. Secure the test fixture Attach the test fixture to your machine so that it runs parallel to the axis being tested.

6. Move the dial indicator into position: Start from away from the block and jog towards the top of the “L”. Set jog

panel mode to incremental when you get close. Move the spindle so that the dial indicator is reading as close to “0” as possible as demonstrated in Figure 6.10.2.

1. NOTE: Only jog towards the block. If you jog too close and have to back up slightly, backlash will be introduced

into your measurement. In that case you will have to back way up and start again.

Figure 6.10.2

Zeroing the dial indicator

Page 81 of 138 6.10 Fine Adjust of DRO Position

7. Zero the software From the main menu, press F1 – Setup → F1 Part → F10 Set Zero as shown below in Figure

6.10.3.

Figure 6.10.3

Setting part zero

8. Raise the spindle: Move the spindle so that it is away from the text fixture. If we are configuring the X or Y axes we need to the raise the Z-axis.

9. Move to the base of the “L”: Jog towards the base of the “L”. Set jog panel mode to incremental when you get close. Move the spindle so that the dial indicator is reading as close to “0” as possible as shown in Figure 6.10.4.

1. NOTE: Only jog towards the block. If you jog too close and have to back up slightly, backlash will be introduced

into your measurement. In that case you will have to start the test again.

Figure 6.10.4

Zeroing the dial indicator again

Page 82 of 138 6.10 Fine Adjust of DRO Position

10. Calculate Values: Go into the motor parameters menu. From the main menu press F1 -Setup → F3 Config. The password is 137, Press enter. Press F2 Mach → F2 Motor.

Figure 6.10.5

Fine adjustment of motor res/in or mm/rev

1. Imperial Units: To calculate the value to be entered in the revs/inch field. Divide the distance moved (DRO

value) by the distance that the axis actually moved. Multiply this result by the current value in the rev/inch field. This the new value that you will enter in the revs/inch field. If the axis traveled 6”, but the command was 7.5” 7.5/6 = 1.25, if the current revs/inch is 5.000 * 1.25 = 6.25 is the new value to enter in the revs/inch field.

2. Metric Units: To calculate the value to be entered in the mm's/revs field. Divide the distance that the axis actually

moved by the distance commanded (DRO value). Multiply this result by the current value in the mm's/rev field. This the new value that you will enter in the mm's/rev field. If the axis traveled 150mm”, but the command was 175mm, 150/175 = .85714285, if the current mm's/rev is 5.08 * 0.85714 = 4.35428 is the new value to enter in the mm's/rev field.

11. Repeat the test as needed until the DRO measures the same as the gauge block.

12. Repeat the test for each axis.

Page 83 of 138 6.10 Fine Adjust of DRO Position

6.11 Removing Backlash

This same procedure is outlined in Technical Bulletin #37, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb037.pdf)

1. Adjust Mechanical Lash: Before configuring the backlash compensation in the control, every effort should be made to reduce the mechanical lash in your machine to less than 0.001”. The “electronic” backlash compensation provided by the control will help, especially in point to point moves, but the overall accuracy of your machine is determined purely by the amount mechanical lash in the machine.

2. Attach a dial indicator: Attach a dial test indicator (also known as a lever arm test indicator or a finger indicator) to the spindle.

1. NOTE: If you purchased a probe from Centroid, there is an easier method of doing this. Use of the probe will not be covered in this document.

3. Zero Previous Backlash Values: Enter into the motor parameters menu. ( From the main menu press F1 -Setup → F3 Config. The password is 137, Press enter. Press F2 Mach → F2 Motor. ) Zero out any backlash that was previously

entered into the control.

4. Secure a Test Fixture: Mount a piece of metal to the machine to act as a reference. A gauge block recommended. You may re-use the test fixture you created for configuring your motors to move the correct distance.

5. Move the dial indicator into position: Start from away from the block and jog towards it. Set jog panel mode to incremental when you get close. Move the spindle so that the dial indicator is reading as close to “0” as possible as demonstrated in Figure 6.11.1.

1. NOTE: Only jog towards the block. If you jog too close and have to back up slightly, backlash will be introduced into

your measurement. In that case you will have to back way up and start again.

Figure 6.11.1

Zeroing the dial indicator

Page 84 of 138 6.11 Removing Backlash

6. Zero the software From the main menu, press F1 – Setup → F1 Part → F10 Set Zero as shown below in Figure 6.11.2.

Figure 6.11.2

Setting part zero

7. Back the spindle 0.025 away from the gauge block at a feedrate of 0.5 inches per minute. This can be done by using the MDI menu (F3 from the main menu) and typing “G1 X- 0.025 F0.5” for the X axis.

1. NOTE: Is is important that you use extremely slow feedrates. Faster feedrates will introduce inconsistencies due to

the inertia of the table.

8. Move the axis back to the zero position. Type “G1 X0 F.5” in the MDI screen.

9. Enter the value shown into the “Lash Compensation” section of the motor parameters menu.

Figure 6.11.3

Adjusting backlash compensation

Page 85 of 138 6.11 Removing Backlash

6.12 Deadstart

Deadstart is located in the jog parameters menu and has to do with direction reversal of an axis. The deadstart usually doesn't have to be changed from the default value on a Milling machine. Sometimes very light wood routing tables with very low friction and low inertia can benefit from a deadstart change along with other "hand tuning." Call in if you have this case.

6.13 Other Misc Tuning Information

Kg, Kv, and Ka in the PID position menu are not used and do not need adjusted. Ki does not need to be adjusted under most circumstances. After tuning the other values of the PID loop, experimentation with Ki values may sometimes help to reduce error. Adjust Ki in increments of 0.005, with the final value falling in the range of 0.001 to 0.25.

6.14 Performing a System Test

In some versions of CNC11 software, when finished, the main menu will display a message saying “Machine Setup Not Completed. Machine Is Not Ready To Run. Contact Your Dealer” as shown below.

At this point you will need to run the System Test to clear this message. Documentation on how to perform a system test is located here. (http://www.ajaxcnc.com/tech/downloads/manuals/install/Systemtest.pdf)

If the instructions outlined in system test do not apply to your system, contact technical support.

Figure 6.14.1

Machine Requiring a System Test

Page 86 of 138 6.12 Deadstart

Appendix A - Windows 8 Preinstallation

The information contained in this procedure is also contained in Technical Bulletin #283, which can be downloaded here (placeholder)

Required Materials

• Samsung 120GB SSD

• USB or SATA DVD player

• USB mouse

• copy of Windows 8 Home Premium 64-bit

• copy of the latest version of CNC11 software

Instructions for Configuring Windows 8

1.) Install SSD and DVD player into servo PC/console. Make sure to plug the SATA cable from the SSD into SATA0 on the motherboard. Software MUST be loaded on the system that you are working on. It CANNOT be loaded onto an SSD remotely and then installed onto the control. Windows does not allow that.

2.) Connect a SHIELDED CAT5/CAT6 Ethernet cable to the on-board Ethernet port and the MPU11.

3.) Power on the MPU11 and servo PC/console.

4.) Insert the Windows 8 DVD and install the Windows software.

5.) Start at the desktop view.

6.) Move your mouse to the right corner of the screen to bring out the side tab and click on the "Settings" button.

Page 87 of 138 Appendix A - Windows 8 Preinstallation

7.) Next click on the "Control Panel"

8.) Go to "Uninstall a Program" directly underneath "Programs”.

9.) Next uninstall any un-necessary programs that might have come from your computer manufacture. Some of these may include McCaffey Antivirus, various trial offers, etc.

Page 88 of 138 Appendix A - Windows 8 Preinstallation

10.) Go back to the main "Control Panel" page and click on "System and Security".

11.) Click on "Windows Update".

12.) Install the Updates. You may need to restart the computer several times.

Page 89 of 138 Appendix A - Windows 8 Preinstallation

13.)Keep going until you see the below screen, stating that no more updates are available. Then click on the "Change settings" on the left side.

14.) From the dropdown under "Important updates" select "Never check for updates" and click OK at the bottom after.

15.) Go back to the Control Panel view and click on "System and Security".

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16.) Click on the "Action Center".

17.) Click on "Change User Account Control Settings" and then drag the bar to the "Never notify" at the bottom and click OK.

18.) Next click on "Change Action Center Settings".

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19.) Un-select every checkbox and click OK.

20.) Go back to the main Control Panel page and click on "System and Security".

21.) Click on "Windows Firewall".

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22.) Click on "Turn Windows Firewall on or off" on the left hand side.

23.) Click on the "Turn off Windows Firewall" buttons on both the Private and Public network settings. Click OK at the bottom.

24.) Go back to the Control Panel Main page and click on "System and Security".

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25.) Click on the "System" option.

26.) Click on "Device Manager" on the left hand side.

27.) Find the "Network adapters" and click to expand them.

28.) Double-click on any Ethernet cards and the below should be displayed.

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29.)Click on the "Power Management" tab and the uncheck all the boxes. Click OK and do the same for any other Ethernet Cards available.

30.) Go back to the "System and Security" screen and click on "Power Options”.

31.) Click on the circle with and arrow to bring up the "additional plans" then select "High performance" and click "Change plan settings".

32.) Click on the "Change advanced power settings".

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33.) Click on the "Change settings that are currently unavailable".

34.) Under "Hard disk" set "Turn off hard disk after" to "Never"

35.) Under the "USB settings" , for "USB selective suspend setting" select "Disabled"

36.) Under "Display" set "Turn off display after" to "Never". Then click "Apply". Than close the open window.

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37.) Press "Ctrl" + "Alt" + "Delete" all at the same time. Select "Task Manager", then click on the more details button.

38.) Next click on the "Startup" tab and click on each Item and then click "Disable" at the bottom. Then close the window.

39.) Click on the "Date and Time" section of the taskbar on the lower right hand corner. Click “Change Date and Time Settings”.

40.) Select the "Internet Time" tab and click on "Change settings..."

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41.) Uncheck the "Synchronize with an Internet time server" box and click OK.

TIP: If you want to eliminate the scan & fix pop up and autoplay pop up when you plug in your USB stick, you will need to do the following. To suppress the scan & fix click on the Windows icon and type: msconfig and click on the "Services Tab" then scroll down and uncheck "Shell Hardware Detection". Click "Apply" then "Ok" and then you will need to power cycle the PC.

TIP: To suppress the autoplay, click on Windows start icon and type: autoplay then uncheck "use AutoPlay for all media and devices" and click "Save".

You may now continue to Section 3.2, CNC11 and PLC Installation.

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Appendix B - Windows 7 Preinstallation

This procedure is outlined in Technical Bulletin 244, the latest version can be found here. (http://www.centroidcnc.com/usersupport/support_files/tbs/tb244.pdf)

Required Materials

• OCZ Vertex Series 30Gb SATA II SSD

• USB or SATA DVD player

• USB mouse

• copy of Windows 7 Home Premium 64-bit

• copy of the latest version of CNC11 software

Instructions for Configuring Windows 7

1. Install SSD and DVD player into servo PC/console. Make sure to plug the SATA cable from the SSD into SATA0 on the

motherboard. Software MUST be loaded on the system that you are working on. It CANNOT be loaded onto an SSD remotely and then installed onto the control. Windows does not allow that.

2. Connect a SHIELDED CAT5/CAT6 Ethernet cable to the on-board Ethernet port and the MPU11 as shown in Section 2.3.

3. Power on the MPU11 and servo PC/console.

4. Insert the Windows 7 DVD and install the Windows software.

5. Using the mouse, right click on the task bar, which is located on the bottom of the screen, and select

“Properties” as shown below.

6. Check the “Auto Hide” option under the “taskbar” tab.

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7. Right click on the “Action Center” icon, which is the green flag that is located on the right side on the task bar.

8. Select “Open Action Center”.

9. Click on “Change Settings”.

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ajax GPIO4D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

1.1 MPU11

1.2 Crimpers

1.3 GPIO4D

1.4 AC/DC

2.1 Introduction

2.2 Power Supply Configuration

2.3 Communication Configuration

2.4 Encoder Set-up

2.5 MPU11 Accessories

2.6 Powering On & Verifying LED States

3.1 Preinstallation

3.2 CNC11 and PLC Installation

3.3 AC/DC Setup Wizard

4.1 Software Configuration

4.2 Bench Testing the AC/DC

4.3 Bench Testing the MPU11 and GPIO4D

5.1 Introduction to Electrical Cabinet Layout

5.2 Electrically Configuring Inputs on the GPIO4D

5.3 Wiring Motors

5.4 Wiring AC/DC Brake Resistor

5.5 Wiring E-Stop

5.6 Wiring Limit Switches

5.7 Wiring Lube Pump

5.8 Wiring Coolant Pump

5.9 Wiring Spindle

6.1 Introduction

6.2 Confirm AC/DC Communication

6.3 Confirm Encoder Communication

6.4 AC Encoder Alignment

6.5 Jogging and Motor Direction

6.6 Coarse Adjustment of DRO Position

6.7 Homing the Machine

6.8 Calculating Maximum Feed Rate

6.9 Tuning Your AC/DC

6.9.1 A Basic Introduction to Tuning and PID

6.9.2 Tuning Software Setup

6.9.3 Acceleration Tuning

6.9.4 Inertia Tuning

6.9.5 KP Tuning

6.9.6 KD Tuning

6.10 Fine Adjust of DRO Position

6.11 Removing Backlash

6.12 Deadstart

Appendix A - Windows 8 Preinstallation

Appendix B - Windows 7 Preinstallation