MPU11 Mill Kit Installation
Last revised 2010-07-20 (277)
Table of Contents
1. Introduction
2. What's included
3. Order Of Installation
4. Desk/Benchtop connection, software and network installation and configuration
5. Mounting major components in electrical cabinet
6. Connecting and testing major components in the electrical cabinet
7. Wiring basic sub-systems
8. Configuring motors, encoders and limit switches in software
9. Wiring auxiliary sub-systems
9.1 Lube pump
9.2 Coolant pump
9.3 Spindle
Introduction
This manual describes how to install the AjaxCNC (Computer Numerical Control) system. It is
strongly recommended that you follow each step in order without skipping steps. The PC based
AjaxCNC system provides 3 to 6 axis closed loop servo interpolated motion, controlled by industry
standard G-Codes. The system is intended for CNC control of milling machines, routers, lathes,
flame, plasma, laser/water jet cutters, and other specialized applications. The AjaxCNC system is
intended for use by competent installers, retro-fitters, and machine tool builders who want to do
their own installation. This installation manual is not intended for casual end users.
Before You Begin:
Installing your new Ajax CNC11 based DC3IOB System is a straight forward process if you follow
the directions included here. 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 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. A troubleshooting procedure is included for each section of
the installation so that if you do run into any problems, you will be able to quickly isolate the cause
and correct it. In addition tot he troubleshooting procedures you can find answers to many
questions in our support forum www.ajaxcnc.com/ajaxbb
If you run into a problem that you can not solve using the troubleshooting procedure or through the
support forum, please fill out the appropriate troubleshooting form included in Appendix A and send
it via email to tech@ajaxcnc.com. Fee based phone support is also available if needed. Please
see http://ajaxcnc.com/tech_support.htm for details.
FIG.1
2. What's included:
Make sure your kit is complete and has not been visibly damaged in shipment. The basic
DC3IOB kit includes:
The Ajax CNC11 Based CNC Kit you purchased contains: Qty
1. DC3IOB Servo Drive with integrated PLC 1 ea.
2. MPU11 Motion Controller 1 ea.
3. Fiber Optic Cable 4 ea.
4. +-12VDC, 5VDC Digital Power Supply 1 ea.
5. 110VAC power cable for digital PS 1 ea.
6. Power Cable - Digital PS to MPU11 1 ea.
7. 110VAC Power cable to DC3IOB 1 ea.
8. 12 pin Phoenix connector for inputs 2 ea.
9. 10 pin Phoenix connector for relay outputs 2 ea.
10. 7 pin Phoenix connector for Spindle analog out 1 ea.
11. Misc connectors/pins/SIPS for aux inputs/outputs 1 ea.
12. Installation/Electronic Documentation CD 1 ea.
FIG.2
3. Order Of Installation
Section 4 - Desktop/Bench top connection -
4.1 Connecting the major components
4.2 Power up for the first time
4.3 Software installation and configuration in Windows XP
4.4 Testing PC, MPU11 and PLC communications
Section 5 - Mounting, connecting major components in your electrical cabinet
Mount, connect and test PC, MPU11 and DC3IOB
Section 6 – Connect and test the major components in the electrical cabinet
Section 7 - Wiring Basic Sub-systems
7.1 Wiring limit switches and Estop PLC Input
7.2 Testing limit switches and Estop input
7.3 Wiring Estop coil
7.4 Wiring encoders
7.5 Testing encoders
7.6 Wiring motors and motor power
7.7 Testing motors and motor power
Section 8 - Configuring motors, encoders and limit switches in software
8.1 Configuring motors to move in the correct direction
8.2 Configuring encoders
8.3 Temporarily zero out limit and home switch PLC input values
8.4 Configuring your motors to move the correct distance
8.5 Configuring backlash compensation
8.6Configuring limit and home switches
Section 9 - Wiring Auxiliary Sub-systems
9.1 Lube pump
9.2 Coolant pump
9.3 Spindle
9.3.1 Reversing Contactors
9.3.2 VFD/Inverter Wiring – AutomationDirect GS2
4. Desk/Bench Top Connection & Software Install.
4.1 Connecting the major components The first step in the installation is to connect the major
components together on your desktop as depicted in Fig. 3 below. Be sure that your surface is
non-conductive and that you use a power strip so that all you components are powered on and off
at the same time. When everything is connected, your setup should look similar to the photo in
Fig. 4 on the following page. At this point, the only connections that should be made are:
a) The 110VAC from the power strip to the DC3IOB PC power supply and MPU11 power supply.
b) The digital power cable from the MPU11 power supply to the MPU11
c) CAT5 network cable from the PC to the MPU11
d) Fiber optic cables (4) from the DC3IOB to the MPU11
a
b
d
c
FIG.3
Desk/Bench Top Connection & Software Install. (cont)
FIG.4
4.2 Powering up for the first time With the major components all connected, confirm that all
components are resting on a non-conductive surface and turn on your power strip to power up your
components and PC. While powering up, you notice that there are 4 LED's next to the power
connector (see yellow rectangle above) on the MPU11 that flicker while the MPU11 is initializing.
After 15-30 seconds the LED's should be in the following states:
FPGA-OK = Solid green
DSP Debug = Flashing ~1 per sec
DSP -OK = Solid Green
+5V = Solid Green
4. Desk/Bench Top Connection & Software Install. (cont)
4.3 Software Installation and configuration on Windows XP With your desktop
configuration completely powered up as described in section 4.2. Install the CNC11
Software and configure Windows to communicate with the MPU11
4.3.1 Obtaining and installing the latest CNC11 Software version
The Centroid CNC11 software can be found in the “Centroid CNC11 Software” directory on
the DVD supplied with all Ajax MPU11 systems is also available for download* from the
AjaxCNC website at: http://ajaxcnc.com/tech/downloads/software/. It is recommended that
check to make sure that you have the latest CNC11 version before installation.
If you are running from the DVD, double click “setup.exe” in the “Centroid CNC11 Software”
directory to begin the software installation. (If you downloaded the software from the
website, extract the files to a local directory and then run “setup.exe” from “Centroid CNC11
Software” directory).
When the installer begins, you will be presented with a list of checkboxes to select which
package – Mill, Lathe, Mill Demo or Lathe Demo. Select only “Mill” and click “next”. When
prompted for the installation drive, leave it at the default location (c:\), click “next”. When the
CNC11 installation is complete, click “Next” and then “Finish”.
4.3.2 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 &
DC3IOB and then click on “basic” under Mill->DC3IOB to select it and click “Next” and then
“Finish” to complete the CNC11 and PLC software installation.
*Requires username and password to access link. If you do not know your username and password, please
email tech@ajaxcnc.com to request it. When emailing, be sure to provide the customer name and address
that your MPU11 system was purchased under or your system serial number. We cannot process your request
without this information.
4. Desk/Bench Top Connection & Software Install. (cont)
4.3.3 Configuring Windows XP and Your PC Hardware To Run CNC11
Before running CNC11 software for the first time, you must first configure Windows XP and
your PC hardware to allow communications with the MPU11 hardware. This involves
configuring the IP address of your network adapter and configuring Windows firewall to allow
CNC11 access to the network to communicate with the MPU11 hardware.
4.3.3.1 Configuring Ethernet card to Communicate with the MPU11
Configuring the network card in your PC to communicate with the MPU11 motion control
card. There are a couple things to note before we get started. All MPU11 systems will be
networked with a static IP network. You will need a second network card for networking your
control to a remote PC for file transfer. The NIC (Network Interface Card) in your PC and the
MPU11 motion card have dedicated IP addresses:
CNC11 PC : 10.168.41.1
MPU11 card : 10.168.41.2
Before you run the CNC11 software in Windows you need to configure the NIC to
communicate with the MPU11. For Windows XP click on the Start Menu → Control Panel →
Network Connections. From the Network Connections window right click on the on board
NIC highlight TCP/IP and select properties.
Check the “Use the following IP Address” and set the fields.
IP Address : 10.168.41.1
Subnet Mask : 255.255.255.0
Leave the Default Gateway blank and click OK.
4.3.4 Configure Windows Firewall To Allow CNC11 to Communicate With The MPU11.
Double click the CNC11 Mill icon on your desktop to start the CNC11 software. Depending
on your XP Windows Friewall configuration you may see the window below whaen you first
try to run CNC11. You must click “Unblock” to allow CNC11 to make changes to your
computer in order for CNC11 to operate correctly.
4. Desk/Bench Top Connection & Software Install. (cont)
4.4.1 Testing PC, MPU11 and PLC communications.
If you have followed the instructions up to this point, you should be looking at the
screen below. Congratulations! You have just confirmed that the PC and MPU11 are
communicating correctly.
Now, Press F10 (Cont) to enter the main screen of CNC11. Don't be alarmed that you don't
see numbers in the DRO, we'll get to that later in section 6.3 when we wire the encoders.
CNC11 Main Screen
4. Desk/Bench Top Connection & Software Install. (cont)
4.4.2 Before you can test the PLC and servo drive, you must first disable the spindle and
lube faults, defeat or jump limits, jump the Estop input and disable encoder faults and
stall detection in the software. NOTE: When this section of testing is complete, leave any
fault, limit or encoder inputs which are not being used jumped and/or disabled in software.
4.4.3 Disabling encoder faults and disabling Stall Detection for testing
To disable stall detection:
From the main screen – F1-Setup->F3 -Config (pw = 137)->F4 PID
Press the “Ctrl” and “v” keys simultaneously to toggle stall detection on/off. Verify that the
message “Stall Detection Disabled” is displayed.
To disable the encoder faults, set parameters 308-315 to 0 and press F10-Save to save
the settings. To enter the parameters screen:
From the main screen – F1-Setup->F3 -Config (pw = 137)->F3 Parms. Once in the
parameters menu use F7 & F8 to navigate between screens.
4.4.4 Disabling the lube fault and spindle fault inputs for testing purposes Input 18 is
dedicated for use as a lube fault input in the PLC and Input 25 is dedicated for use as a
spindle fault input in the PLC. When the lube fault or spindle fault input is open a the
appropriate fault is displayed on the screen. These faults need to be disabled for testing
purposes. To disable these faults:
Press F1 -Setup → F3 Config, password = 137, Press enter → F3 Parms
Once in the parameter screen, press F8 -Next Table once and then set parameter number
178 to 3.0000 Press F10 to save your changes and then press the escape key twice to
return to the main sceen
4. Desk/Bench Top Connection & Software Install. (cont)
4.4.5 Testing PC, MPU11 and PLC communications – Limit Switch Inputs.
With the main screen displayed as in the previous page, hold down the “alt” key and then
press the “i” key to bring up the real-time I/O display as shown below.
Toggle the “Limit DIP Switches” located on the DC3IOB drive to defeat and enable the limit
switch inputs while observing the real-time I/O screen. Setting a switch to the “up” position
defeats (shorts) that limit input, setting it to the “down” position enables it. When an input is
closed (switch is the up position and input “defeated”), the LED in the real-time I/O screen
for that input will be GREEN, when an input is open the LED in the real-time I/O screen for
that input will be RED. It should be noted that setting a switch to the up position is
electrically the same as jumping that input to input common.
After confirming operation for each limit input, leave the defeater in the “up” position for any
axis/dir that you will NOT be wiring a limit switch to.
4. Desk/Bench Top Connection & Software Install. (cont)
4.4.6 Testing PC, MPU11 and PLC communications – E Stop Input
Connect a jumper between the E Stop input on DC3IOB and input common just below it
shown below. Alternatively, open and close the jumper and observe that the status display
window (upper right of screen) displays “Emergency Stop Detected” when the jumper is
removed and “Emergency Stop Released when the jumper is connected.
4.4.7 Testing PC, MPU11 and PLC communications – Drive Fault Relay
While opening and closing the E Stop input with the jumper, connect an ohm meter to the
drive fault realy output on the DC3IOB as shown below. Confirm that you have continuity
between Drive Fault Rly 1 and Drive Fault Rly 2 when the jumper is installed – Emergency
stop released- and that the relay opens when the jumper is removed -Emergency stop
detected.
Note: This behavior is used to remove motor power from
the servo drive when E stop is detected. It is “hard
wired” and can not be modified by the PLC or any other
manner . For this reason, your Estop switch MUST
be a normally closed type. If the E stop input is open,
Measure the drive fault relay will be open and motors will be
Here disabled.
Bench top configuration is complete. Power off your
system and proceed to section 5
5. Mounting major components in your electrical cabinet
5.1Panel Layout Below is a suggested layout for the major components on your electrical
panel. This layout keeps the heavier components (transformer) at the bottom to keep the
enclosure from being top heavy and separates power from signal wiring wherever
possible. and helps keep the distance short when routing the DC motor power (We
recommend that motor power routing be less than 6 feet)
Mounting the terminal strip in the
middle provides easy access to
and from any component
Mounting the cap and bridge
under the DC3IOB leaves
more room for contactors in
other areas of the cabinet
5. Mounting major components in your cabinet (cont)
Mount the DC3IOB
directly over the cap
and bridge.
The easiest and most
convenient way to mount the
MPU11 is to install standoffs
on the cover of the DC3IOB
and mount the MPU11 on top.
Be sure to leave room to see
the labels on the I/O.
6. Connect major components in your cabinet
Connect the major components in your electrical cabinet just you had done on your desktop in
section 4 but wire your 110VAC service through your cabinet disconnect instead of a power strip.
a) The 110VAC from the disconnect to the DC3IOB PC power supply and MPU11 power supply.
b) The digital power cable from the MPU11 power supply to the MPU11
c) CAT5 network cable from the PC to the MPU11
d) Fiber optic cables (4) from the DC3IOB to the MPU11
a
b
d
c
Power up and test the system as described in section 4 but omit the software installation process.
7. Wiring Basic Sub-systems
7.1 Limit switch and Estop PLC input wiring Limit switches on the DC3IOB MUST be a
normally closed type switch (contact closure). This is because the DC3IOB electrically
disables motor rotation in one direction when a limit switch is open. The limit switch
inputs (inputs 1-6) are dedicated and can not be used as a general purpose input. Any
limit switch input that you will not be using must be disabled in order for your system to
operate properly. To disable a limit switch input, you can either pull UP the Limit Dip
Switch for that axis and direction as shown in the photo below left or jumper the input to
the common for that axis as shown below right (photo depicts all limits and Estop input
jumpered and defeated). NOTE: The two methods are electrically identical:
Connect your limit switches as shown:
7. Wiring Basic Sub-systems (cont)
7.1 Limit switch and Estop PLC input wiring (cont)
Estop PLC input wiring The Estop input (input 11) on the DC3IOB must be wired to a
normally closed switch (contact closure). When the Estop input is open, the motors are
disabled.
Estop PLC input wiring – no pendant
Estop PLC input wiring – with pendant
7. Wiring Basic Sub-systems (cont)
7.2 Limit switch and Estop PLC input testing Power up your system to test the limit
switch and Estop PLC input wiring. Start the CNC11 software by double clicking on the
CNC11 Mill icon on your desktop. After the MPU11 has initialized, press F10 to continue
to the main screen. Now, hold down the “alt” key and press the “i” key at the same time
to bring up the real-time I/O display.
The image to the right shows the limit
switches, inputs 1-6, in the upper left in
the normally closed and operational
state.
The Estop input, input 11, is also in the
normally closed and operational state.
Trip your Estop and limit switches individually and confirm that the display changes from
green to red and then back to green when you trip and release each switch that you
have wired. Confirm that, when none of the limits are tripped, ALL limit switch inputs (1-
6) MUST be green. If they are not, please check your limit switch wiring or review
section 4.4.2 to defeat your unused limit switch inputs. Confirm also that the Estop input,
input 11, is green when the switch is not tripped.
Confirm that the 7 segment LED display on
the DC3IOB displays a steadily lit “1”
Check the drive fault relay Use an ohm
meter to confirm that the drive fault relay opens
when the estop switch is pressed and closes
when it is released.
Power off your system and continue to section 7.3 “Encoder Wiring”
7. Wiring Basic Sub-systems (cont)
7.3 Encoder wiring Wire the db9 connector that connects your encoders to the MPU11 as
shown below:
When you have completed wiring your encoder cables, connect them to the MPU11 as
shown below and continue to section 7.5 “Testing Encoder Wiring”
Z axis
Y axis
X axis
7. Wiring Basic Sub-systems (cont)
7.4 Testing Encoder Wiring Start the CNC11 software by double clicking on the CNC11
Mill icon on your desktop. Re-enable your encoders by restoring parameters 308-310 to
values of 1, 2 and 3 respectively. Press F10 to save, exit the software and reboot. After
the MPU11 has initialized, press F10 to continue to the main screen.
F1 -Setup → F3 Config, password = 137, Press enter → F4 PID
This will display the PID screen below and allow you to monitor the encoder counts by
watching the values in “Abs Pos” for each axis.
7.5To confirm that each encoder is wired correctly, rotate the motor shaft CCW (as seen
while looking at the face of the motor as shown below) and confirm that the position
displayed in the ABS Pos becomes more positive while rotating the shaft CCW and
becomes more negative rotating the shaft CW:
Motor face plate
Rotating the shaft CCW increases
the value in the Abs Pos field
For each axis, note the value of “Abs Pos”, rotate the motor shaft exactly 1 revolution and
note the new ABS Pos. Subtract the two and write down this value. This is the number of
encoder counts per revolution of the motor. We will use this value in section 8 when
configuring your motors.
7. Wiring Basic Sub-systems
7.5 Wiring the Estop Coil The coil voltage that controls the Estop contactor is routed
through your Estop switch and the drive fault relay. The Estop switch and drive fault
relay are wired in series so that, if either opens, motor power will be removed from the
DC3IOB during an Estop or other fault condition. The drawings below route 24VAC to
the coil of the Estop contactor but the coil on your contactor may use a different voltage.
If that is the case, simply substitute your supply voltage for the 24VAC shown in the
drawings.
Estop coil circuit with pendant
7. Wiring Basic Sub-systems (cont)
7.6 Testing Estop Coil Wiring Power up your system to test the etop contactor wiring.
Start the CNC11 software by double clicking on the CNC11 Mill icon on your desktop.
After the MPU11 has initialized, press F10 to continue to the main screen.
Press your Estop switch in and then release it Observe the estop contactor engages
when the Estop switch is released and disengages when Estop is pressed.
Power off the system and proceed to section 7.7 “Wiring Motors and Motor Power”
7.7 Wiring Motors and Motor Power. Wire the motor power from your servo power
supply and connect your motor power cables to the DC3IOB as shown below:
7. Wiring Basic Sub-systems (cont)
7.8 Testing Motor power and motor wiring.
Do NOT try to jog your motors until instructed to do so in the procedure below.
Before powering up the system, push your Estop switch in. Power up your system. Start
the CNC11 software by double clicking on the CNC11 Mill icon on your desktop. After the
MPU11 has initialized, press F10 to continue to the main screen.
Test your wiring as follows:
7.8.1 Measure the output voltage of your servo power supply With the Estop
switch pushed in, measure the DC voltage at the output of the servo power supply (if
we supplied the servo power supply, check across the terminals marked “+” and “-”
on the cap board.) If using an pre-exisiting servo power supply, usually a good place
to measure is across the terminals on the big capacitor (cylinder about the size of a
soda can). Confirm that the voltage is between 20-130VDC. Before continuing,
PLEASE double check your wiring for VM+ and VM- to make sure that they go to the
correct terminals on the DC3IOB.
7.8.3 Release Estop and measure the DC voltage at VM+ & VM- on the DC3IOB
When you release Estop, you should hear the Estop contactor pull-in. Measure the
voltage on the VM+ and VM- terminals on the H3 header on the DC3IOB and confirm
that the DC voltage is the same that was measured at the output of the servo power
supply.
7.8.4 Use MDI to Manually Set Home From the main screen, press F3 -MDI to bring
up the MDI command prompt. Now type:
M26 /x/y/z Now press the cycle start key, or simultaneously press “alt” and “s”
keys. This will display numbers in the X, Y and Z DRO's
7.8.5 Moving motors for the first time If you are using a jog pendant, make sure
that the Fast/Slow jog LED is lit (located between the X- & X+ jog keys) is you are
using the keyboard to jog, press the “alt” and “j” keys simultaneously to bring up the
keyboard jogging screen. Look in the top right of the main screen and press the “ctrl”
and “f” keys simultaneously to toggle fast/slow jog mode. Select “Slow Jog and
slowly jog all axes in both directions to confirm movement and feedback on all axes.
8. Configure motors, encoders and limit switches in software
8.1Configuring 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. 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
illustrations below describe this concept.
Correct tool motion for each axis
Difference between table motion and tool motion on X axis of knee mill
In the above illustration, the tool is moving in the X+ direction relative to the part
while the table moves to the left.
8. Configure motors, encoders and limit switches in software
Configuring motors to move in the correct direction (cont.) Jog 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:
Press F1 -Setup → F3 Config, password = 137, Press enter → 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.
8.2 Configuring encoder counts/rev Use the arrow keys to the “Encoder counts/rev” field
for each axis and enter the number of encoder counts per revolution of the the motor that
you wrote down in section 7.5
8.3 Temporarily zero out limit and home switch PLC input values In order to determine
whether the limit switches are wired correctly (section 8.7 below), you will need to zero
out the software limit switch settings to prevent a conflicts between the software and
hardware limit detection. Use the arrow keys to select the “+” & “-” Limit and Home fields
for all axes and enter 0's in all of them. Be sure to press F10-Save to save all of the
above values before exiting this screen.
8. Configure motors, encoders and limit switches in software
8.4 Configuring your motors to move the correct distance Configuring your motors to
move the correct distance involves calculating the number of motor revolutions required
to move 1”. Prior to this step, you must have correctly configured your encoder counts
per motor revolution as determined in section 7.5 and entered in section 8.2.
To determine your motors revs/inch, set up a block on the table. Use a standard or
anything that you can accurately measure, a 6” parallel works nicely as shown below:
1. Jog in slowly from 1
direction to take up lash
2. Zero indicator and axes
3. MDI Z to .5” to clear
4. MDI command X to 6”
5. Read indicator to measure
distance traveled
6. Compute and enter new
motor revs/inch
Set X0, Y0, Z0
Spindle
Block measured 6”
How to compute motor revs/inch:
Commanded distance / Distance moved = multiplier
Multiplier * Current revs/inch = corrected revs/inch
Ex: Commanded Distance = 6.0000” = .99400~ (multiplier)
Distance moved = 6.0036”
.99400 * 5.0000 = 4.97000 New motor revs/inch
To change your motor revs/inch:
Press F1 -Setup → F3 Config, password = 137, Press enter → F2 Mach → F2 Motor
After you have made your changes, start again at step #1 above to confirm the new settings.
You should be able to accurately position to within a .0001 or so after performing this
procedure 1 or 2 times.
8. Configure motors, encoders and limit switches in software
8.5 Configuring backlash compensation A note on backlash and backlash
compensation: Before configuring the backlash compensation in the control, every effort
should be made to reduce the mechanical lash in your machine to less than .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.
NOTE: Before measuring backlash, make sure any existing backlash compensation is
removed. As shown below, always use MDI and slow feedrates when measuring
backlash. If you jog or using faster feedrates, your measurements may be inconsistent
due to the inertia of the table.
1. Zero indicator and axis
2. MDI G1 X- .025 F.5
3. MDI G1 X0 F.5
4. Read indicator to measure
backlash
5. Enter backlash amount
Spindle
To enter backlash compensation values:
Press F1 -Setup → F3 Config, password = 137, Press enter → F2 Mach → F2 Motor
8.6 Configuring limit switches Use the escape key to go to the main screen. Confirm
that all axes now move in the correct directions, if any do not, perform the procedures in
section 8.1 again. When all axes are moving in the correct directions, jog all axes to the
middle of their physical travel and press the “alt” and “i” keys simultaneously to display
the real-time I/O screen. For each axis:
Trip a limit on an axis -if you tripped the + limit, it should only let you move the opposite
(minus). If it lets you move positive while the plus limit is tripped - your limit is incorrectly
wired, switch the + and - limit wires for that axis at the DC3IOB to correct.
When you have done this for all axes and confirmed that the limit switches are wired into
the correct inputs, watch the real-time I/O screen and trip each input making a note of
which LED changes when your the X+ trips, the X- etc.... write that number down (1, 2
etc..)
Go back to the motor setup screen as described above and enter the appropriate input
numbers as observed above for both the home and limit for each axis and direction. If a
direction does not have a switch wired - leave it at zero.
Power off the control
9. Wiring Auxiliary Sub-systems
9.1Lube Pump Wiring
LUBE
PUMP
ALARM COM
GND
ACN
ACH
ALARM NO
ALARM NC
AC POWER 110V
FOR LUBE PUMP
N
H
H16
FLOOD COM
FLOOD
LUBE COM
LUBE
NO
NC
SPIN RESET COM
NO
NC
SPIN DIR COM
H20
+5 VOLTS
RANGE IN9
ROT A CK IN31
COMMON
ROT HM IN30
SPIN FLT IN25
COMMON
REL SW IN25
LOW LUBE IN18
COMMON
DP4 DETECT IN15
DP4 INPUT IN14
4A
OUT 2
OUT 15
OUT 13
DC3IOB
+5VDC
Opto isolator
TYPICAL
INPUT
INPUT
INPUT COMMON
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 18. 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.
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:
1. The Mechanical Cam Actuated Lube 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 ever 10
minutes for 5 seconds of machine use.
2. Electronic Lube 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 is type is on small jobs your machine
may never get any lube, therefore possible 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.
3. Direct controlled lube 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.
9. Wiring Auxiliary Sub-systems
9.2Coolant Pump Wiring
POWER FOR FLOOD
CONTA CTOR COIL
+24V
QUENCHARC
FLOOD
CONTA CTOR
THERMAL
OVERLOA D
PROTECTOR
3 Phase
Flood Pump
220v@3AMPS
3 PHASE POWER
FOR FLOOD PUMP
L3
L2
L1
T3
T2
T1
T3
T2
T1
L2
L1
L3
FG
A1
COIL
A2
97
98 95 96
H16
FLOOD COM
FLOOD
LUBE COM
LUBE
NO
NC
SPIN RESET COM
NO
NC
SPIN DIR COM
DC3IOB
OUT 3
4A
OUT 2
OUT 15
OUT 13
Coolant Flood Pump Sub-circuit Diagram
This sub-circuit shows how to hook up a 3 phase Flood Pump. Because the
pump draws higher current at 220V a Flood Contactor PART# 3959 is needed.
Notice the Quencharc PART# 1819 on the coil of the contactor, this prevents
electrical noise when the coolant flood 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 dips in the pump.
NOTE: This 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.
9. Wiring Auxiliary Sub-systems
9.3 Spindle Wiring
9.3.1 Spindle Contactor Wiring
SPIN CW
CONTACTOR
3 Phase In
L2
T2T1 T3
L2
T2T1 T3
L3
L3
97
NO
THERMAL
OVERLOAD
PROTECTOR
L1
L1
To Spindle Motor
A1
COIL
A2
SPIN CCW
CONTACTOR
95
98
NC
NO
24COM 24VAC
L3
L2L1
T2T1 T3
96
NC
A1
COIL
A2
SPIN CCW
SPIN CW
H16
FLOOD COM
FLOOD
LUBE COM
LUBE
NO
NC
SPIN RESET COM
NO
NC
SPIN DIR COM
H17
DRV FLT RLY 1
DRV FLT RLY 2
MIST COM
MIST
NO
NC
OUT 30 COM
NO
NC
SPIN EN COM
OUT 3
4A
OUT 2
OUT 15
OUT 13
DRIVE
FA ULT
2A
OUT 4
OUT 15
2A
H20
+5 VOLTS
RANGE IN9
ROT A CK IN31
COMMON
ROT HM IN30
SPIN FLT IN25
COMMON
REL SW IN25
LOW LUBE IN18
COMMON
DP4 DETECT IN15
DP4 INPUT IN14
DC3IOB
9. Wiring Auxiliary Sub-systems
9.3.2 Spindle Inverter Wiring -AutomationDirect GS2
ACM
AO
+10V
AI
DCM
DI6
DI5
DI4
GS2
DI3
DI2
DI1
R1O
R1C
R1
R2O
R2C
R2
See the inverter manual for connection of
incoming and motor power wires.
H16
FLOOD COM
FLOOD
LUBE COM
LUBE
NO
NC
SPIN RESET COM
NO
NC
SPIN DIR COM
H17
DRV FLT RLY 1
DRV FLT RLY 2
MIST COM
MIST
NO
NC
OUT 30 COM
NO
NC
SPIN EN COM
H20
+5 VOLTS
RANGE IN9
ROT A CK IN31
COMMON
ROT HM IN30
SPIN FLT IN25
COMMON
REL SW IN25
LOW LUBE IN18
COMMON
DP4 DETECT IN15
DP4 INPUT IN14
H2
OUT 3
4A
OUT 2
OUT 15
SPIN AN (+)
SPIN COM (-)
OUT 13
DRIVE
FA ULT
2A
OUT 4
OUT 15
2A
DC3IOB
+5VDC
TYPICAL
INPUT
INPUT
INPUT
COMMON
PA RAMETER
NO
0.00
0.01
0.03
0.04
1.00
1.01
1.02
3.00
3.03
4.00
8.00
9.08
VALUE
Depends on motor
Depends on motor
Depends on motor
Must be set w ith a tachometer
to match max spindle speed
01 = Coast to a stop
3 – 5 seconds
3 – 5 seconds
01 = External control terminals
02 = External reset
02 = Frequency determined
By 0 – 10vdc on A I1
1 = Motor s peed (RPM)
To restore factory default settings set to 99
UNITS
Volts
Amps
RPM
RPM
Sec
sec
DESCRIPTION
Motor nameplate voltage
Motor nameplate amps
Motor nameplate RPM
Motor maximum RPM
Stopping method
Ac celeration time
Deceleration time
Control method
DI4 Multi function input
Source of frequency
command
Drive display
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