AxeMotion PULSEMAKER User Manual

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--2--

SSAAFFEETTYY IINNSSTTRRUUCCTTIIOONNS

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Please keep this user's guide! It contains important instructions you should
refer to when installing, maintaining and using your AxeMotion module and the
machine it drives. It has been written for people who use, configure, install,
handle or maintain this hardware.

Electric hazard:

To avoid risks of fire and injuries due to electric shocks, pay attention to the
safety guidelines when using this product.

- Carefully read and study the instructions of this user's guide.

- Always use a grounded outlet for the electric connection of the machine. If
you do not know if your socket outlet provides a ground plug, then get infor­mation from a qualified electrician.

- Unplug all electrical connections before cleaning the hardware.

- Do not install the AxeMotion module or the machine it drives near water or in
an moist environment. Do not handle or use the machine if you are wet.

- Always install your hardware on a stable flat bed, in a clean and protected
place where nobody can step or stumble on electric connection cables.

Safety instructions for use:

Warning: to avoid any risk of injury due to eventual projections
when using an automated machine tool, including in manual
mode, you must imperatively wear safety eyeglasses.

Furthermore, depending on the type and the
use of your machine, it must be integrated in an approved
safety cabinet or protected area.

--3--

W

WAARRRRAANNTTYY // LLIIAABBIILLIITTYY

The AxeMotion CNC modules are guaranteed against defects in materials and
workmanship for one full year from the date of purchase.

This warranty cannot apply if electrical connections and prescriptions of use
that are described in this guide have been strictly observed. An installation that
does not comply with these prescriptions invalidates the warranty for cons e­quent damages.

AxeMotion CNC modules are provided without any warranty, even implicit,
concerning the results that can be obtained by their use, or the fact that any
user will be able to run them succes sfully, or regarding overall satisfaction with
the end products which can be obtained using the modules. The purchaser
explicitly recognises that he/she is solely responsible for choosing this module,
for running and using it and its related sof tware, and for obtaining the actual
results.

Connecting an AxeMotion CNC module requires skills in electrical wiring and
connecting, in motors and power stages, and in computerised motion control.
After integrating a CNC module, it is strongly recommended that the purchaser
begins to get familiar with the machine control by making the first tests on
valueless workpieces.

Strict safety rules exist for building or using an automated machine tool. These
rules must be observed very accurately, and especially for the electrical wiring,
the containment of mobile parts in a protection cabinet, the risks of injury
caused by impacts of chips or fragments of broken tools.

No liability can be accepted concerning the AxeMotion modules, their manufac­turer or distributor, for direct or indirect damages caused by a misuse or non
complying use, on persons who handle the module or the machine it drives, on
objects or materials subject to machine work, or on computer data subject to
the software processes.

Obviously none of the above terms and conditions may affect your statutory
rights under current law or legislation.

--4--

CCHHAARRAACCTTEERRIISSTTIICCS

S

Miscellaneous:

Almost all power stages for stepper motors, and many servodrives are co n­trolled by couples of 5V signals Clock (or Pulse, i.e. rota tion of an increment)
and Direction (rotation sense). AxeMotion CNC modules are able to produce
these signals in an intelligent way by receiving and processing high-level
commands that are sent by the supervision software.

The AxeMotion PulseMaker is a complete and high performance computerised
numerical controller that includes advanced functions. Its internal memory
buffer and the availability of different linear interpolation modes render it capa­ble of producing motion with a rare fluidity, especially i n non-circular curves.
Especially developed to be integrated in a motor control rack, it requires some
wiring to connect the miscellaneous input signals (USB connection, axis end
switches, tool measurement, digitising probe, safety system) and output signals
(power stage, spindle control, coolant and other peripheral devices).

Important: the AxeMotion PulseMaker is not opto-isolated, and signals must
be TTL 0-5V strictly. A maximum of 20 mA is allowed on each input and 10 mA
on each output, with a total of 50 mA on all outputs.

Technical data:

- Connection and power supply from USB port (consumption < 90 mA)

- Control for 4 axes, interpolated simultaneously

- Maximum output frequency 35 KHz in interpolation

- Local memory buffer 3.3 Kb (250 commands ahead)

- Interpolations for constant speed, for variable speed, for double ramps

- Management of fast braking along multiple vectors

- Override function for real-time control of speed

- 12 inputs, 6 outputs plus the 8 Clock / Dir signals

- Replaceable TTL buffers on output signals (mounted on sockets)

- 10 bits analog input (input #8 with binary or analog read)

- 10 A / 250 V integrated relay (output #5) with "on" connector

- PWM output for spindle or hot wire control

- Optional 0-10 v / 10 mA analog output, no external power supply required

--5--

IINNTTEEGGRRAATTIIOON

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The XY dimensions of the AxeMotion PulseMaker card are 100 x 80 mm and a
thickness of about 25 mm (from solders to power relay).

Unit : mm

It is obvious that the card should not be mounted directly on a met al support
that would shortcut the solders. Use an isolation sheet or, even better, screw
the card at a small distance from the board so the solders do not touch the
surface. Electrical wires and tapes must be soft enough to avoid bending that
can create bad contacts. Also, a USB communication may be working badly if
the cable is too close to a source of electrical noise (motors, power supplies,
neon lights, etc.). Do not place the card itself in the neighbourhood of a possi­ble source of electrical noise an d, whenever possible, integrate it in an iron box
or rack.

--6--

W

WIIRRIINNGG

Important: before operating any modification in the card wiring, always discon­nect it from its power-supply (unplug the USB cable and cut the mains of the
power stage and all peripherals).

A poor quality wiring is the cause of recurrent errors. Please take great care of
the integration and the electrical wiring of your AxeMotion card.

The inputs of the PulseMaker card are default "pulled -up" to the +5 V. Conse­quenly, an input is trigge red when connected to the ground (GND) of the card.
Whatever its polarity can be, normally open or normally
closed, a sensor must link the chosen input and the
ground, any other wiring being wrong and not working.
Inputs are dispatched on two connectors, the first one giving access to inputs 1­8 and the second one to inputs 9-12, each connector providing a GND pin.
Please note that the input #8 can be read as 0 -5 V binary input (instable state
between 0.8 V and 2.4 V) or as 10 bit analog input. If you have a 0-5 V analog
probe, its + pole should be connected to this inputs #8.

The outputs provide a low state (0 V) by default, and a high state (+5 V) when
activated. These outputs are dispatched on two connectors, the first one giving
access to motor signals Clock / Dir , and the second to outputs that can drive
peripheral devices, each connector providing a ground (GND) pin. Please note
that the outputs #6 can be used as binary or PWM output (which controls the 0­10 V), and the output #5 is available on its connector but also triggers the
power relay with its separate connector.

The USB connection can be taken either from the classic USB-B connector, or
on its neighbour pins. Please be careful with the signals.

Reminder: inputs and outputs are not opto-isolated and accept 0-5 V TTL
levels only. Furthermore, the outputs can provide a maximum current of 10 mA
each, and a maximum of 50 mA for the whole set. Consequently, a bad con-

nection or a too heavy load may damage the card, or even the host com­puter. So it is extremely important to make sure that the peripheral devices that

the card will drive are correctly isolated and do not need too much current.
AxeMotion provides the PulseMaker cards either with screw connectors (sta n-

dard), or HE10 connectors (optional) for wire tapes.

--7--

VVEERRSSIIOONN WWIITTHH SSCCRREEWW CCOONNNNEECCTTOORRSS

--8--

Important: connections differ for the
AxeMotion PulseMaker version that is
fitted with HE10 male connectors with
double rows of pins and locator which
require female connectors to be
clipsed on wire tapes.

Warning, the list of numbered
signals on a wire tape will not be
the same wether you have a HE10
or a screw connector.

Inverting motor signals or outputs will
not cause any damages to the card or
the power stage, provided that this
inversion does not concern the ground
(GND pins). Simply, the connected
motors or peripheral devices will not
work. On the other hand, inverting

the GND and a signal destroys the
74LS541 output circuit. Fortunately,

this chip is mounted on a socket so
you may replace it easily in case the
wiring was wrong. Inverting the GND

with the +5 Vcc on a peripheral may
damage the host computer.

Much less serious, inverting input
signals, including with the GND pin,
will not cause any damages except a
simple malfunction of the manage­ment of the sensors or any peripheral
devices that are presumed to return
information to the card and its
supervising software.

If you do not wish to plug the communication cable directly in the standard
USB-B connector because the card has been integrated in a cabinet, then you
may use instead the neighbour 4-pin connector that
reproduce the USB signals. In such case, it is very
important to carefully check the wiring of these
signals: a wrong connection on the USB signals

may seriously damage the card and the host
computer. To help you find the correct signals, the

wire colours in USB cables are standard. Unfortunately, the connection plug on
the board with only four pins cannot provide a locator. So, be very careful not to
invert the connection.

--9--

VVEERRSSIIOONN WWIITTHH HHEE1100 CCOONNNNEECCTTOORRSS FFOORR WWIIRREE TTAAPPEESS

--10--

VVEERRSSIIOONN WWIITTHH SSCCRREEWW CCOONNNNEECCTTOORRSS

CN1 : USB

1 - Vcc (+5 V)
2 - Data –
3 - Data +
4 - GND

CN2 : Reserved
CN3 : USB-B
CN4 : Inputs

1 - input # 9
2 - input # 10
3 - input # 11
4 - input # 12

CN5 : 0–10V output

1 - 0–10 V
2 - GND

CN6 : Outputs

1 - Vcc
2 - output # 6
3 - output # 5
4 - output # 4
5 - output # 3
6 - output # 2
7 - output # 1
8 - GND

CN7 : Motors

1 - GND
2 - Y dir
3 - Y clock
4 - X dir
5 - X clock
6 - Z dir
7 - Z clock
8 - A dir
9 - A clock
10 - Vcc (+5 V)

CN 8 : Inputs

1 - input # 1
2 - input # 2
3 - input # 3
4 - input # 4
5 - input # 5
6 - input # 6
7 - input # 7
8 - input # 8
9 - GND

CN9 : Reserved
CN10 : Relay

--11--

VVEERRSSIIOONN WWIITTHH HHEE1100 CCOONNNNEECCTTOORRSS FFOORR WWIIRREE TTAAPPEESS

CN1 : USB

1 - Vcc (+5 V)
2 - Data –
3 - Data +
4 - GND

CN2 : Reserved
CN3 : USB-B
CN4 : Inputs

1/3/5/7/10 - GND
2 - input # 9
4 - input # 10
6 - input # 11
8 - input # 12
9 - N.C.

CN5 : 0–10V output

1 - 0–10V
2 – GND

CN6 : Outputs

1 - output # 2
2 - output # 3
3 - output # 1
4 - output # 4
5 - N.C.
6 - output # 5
7 - N.C.
8 - output # 6
9 - Vcc (+5 V)
10 - GND

CN7 : Motors

1 - Z dir
2 - X clock
3 - Z clock
4 - X dir
5 - A dir
6 - Y clock
7 - A clock
8 - Y dir
9 - Vcc (+5 V)
10 - GND

CN 8 : Inputs

1/3/5/…/15 - GND
2 - input # 8
4 - input # 7
6 - input # 6
8 - input # 5
10 - input # 4
12 - input # 3
14 - input # 2
16 - input # 1

CN9 : Reserved
CN10 : Relay

--12--

IINNSSTTAALLLLIINNGG TTHHEE DDRRIIVVEER

R

When the AxeMotion PulseMaker module is plugged for the first time on the
USB port of a PC under Windows, the system needs to install a driver to allow
dialoguing with this new peripheral. A message "New Hardware detected" is

followed by a "Wel-

come to the Found
New Hardware Wi­zard", allowing you to

tell Windows how this
driver should be ins­talled.

To the first prompt

"Can Windows con­nect to Windows
Update to search for
software?", answer
"No, not this time"

and then click on
button "Next >" at the
bottom of the dialog
box.

The next dialog box
remains you that you
are about to install
the software driver
for the "USB AxeMo-
tion PulseMaker".

If you have got a CD
provided with the
card, please insert it
in the drive: Win­dows will then seek
for the driver on that
CD. Otherwise click
on "Install from a

list or specific
location" then down
on button "Next >".

--13--

If you have down­loaded the driver
from the AxeMotion
website and have
saved it somewhere
on your hard disk,
then click on option

"Include this loca­tion in the search"

and use the button
"Browse" to find the
directory on the disk
where the uncomp­resssed driver has
been stored. Once
you have found it,
click down on button
"Next >".

Once Windows has found the
location of the driver to be
installed, from the CD-ROM or
from your hard disk, depending
on your Windows version you
might get a warning message
which indicates that the driver
found does not have any
Windows certificate and therefore
recommends to stop installing.

Do not worry about this warning
and skip to button "Continue
Anyway" at bottom.

Normal installation of the driver is then in
progress, copying system files to Windows
directory. This usually takes a few seconds but

may be longer depending on the computer and Windows version.
Once the installation is completed, a last message "The wizard has finished

installing the software" ends the process. Click on button "Finish" at bottom.
The AxeMotion PulseMaker driver is now installed on your computer.

--14--

UUNNIINNSSTTAALLLLIINNGG TTHHEE DDRRIIVVEER

R

In case you encounter system
configuration problems or expe ­rience communication failure
with the AxeMotion module, you
might want to uninstall your
PulseMaker driver from your
computer. In Windows "Start"
menu, click on "Parameters"
then on "Control Panel" (also
available from the Windows File
Explorer).

Double-click on the "System"
icon or line. In the multiple page
dialog box this pops up, open
the "Hardware" section tab and
then click on button "Device
Manager".

The list of devices that are already installed on your computer is displayed in a

new window. Double-click on line

"Universal Serial Bus control­lers" to see the USB peripherals

that are connected. The module
"USB AxeMotion PulseMaker"
should appear in that sublist, if it is
still alive seen from the computer.
Click on its line using the right
mouse button and, in the context
menu that pops up, click on option
"Uninstall" and confirm that you
want to remove the device. Your
AxeMotion driver is then suppres­sed from your computer. If you
wish to re-install it, just plug the
module again and return to the
normal installation procedure.

--15--

PPAARRAAM

MEETTEERRSS IINN GGAALLAAAADD

Galaad integrated software for CAD -CAM-CNC is compatible with the AxeM o­tion PulseMaker module that it can drive in optimal conditions.

In Galaad or one of its
related modules, call the
menu command "Para-

meters / Machine / Full
data". The page "Table"

allows you to select the
AxeMotion modules and
also the number of axes
of the machine, the
screw pitches and the
number of pulses per
motor revolution (micro­stepping). Please enter
here the values that
correspond to your
machine.

Click then at top on the
tab that correspond to
the page "Controller"
and indicate here that
the communication runs
on a USB port.

Important: it is necessary
to tell Galaad where the
machine zero position
is located (generally left­hand side and either the
front or the back of the
table). This is going to
define the orientation of
the machine.

--16--

Now you must setup the internal data of the PulseMaker card. Still in this

"Controller" page of Galaad machine parameters, click on the small button
"More…" at top-right aside the controller type. This pops up a sub-window that

provides access to all special parameters for your card.

The status of outputs
at boot allows you to
enable some output as
soon as the card is
powered on, before it is
communicating with
Galaad, for example to
trigger a safety device
or the power stage.

The parameters for
Start/Stop frequency
and the acceleration
depend on the mecha­nical characteristics of
your machine (inertia,
motor power, axis
reductions). So it is not
possible to indicate
standard values here. You must try different settings. Let us say at least that
the Start/Stop frequency is the initial starting speed of the motor (instant pas s­ing from still to motion and reciprocally). If your motor "knocks" when starting to
move, then you should reduce the value. On the other hand, if the acceleration
starts from too low, you must increase it. The acceleration indicates the speed
slope, from the Start/Stop frequency. If your motor is unable to drag up the
speed, then reduce the value. If the acceleration is too soft, increase it.

The enable signal from power stage says on which input the information is
received for knowing if the power stage is ready. If not, Galaad will warn the
user to power-on the stage. The current per phase is for power stages with
digital potentiometers (AxeMotion option) so you can set the current directly
from Galaad. If you do not have such connection, this parameter is useless.
The error or stop signal defines a critical input that will stop the motion and
abort the automatic process when triggered. That can be for example the Drag
Error bit of a servodrive.

--17--

Important: for the inputs, an "Enabled" polarity corresponds to a normally
open (N.O.) circuit or switch; while a "Disabled" polarity corresponds to a
normally closed (N.C.) circuit.

Galaad receives from AxeMotion the eventual corrections or updates of the
firmware (the card internal program) for their CNC modules. Consequently, a
Galaad update may induce an automatic firmware update if the option is
ticked. You may also force the reload of the firmware if necessary.

The data transfer corresponds to the USB flow speed to the card. It should be
set to "Very fast". That speed should not be change unless you experience
communication breakdowns due to electrical problems (noise generated by big
motors, neon lights, etc.). Also the buffer overflow error trigger should be set
to medium or low sensitivity. This error raises up when the automatic milling
goes faster than the transmission and therefore the buffer gets drained.

The zero-end switches correspond to the reset of the absolute co -ordinates,
i.e. the machine zero, using a reference run. This reset is managed by Galaad
which must know the inputs that are connected to the end switches and their
polarity (normally closed or normally open).

Important: if you do not know the inputs that correspond to the end-switches,
the command "Parameters / Machine / I-O Test" may help you find which
switch or sensor is connected to which input with which polarity. A normally
dark input that lights up when the switch is triggered corresponds to an "En-
abled (NO)" input. Reciprocally, if the input is normally light and darkens when
the switch is triggered, then the polarity is "Disabled (NC)".

--18--

TTRROOUUBBLLEESSHHOOOOTTIINNG

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- The computer does not detect the card
Please check the USB connection and the correct installation of the driver that
corresponds to the card (see previous pages). The system must react when the
card is plugged or unplugged, and must display "AxeMotion PulseMaker" in the
list of available USB peripherals. If it is not the case, it is better to uninstall the
driver and reinstall it.

- The motors vibrate when the card is plugged

The card ground is probably not connected to the power stages, so their inputs
receive an erratic signal.

- A motor does not turn, or no motors are turning
Please ensure first that the motor gets blocked when the power stage is acti­vated. If not, the motor does not receive current and the problem comes from
the power stage. Then check accurately that the Clock input (or Pulse, or Step)
of your power stage is connected to the corresponding Clock output of the
PulseMaker card, and that the ground is also well connected. If other motors
turn, try to swap its Clock and Dir signals with another motor that works, to see
if the problem comes from the card or from the power stage. If no motors turn,
first check that the GND pin is indeed conn ected to the – pin of each input of
the power stage. It may also occur that the power stage requires an enable
signal for activating the motor current. Then you must connect this "Enable"
signal to a card output and set the corresponding parameter in the s oftware.
You may also unplug the Clock wire from the card and make a manual contact
with a Vcc (+5 V) pin. If the motor reacts at each pulse, then the Clock signal
does not work anymore. Try to swap the two 74LS541 output circuits. If the
motor now turns, then we can consider that the integrated circuit was damaged
and must be replaced.

- A motor turns in the wrong direction
Please invert the axis direction in the software parameters (or invert the direc­tion on the power stage whenever possible). With bipol ar stepper motors, just
swap a pair of a motor coil – and one only – to flip the direction. Be careful not
to swap a wire with one of another coil, this mistake is usually destructive for
the power stage.

--19--

- A motor always turns in the wrong direction
The Dir signal is not carried to the power stage. Please check that this signal is
not swapped with one of another axis, and that the ground is well connected to
the Dir input (or Direction, or Sense) of the corresponding power stage.

- An axis makes its reference run toward the wrong direction
If the motion is fast, then the axis is completely inverted an dits direction must
be changed from Galaad parameters or from the power stage or from the
motor. On the other hand, if the motion is slow, then probably the zero-end
switch input is wrongly set, i.e. the corresponding input is not the right one or its
polarity is reversed. Then the software tries to release the axis from the switch
though it is not triggered. It is important to find the right numbers and polarities
for the inputs that correspond to the end switches. If you are using Galaad
software, then check the function "Parameters / Machine / I-O test" as previ­ously described.

- The axis does not stop during the reference run
The input that actually corre sponds to the zero-end switch is not the one that
has been parametered, or the switch is not working, or is not triggered by the
axis, or the connection wire is cut or unplugged.

- The spindle does not start
The power relay corresponds to the output # 5. Please check that this is the
actual output in the software. If the spindle is under control of the PWM output
or the 0-10 V analog output (associated to the PWM), then check that this has
been accurately set and calibrated in the software.

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AxeMotion / 106 rue de la placette / 06620 Cipieres / France

RCS Grasse 411 582 471 / SIRET 411 582 471 00024

Copyright © 2007 AxeMotion / All rights reserved