Flashcut CNC Pro Series Hardware Manual
8 Amp Micro Stepping
Pro Series CNC Controller
Hardware Guide
Midwest Office
444 Lake Cook Road, Suite 22
Deerfield, IL 60015
Phone (847) 940-9305 Fax (847) 940-9315
www.flashcutcnc.com
Revised 11/02/2010
© 1998-2010 WPI, Inc.
Table of Contents
1. GETTING STARTED ....................................................................................................................................... 6
ABOUT THIS MANUAL ................................................................................................................................................ 6
TURNING OFF THE CONTROLLER ............................................................................................................................... 6
SAFETY AND USAGE GUIDELINES ............................................................................................................................... 7
2. STEPPER CNC CONTROLLER ..................................................................................................................... 8
FRONT PANEL............................................................................................................................................................. 8
REAR PANEL .............................................................................................................................................................. 9
3. SYSTEM CONNECTIONS ............................................................................................................................ 13
4. REMOVING THE TOP COVER ................................................................................................................... 14
5. SIGNAL GENERATOR ................................................................................................................................. 15
INPUT ................................................................................................................................................................ ....... 15
OUTPUT .................................................................................................................................................................... 16
JUMPER SETTINGS .................................................................................................................................................... 17
JP83 – DB to USB Ground ................................................................................................................................ 18
JP84/JP85 – Input Power Select ........................................................................................................................ 18
JP 86 – USB to Chassis Ground ........................................................................................................................ 19
JP 87 – Internal Signal to Chassis Ground ...................................................................................... 20
INTERNAL CONNECTIONS ......................................................................................................................................... 20
JP30 – Auxiliary Inputs ..................................................................................................................................... 21
JP31 – Status LEDs ........................................................................................................................................... 21
JP32 – Bus Expansion ....................................................................................................................................... 22
JP33 – Step & Direction .................................................................................................................................... 22
JP40 – Input Aux Header ................................................................................................................................... 23
JP50 – Output Aux Header ................................................................................................................................ 23
JP80 – Rear Panel Power .................................................................................................................................. 24
JP81 – Rear Panel Fuse .................................................................................................................................... 24
JP82 – Front Panel Switch .......................................................................................................... 24
AXIS PLUG-IN INTERFACES ...................................................................................................................................... 24
6. DRIVE SETTINGS .......................................................................................................................................... 26
CONFIGURING THE DRIVES ....................................................................................................................................... 27
Selecting a Motor............................................................................................................................................... 27
Setting the Current ............................................................................................................................................. 29
Setting Idle Current ............................................................................................................................................ 29
Load
Inertia ........................................................................................................................................................ 30
Step Size ................................................................................................................................... 30
STEP PULSE NOISE FILTERING .................................................................................................................................. 32
SELF TEST ................................................................................................................................................................ 33
ALARM CODES ......................................................................................................................................................... 33
7. MOTOR SIGNAL SETTINGS ....................................................................................................................... 34
8. STEPPER MOTOR CABLING ..................................................................................................................... 35
MOTOR WIRING FOR OTHER STEPPER MOTORS ....................................................................................................... 35
9. POWER BOARD ............................................................................................................................................. 37
10. DRIVER MODULE UPGRADES .................................................................................................................. 39
11. APPENDIX ....................................................................................................................................................... 45
SAMPLE WIRING DIAGRAMS .................................................................................................................................... 45
Typical Output Line Circuit ............................................................................................................................... 45
Typical Input Line Circuit – Internal Power ...................................................................................................... 46
Typical Input Line Circuit – External Power ................................................................ ................................ ..... 47
Signal Generator Board Layout ......................................................................................................................... 49
Connector Pin-Out Table ............................................................................................................ 50
POWER ..................................................................................................................................................................... 52
OUTPUTS .................................................................................................................................................................. 53
INPUTS ..................................................................................................................................................................... 54
CONNECTORS ........................................................................................................................................................... 55
AXIS PLUG-IN INTERFACE ........................................................................................................................................ 56
12. INTERNAL CONNECTIONS ........................................................................................................................ 57
CONNECTION SCHEMATIC ........................................................................................................................................ 58
REVISION HISTORY .................................................................................................................................................... 1
6
1. Getting Started
Always turn off the CNC Controller when it is not in use.
About This Manual
FlashCut CNC is a unique application involving hardware and software. We
recommend that you read all of these instructions before using the product.
Since automated machining is potentially dangerous, please take
the time to completely read through this manual and the software
User’s Guide to understand the operation of the electronics,
software and machine before cutting a part.
FlashCut CNC Section 1 Getting Started
Turning Off The Controller
FlashCut CNC Section 1 Getting Started
7
When running an automated machine tool, safety is of the utmost
importance. For proper and safe use of the FlashCut CNC program and
your CNC machine, the following safety guidelines must be followed:
1. Never let the machine tool run unattended.
2. Require any person in the same room as a running machine tool to
wear safety goggles, and to stay a safe distance from the machine.
3. Allow only trained operators to run the machine tool. Any operator
must have:
Knowledge of machine tool operation.
Knowledge of personal computer operation.
Knowledge of Microsoft Windows.
Good common sense.
4. Place safety guards around the machine to prevent injury from flying
objects. It is highly recommended that you build a safety shield
around the entire tool envelope.
5. Never place any part of your body within the tool envelope while the
machine is online, since unexpected machine movement can occur at
any time.
6. Always keep the tool envelope tidy and free of any loose objects.
7. Be on alert for computer crashes at all times.
FlashCut CNC, Inc. is not responsible for the safe installation and use of
this product. You and only you are responsible for the safety of yourself
and others during the operation of your CNC machine tool. FlashCut CNC
supplies this product but has no control over how it is installed or used.
Always be careful!
FlashCut CNC, Inc. or its affiliates are not responsible for damage to any
equipment or workpiece resulting from use of this product.
If you do not understand and agree with all of the above safety guidelines,
do not use this product.
Safety and Usage Guidelines
FlashCut CNC Section 2 Stepper CNC Controller
8
2. Stepper CNC Controller
Front Panel
The front panel of the CNC controller has the power switch, the fan and 7 LED’s with the
following functions:
AXIS LED’s 1, 2, 3, 4, 5 – Turns green when the respective axis is moving.
USB LED– Turns yellow when connected to the host PC USB port.
POWER LED– Turns green when the power switch is turned on.
POWER SWITCH – Turns the unit on and off. “I” is on and “O” is off. If there is ever a
communications error while running FlashCut CNC, turn the switch off and on to reset
the internal microprocessor.
9
Rear Panel
The rear panel has connectors for input and output signals as described below.
FlashCut CNC Section 2 Stepper CNC Controller
POWER INLET – Receptacle for the power supply. The unit is shipped with a standard
grounded power cable for use with a 115VAC wall outlet.
USB – USB connector for communication with the USB port on the host PC. Use a USB-A
to B cable with a maximum length of 3 meters to make the connection. For the most robust
communication, plug the cable directly into PC, as opposed to a USB repeater or a hub. If
the FlashCut software loses communication with the Signal Generator, electrical noise may
be the cause. To reduce electrical noise problems, try using a shorter USB cable, or attach
one or more ferrite chokes to the USB cable. Toroid-shaped chokes are more effective than
snap-on cylindrical chokes. If you need more than 3m of USB cable length, you can use an
active extension cable which comes in 4.5m lengths. Note that when running an active
extension cable, the USB will run in Full Speed mode.
INPUT – The connector for up to 8 input lines. The most common use of the input lines
is for limit or safety switches. These lines are all TTL- and CMOS-compatible optically
isolated inputs. When a switch is open, its input signal is high (+5V). When the switch is
closed, its input signal is grounded low (0V). If you need more than 8 input lines, an I/O
extension board is available.
OUTPUT – The connector for up to 8 output lines. These lines are all compatible with
TTL/CMOS level outputs. The Output ports are not setup to drive a 24V external system
unless it accepts TTL/CMOS levels. They are all driven by HCT family logic. Output
logic high is normally 5V and can go down to 3.9V at full load. Output logic low is
normally 0V and can go up to 0.3V at full load. Each of these signals can provide up to
20mA of current. If you need more than 8 output lines, an I/O extension board is
available.
FlashCut CNC Section 2 Stepper CNC Controller
10
FUSE – In this drawer is a 250V/ 10Amp slow blow fuse. If you have chronic fuse
problems, please call FlashCut CNC or your distributor for assistance.
RELAY OUTPUT – This connector is a back compatible relay output. Connection
should be made in pins 7 and 8 of the 10 pin Phoenix terminal block. Output provides an
optically isolated switch closure for controlling both AC and DC devices. Max current
loading is 0.5 Amps for this non-polarity sensitive connection.
115-230 VAC SELECTION SWITCH– This switch allows you to use an external power
source of 115 or 230 VAC. If your building is wired for 230VAC, then simply flip the
switch with a flat-head screwdriver so that “230V” is clearly visible. If your building is
wired for 115 VAC, then flip the switch until “115V” is clearly visible. Note that severe
damage can occur if you have 115 selected and your building is wired for 230VAC.
DB-25 CONNECTOR FOR MOTOR SIGNALS – This uses a DB-25 Cable to send step
and direction signals from the FlashCut CNC Signal Generator to an additional external
drive box. The pin assignments are as follows:
FlashCut CNC Section 2 Stepper CNC Controller
11
1
13
14
25
DB25
Pin No.
Signal
DB25
Pin No.
Signal
1
OUTPUT 1
14
ENABLE ALL
2
OUTPUT 2
15
INPUT 1
3
STEP AXIS 5
16
INPUT 2
4
DIRECTION AXIS 5
17
INPUT 3
5
INPUT 5
18
INPUT 4
6
INPUT 6
19
DIRECTION AXIS 4
7
INPUT 7
20
DIRECTION AXIS 3
8
INPUT 8
21
DIRECTION AXIS 2
9
DIRECTION AXIS 1
22
Internal VCC +5V
10
STEP AXIS 4
23
OPT VCC (INPUT)
11
STEP AXIS 3
24
Internal GND
12
STEP AXIS 2
25
OPT GND (INPUT)
13
STEP AXIS 1
Molex Pin
Wire
1 B 2
Cable Ground Shield
3 A 4
B~ 5 No Connection
6
A~
POWER CONNECTOR TO MOTORS – The motors for axes 1-5 plug into these
connectors. The motor lines 1-5 are correlated to any combination of the X, Y, Z, A
and/or B axes in the Motor Signal Setup menu in the FlashCut CNC software. A dummy
plug as installed on any unused motor connector for units with less than 5 axes. Each
motor connector is a Molex Mini Fit Jr. 6 Pin Receptacle with Male Pins (See Section on
Motor Cabling for Mating Connector Information). The pin assignments for the Motor
Connector are as follows (looking from the rear of the unit):
FlashCut CNC Section 2 Stepper CNC Controller
12
Never connect or disconnect motor cables while the power
is on. This will result in damage to the driver box.
The mating motor cable connector is a Molex - Waldom 6-Pin Mini-Fit Jr. Receptacle Housing
Part # 39-01-2060 with Female Pins Part # 39-00-0039 or 39-00-0047. Please see the section on
Stepper Motor Cabling later in this manual for more information.
FlashCut CNC Section 3 System Connections
13
3. System Connections
FlashCut CNC Section 4 Removing the Top Cover
14
4. Removing the Top Cover
To remove the cover from the unit remove the 8 total screws located on the left and right
sides of the unit. There are 4 screws on either side. Then lift the top cover off.
FlashCut CNC Section 5 Signal Generator
15
5. Signal Generator
Input
The default setting for each of the input lines is normally closed (NC). The input line
settings can be individually changed between normally closed (NC) or normally open
(NO) input lines using FlashCut CNC software. Please refer to the FlashCut CNC
User’s Guide under “Input Line Settings” for further information.
In the FlashCut CNC software, the Input Line Status dialog displays "OPEN" for a
high-level input voltage, or open switch, and "CLOSED" for a low-level input voltage
or closed switch.
The input lines are all optically isolated. Jumpers J84 and J85 enable you to choose
between the internal power of the Signal Generator and isolated power from an
external source. Both jumpers must be set on the same pair of pins (either both must
be on pins 1 and 2 or both must be on pins 2 and 3).
Internal Power- This is the most convenient option and works well for most
applications, but negates some of the signal isolation. When JP84 shorts pins 1
and 2, OPT VCC gets its power from the Internal 5V power source. When JP85
shorts pins 1 and 2, OPT GND is directly connected to the Internal GND.
External Isolated Power
For the best noise immunity, connect an external 5V-24V power supply to the
LED side of the optical couplers. When JP84 shorts pins 2 and 3, OPT VCC gets
its optically isolated power from the TB-VCC. When JP85 shorts pins 2 and 3,
OPT GND is directly connected to the TB-GND.
Choose only one of the following methods to supply power:
1. Connect a power source to the TB 40 screw terminal.
2. Connect a power source through pins 23 and 25 of the DB-25 connector.
If you are providing an external voltage through pins 23 and 25 of the DB25
Motor Signal connector or via TB-40, then you must have both JP84 and
JP85 jump pins 2 and 3, OTHERWISE SEVERE DAMAGE COULD
RESULT.
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER
WIRING WILL DAMAGE THE SIGNAL GENERATOR.
Input lines 1, 2, 3 & 4 are also connected through pins 15, 16, 17 & 18 respectively of
the Motor Signal connector, and input lines 5, 6, 7 & 8 are also connected through
pins 5, 6, 7 & 8 respectively of the Motor Signal connector. This makes it convenient
to send any signals from an external motor driver box, such as limit lines or servo
position error signal, back to the Signal Generator through the DB25 cable without
FlashCut CNC Section 5 Signal Generator
16
Mini-Fit Jr.
Pin No.
Signal
Mini-Fit Jr.
Pin No.
Signal
1
OPT-GND
9 INPUT 1
2
OPT-GND
10
INPUT 2
3
OPT-GND
11
INPUT 3
4
OPT-GND
12
INPUT 4
5
OPT-GND
13
INPUT 5
6
OPT-GND
14
INPUT 6
7
OPT-GND
15
INPUT 7
8
OPT-GND
16
INPUT 8
16 15 14 13 12 11 10 9
◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦
◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦
8 7 6 5 4 3 2 1
using a separate input cable. Note that if an input line is being used through the
Motor Signal connector, that line must remain open in the Input connector.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr. Series
16 pin receptacle (part number 39-01-2160), with female pins (part number 39-000039 or 39-00-0047 for 22 gauge or thinner wires).
The Molex 63811-1000 for 14-24 AWG universal or Molex 11-01-0197 Crimp Tools
are recommended for installing the pins. Kits containing connectors and pins are
available through FlashCut CNC or an electronics distributor.
The input lines as seen from the back of the box are arranged as follows (all
connections denoted by “OPT-GND” are optically isolated ground.):
Output
This connector is for up to 8 output lines. These lines are all compatible with
TTL/CMOS level outputs. The Output ports are not setup to drive a 24V external
system unless it accepts TTL/CMOS levels. They are all driven by HCT family
logic. Output logic high is normally 5V and can go down to 3.9V at full load.
Output logic low is normally 0V and can go up to 0.3V at full load. Each of these
signals can provide up to 20mA of current.
Two additional pins on this connector are provided for your output lines: ground and
+5V. These are connected to GND and +5V and are not optically isolated. This 5V
circuit can source up to 100 mA. Any larger current demand would require a larger
power source.
FlashCut CNC Section 5 Signal Generator
17
Mini-Fit Jr.
Pin No.
Signal
Mini-Fit Jr.
Pin No.
Signal
1
OUTPUT 1
6 OUTPUT 2
2
OUTPUT 3
7 OUTPUT 4
3
OUTPUT 5
8 OUTPUT 6
4
OUTPUT 7
9 OUTPUT 8
5
+5V
10
GROUND
10 9 8 7 6
◦ ◦ ◦ ◦ ◦
◦ ◦ ◦ ◦ ◦
5 4 3 2 1
BE VERY CAREFUL WHEN DOING ANY WIRING. IMPROPER WIRING
WILL DAMAGE THE SIGNAL GENERATOR.
The output lines are all initialized to low (0V) when you turn on the Signal
Generator. Output lines 1 and 2 are also connected through pins 1 and 2 respectively
of the Motor Signal connector. This makes it convenient to connect up to 2 output
signals to an external motor driver box to drive devices such as solid-state relays that
might be in an external motor driver box.
The receptacle that plugs into this connector is a Molex-Waldom Mini-Fit Jr. Series
10 pin receptacle (part number 39-01-2100), with female pins (part number 39-000039 or 39-00-0047 for 22 gauge or thinner wires).
The Molex 63811-1000 for 14-24 AWG universal or Molex 11-01-0197 Crimp
Tools are recommended for installing the pins. Kits containing connectors and pins
are available through FlashCut CNC or an electronics distributor.
The output lines as seen from the back of the box are arranged as follows:
Jumper Settings
Pin 1 of all jumpers is indicated by a small white dot printed on the PCB.
FlashCut CNC Section 5 Signal Generator
18
JP83 – DB to USB Ground
This connects the DB 25 ground to the USB ground. By default pins 1 and 2, 3 and
4, and 5 and 6 are jumped as pairs
.
JP84/JP85 – Input Power Select
These two jumpers enable you to choose between the internal power of the Signal
Generator and isolated power from an external source. Both jumpers must be set on
the same pair of pins (either both must be on pins 1 and 2 or both must be on pins 2
and 3).
Internal Power
This is the most convenient option and works well for most applications, but
negates some of the signal isolation. When JP84 shorts pins 1 and 2, OPT VCC
gets its power from the Internal 5V power source. When JP85 shorts pins 1 and
2, OPT GND is directly connected to the Internal GND.
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