Vital CNC Control User Manual (HiCON Integra)
Contents
1. HiCON Integra Ethernet Motion Controller pn7766 24V Power Supply a gt GIGABYTE pe 24V Power Supply Fuse yafiSnog iy f o 7o pnanit t ss eae zii n Pa 2014 Vital Systems Inc 6 www vitalsystem com Vital CNC Control User Guide Digital I O Signals NOTE Please verify the model of your 7535 Digital I O Breakout Board before continuing as they can be provided in PNP 7535P and NPN 7535N versions Wire the required Digital O signals of your machine to the provided Digital O Breakout Board This breakout board controls the whole Port12 in Mach3 16 Inputs 8 Outputs and allows the use of 24V one these I O Detailed Wiring instructions for PNP and NPN versions can be found in their respective sections See Internal Layout section for location of the I O Breakout Board Check to see if your board is PNP or NPN Attach ground wire from switches to these inputs C 2 34 372 24 3139 13921 l h d A 4 yl S 4 gt 1 oe eid eee ral These outputs are open draint e ai These outputs vod i Lea 7 WE PNP Digital I O Wiring NPN Digital I O Wiring NOTE You must also wire your 3 phase contactor supplying power to your Servo Drives to the Estop button contact located inside the Vital CNC Control to achieve a true hardware E Stop Wire your 3 phase contactor to this N C Estop switch The Red Disarm Button located on your MPG Handwh2. Settings Alt 6 Diagnostics Alt 7 _ Mil gt G15 G80 G17 G40 G20 G90 G94 G54 G49 G99 G64 G97 Zero All RefX abs max x y z 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 Min 0 0000 0 0000 D 0000 0 0000 0 0000 0 0000 0 0000 0 0000 0 000 0 0000 0 000 0 d a 0 0000 Brain Time ms Port 1 Pins current State us mmmmmmmummmm Pulse Frequency E EN NN NN NND UN EN ND EN EH external Input Signals current State d ogr dli EJogA 392 Offset Tool Offset 0 0000 WorkOffset 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 Current Position Machine Coord aM XPos 0 0000 Refy Y Pos 0 0000 Ref Z MJ ZPos 0 0000 RefA l APos 0 0000 RefB l Mi 8 Pos 40 0000 RefC ll Pos 0 0000 Edit Spindle Toggle Flood Toggle li Jog ON OFF Ctrl Alt J H Mist Toggle l Time in Int 0 0 Blended Spd 0 0 Dwell Active m lg EJoc7 ln Run Buffer Load 96 m EJogx Em Tool Request Cycle Start l FeedHold Rewind l Stop l Single NN Queue Depth WMorstCase PW Base Time Scale Reduced Bd ogy Bl it Limit Bl wt Bl 3 Limit m M4 Limit Bl usn m M6 Limit m Torch On Bd Eog B Limit Bl wi Bl unt BB usn B unt M6 Limit E Torch UP Bl Joga Bl iHome m M2Home Bl iHome E M4Home m M5Home MBHome Torch Dn LookAhead al CPU Speed 31000000 000
3. Range varies from 0 left to Analog Input O 25096 right Feedrate Override 2014 Vital Systems Inc 17 www vitalsystem com Vital CNC Control User Guide Turns ON the Vital CNC Control if pressed Turns OFF the Vital CNC ON OFF Button Control if held while the unit is currently ON The power sign glows blue to indicate that the Vital CNC Control is turned on Spindle RPM Overrides the current Spindle RPM Range varies from 0 left to Integra Override 250 right Analog Input 1 Cycle Start Initiates the execution of the current GCode File in Mach Integra Button P11 Input 15 Cycle Stop Stops the execution of the Current GCode File in Mach Integra Button P11 Input 13 2014 Vital Systems Inc 18 www vitalsystem com Vital CNC Control User Guide MPG Handwheel If you have purchased an MPG Handwheel from Vital Systems Inc you can simply plug the Handwheel into the Port J10 on the HiCON Integra Provided that one of the factory default Mach3 profiles is used the MPG should be useable without any need for I O configuration 2014 Vital Systems Inc 19 www vitalsystem com Vital CNC Control User Guide TroubleShooting My unit is powered up and the CPU LED is blinking but the Digital I O do not physically turn ON OFF correctly Check the 24V Power Supply and see if the red LED is turned on If not check the fuse close to it If it is blown then the 24V are not supplied to the H
4. 0 _Regen JoqFollow B Display Servo Freq Generator Output Signals current State ewPahowot EN id il Ense O Erao nadie 3 BH E65 E Enables Rese t Press Reset Emergency G Codes M Codes NN Output 1 BN output 2 History Clear Im Emergency Ni Enable 4 B output 3 B Digitize Output 4 B outputs B outputs HiCON Plugin 1 36 1 Board 7766 FW 2 24 Serial 259955 FPGA 787E IP 192 168 HiCON Check if these signals activate correctly with the Digital I O state 2014 Vital Systems Inc 13 www vitalsystem com Vital CNC Control User Guide Creating your own Mach3 profile Should you want to create your own Mach3 profile you would need to perform these steps to get your profile working correctly with the Vital CNC Control NOTE This method requires a better understanding of Mach3 as well as experience with the HiCON or DSPMC plugin config It is always recommended to use one of the default profiles Open the Mach3 application which can be found in C Mach3 Mach3 exe The profile selection screen will show up when you open Mach3 1 Click on Create Profile ikeson Pria Current Profiles Create Profile Delete Profile 3 Your new profile should now be useable 2014 Vital Systems Inc 14 Session Profile Current Profiles New Profile Name myNewProfile Default Profile Values Do not put any extension on the new profile 2 Type
5. OMENI SOO CNS ooi tdecetEudadieo deem iE Mam Mb MEMINI dud dm NIMM MUI EM NEUE d d 20 2014 Vital Systems Inc 1 www vitalsystem com Vital CNC Control User Guide License Agreement Before using the Vital CNC Control and any accompanying software tools please take a moment to review this License agreement Any use of this hardware and software indicate your acceptance to this agreement It is the nature of all machine tools that they are dangerous devices In order to be permitted to use the Vital CNC Control on any machine you must agree to the following license agree that no one other than the owner of this machine will under any circumstances be responsible for the operation safety and use of this machine agree there is no situation under which would consider Vital Systems or any of its distributors to be responsible for any losses damages or other misfortunes suffered through the use of the Vital CNC Control and its software understand that the Vital CNC Control is very complex and though the engineers make every effort to achieve a bug free environment that will hold no one other than myself responsible for mistakes errors material loss personal damages secondary damages faults or errors of any kind caused by any circumstance any bugs or any undesired response by the board and its software while running my machine or device fully accept all responsibility for the operation of this machine while under the
6. Vital CNC Control HiCON Integra pn7766 CNC Control for Milling Lathe Plasma Machines User Guide Document Revision 1 1 Updated July 26 2014 O 2014 Vital Systems Inc Phoenix AZ USA For more information please visit the product web page http www vitalsystem com cnc Vital CNC Control User Guide Table of Contents Ceme Fai ei SU T Ure 2 OUO MENTRE o E omm 3 Package COMON er toe codes ateceiceirdet ad vee tenda ibesiu termi dita eu A 3 IN uj m 4 Setting up the Vital CNC Control NE UU 4 Integrating the Vital CNC Control with your machine eessssssssssssresesrrnssrreresrrrsssreresrrereseeresereesseereserreseeeee 6 dz E des Rm m 6 Digital OSI SVAN EA enm dde UP tep UM E ununi Db AE TA N 7 Drive Connection with Maxsine AC Servo Drives and 7736 Board cccccccccccsssssssseccecessaaesseeeceeeeeaaas 8 Drive Connection Without Using the 7736 Board ccccccccssscccceeseccceeseceeeeecceseeseceseuecesseeceeseeseeetas 9 Mach aBd Owae ucsssetissue vitali oar en ene enn ent een nee cd Select a nee aren eee 10 contmsuring tie Derault Prole oo ease eer Ua diuerso E 10 Creating your own Mach3 profile cccccceseccccesseccceesececceecceceesececeuseceseuseceseeneceeeanecessunecesseneceeseges 14 M OS ALON NNMERO mom E 17 FROME Panel COMUONS TEE EO 0 0 OO T STE 17 IVP Ge TANGY CC ERR E TEN 19 M
7. anew profile name You can either start with default profile values or clone an existing profile A Mach3 Loader Target type Application Target location Mach3 Add p followed by your new profile name Target C Mach3 Mach3 exe 4 Youmay also create a shortcut to your new profile by creating a shortcut of the Mach3 exe file then right click to Properties www vitalsystem com Vital CNC Control User Guide After creating your own profile you must perform these additional steps 1 Copy the macropump m1s file from the macros folder of any default profile Mach3 macros lt profile gt macropump m1s and paste it into the macros folder of your new profile Mach3 macros lt yourNewProfile gt macropump m1s CS je gt Computer Local Disk C Mach3 macros HiCON Organize Ej Open Burn New folder E Name i a U5 Favorites BE Desktop S Recent Places al Music Magic Briefcase di dev 2 spindlespeed mis a VerifyTest mis i macropump mis Date modified 2 27 2014 3 51 PM MIS File a Size D bytes Date created 2 27 2014 3 51 PM 2 After Mach3 is opened Go to the general config to enable the macropump j Config Function Cfg s View Select Natrre Units Ports and Pins Motor Tuning General Config System Hotkeys 320 321 Control Lock DRO s to set
8. ase Vital CNC Control MPG Handwheel with optional stand Optional Power cable 2014 Vital Systems Inc 3 www vitalsystem com Vital CNC Control User Guide II Setup Setting up the Vital CNC Control NOTE It is recommended to mount your Vital CNC Control or assemble the optional stand before proceeding with the setup phase 1 Plugin the power cable to the Vital CNC Control and connect the other end to an outlet If you intend setup any wiring such as inputs it is recommended that you keep the power switch at 0 Power switch Plug power cable here 2014 Vital Systems Inc 4 www vitalsystem com Vital CNC Control User Guide 2 Your Vital CNC Control should now be operational and can be turned on with the ON OFF Button The next steps will cover integrating the Vital CNC Control with your machine During this phase the unit must be turned off and unpowered Unit is ON 2014 Vital Systems Inc 5 www vitalsystem com Vital CNC Control User Guide Integrating the Vital CNC Control with your machine For these next steps you will need to open your Vital CNC Control to inspect the internal components Internal Layout Below is an image of the contents of the Vital CNC Control Please use this image as reference while continuing with the next setup procedures NOTE Some Vital CNC Controls may contain different parts as requested by the user before shipping StepGen Board pn7736
9. control of the Vital CNC Control and for its operation by others who may use the machine It is my responsibility to warn any others who may operate any device under the control of the Vital CNC Control of the limitations so imposed fully accept the above statements and will comply at all times with standard operating procedures and safety requirements pertinent to my area or country and will endeavor to ensure the safety of all operators as well as anyone near or in the area of my machine WARNING Machines in motion can be extremely dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the system VITAL Systems shall not be liable or responsible for any incidental or consequential damages By using the Vital CNC Control you agree to the license agreement 2014 Vital Systems Inc 2 www vitalsystem com Vital CNC Control User Guide I Introduction Package Contents Before proceeding to setup your Vital CNC Control please take a moment to verify that all necessary components are present within the delivery The Vital CNC Control Package should contain the following items Vital CNC Control Power Cable Vital CNC Control Stand optional MPG handwheel optional Operator s Keys Backup Software disc Windows 7 NOTE The Vital CNC Control may contain either the HiCON Integra pn7766 or DSPMC pn7762 motion controller depending on the purch
10. e accessed from Port 12 for the Mach3 Ports and Pins Config Digital I O Signals connected directly on the HiCON Integra can be accessed from Port 11 for the Mach3 Ports and Pins Config The image below shows an example for X Home and Limit switches connected to the HiCON Integra and the Y homing and limit switches connected on the 7535 I O Board Engine Configuration Ports tt Pins Port Setup and Axis Selection Motor Outputs Input Signals Output Signals Encoder MPG s Spindle Setup Mill Options RB D Gonnected on the HIGON Integra 1 1 i T z e d l 0 Digital l O connected on the 7535 VO Board Z ar i x a 0 Z Home Y i a 4 0 P4 1 w a 1 A hr i hr hr n v Pins 10 13 and 15 are inputs Only these 5 pan numbers may be used on this screen Automated Setup ol Inputs x ewes m 2014 Vital Systems Inc 11 www vitalsystem com Vital CNC Control User Guide You can monitor the current I O states and other status information via the Status Window Mach3 CNC Licensed n 4 Fie Config Function Cfgs View Weards Operator BELEGEN TV Help 4 MDI AI2 T asai Current Position Program Run HICON Status HiCON Plugin 1 36 1 Board 7766 Encoder 0 Feedback 0 Stepaenn 0 cmdPoso FW 2 24 Serial 2599535 FPGA 787E IP 192 168 0 35 Encoder 1 Feedback 1 o StepGeni p Omd Posi T Encoder 2 Feedback 2 o Stepaenz p cmd Pos 2 Clea
11. eel if you have purchased it only This switch can be fc Jj d disarms the motion controller your Vital CNC Control 2014 Vital Systems Inc 7 www vitalsystem com Vital CNC Control User Guide Drive Connection with Maxsine AC Servo Drives and 7736 Board AC Servo Motor and Drive Packages purchased from the Vital Systems website come with additional components for a simple and quick plug and play wiring setup Said components are 1x Drive Interface Board EPx DIB plugs on the servo drive 1x Blue RJ45 Drive cable 1x Green RJ45 Encoder cable 7736 Differential Encoder and StepGen Board NOTE the 7736 board works with both DSPMC and HiCON Integra motion controllers However this is only used for the Step Dir Outputs with the DSPMC Setting up the drive connection is simply a matter of plugging the colored cables to the corresponding colored and labeled RJ45 Ports on the 7736 board and the Drive Interface Board The Blue RJ45 cables connect to the drive ports while the green cables connect to the encoder ports WARNING NEVER interchange the Blue Drive cables with the Green Encoder cables Doing so may damage your drives and the Vital CNC Control Connection on 7736 Differential Encoder and StepGen Board NOTE You may also view a video tutorial for this connection method link http www youtube com watch vxDHRHOZVeow Connection on Maxsine AC Servo Drives 2014 Vital Systems Inc 8 www vitalsyste
12. iCON Integra 24V are required for Digital Inputs and Outputs I have plugged My MPG Handwheel into Port J10 on the HiCON motion Controller but it is not functioning Make sure that the MPG Buttons Selector brain is enabled for the current Mach3 profile I can t enable arm my Vital CNC Control Make sure that the operator keys are inserted into the keyslot on the front panel and turned clockwise Check the error LED on the front panel if it is lit up This could mean that one of the Estop Buttons is currently triggered Estop buttons are sticky switches and will need to be rotated clockwise to deactivate I have wired my drives but I can t get any motion Make sure that the axes are properly configured within the plugin config o Setthe Output Type to Stepper o Setthe Output Index to the correct channel o Set the Control Input Source to Machxx Ensure the drive enable signal Enable1 is mapped to the correct output in the Ports and Pins Config Check that the Axes are enabled in the Ports and Pins config Motor Outputs tab A Directions on doing these can be found in the HiCON Software Integration Manual for Mach3 For more information visit vitalsystem com or email us at support vitalsystem com 2014 Vital Systems Inc 20 www vitalsystem com
13. m com Vital CNC Control User Guide Drive Connection Without Using the 7736 Board This method is used in case the 7736 Board is not installed or interfacing with non Maxsine AC Servo Drives NOTE With this method it is highly recommended to read the User Guide for the HiCON Integra Ethernet Motion Controller Encoders 3 through 7 are only accessible via the 7736 Differential encoder and StepGen Board Connect your stepper drives to these Step Dir Output Channels n E M M uu M Susa ea TELL HH HEATH JL MMUIBRLBILILNMEISEENE A 7736 Differential Encoder and StepGen Board must be connected to J8 to use encoder feedback NOTE The 7736 Board uses RJ45 ports for Encoders For wiring differential quadrature encoders to the 7736 Differential Encoder and StepGen Board please refer to the 7736 Wiring Guide 2014 Vital Systems Inc 9 www vitalsystem com Vital CNC Control User Guide Mach3 and Software Setup Configuring the Default Profile After the digital I O and the drives have been properly wired it is now time to switch ON your Vital CNC Control NOTE Your Vital CNC Control may be password protected on the windows log in The default password is CNC It is recommended that the user change this to their own password NOTE Although the purchase of a Vital CNC Control along with Maxsine Motors and Drives allows Vital Systems to make several configurations within the factory Digital I O will have
14. r Position Aa Clear Position Encoder 3 Feedback 3 o Stepaen3 p cmd Pos 3 Buffer Transfer Size Encoder 4 Feedback4 po sStepaed gg CmdPos4 o Eth LC i ee ee Encoder 5 Feedback5 g StepGenS og md PosS OQ Code Message Cnr HiCON Buffer Size Encoder 6 Macro Programming is Activated Bape m Digital IO Ports 12 13 are Activated Buffer Fill Level Encoder 8 1 Click on the Encoder count to reset Eel m errare LE ea rad INPUTS OUTPUTS IE NE a 4 S a 7 a UE E 4 15 O E a ec E ES Pu DID IE JE JE IE IE JE JE IE IE JE dE IE IE IC Pu DIL JE JE IL IE JE JE 1 Ple LID IL IL IE IE IE IE IE IL IL JL IL IL IL JE Piz LIL IE JE JIL IE IL JL ee ee en en en ee ee ee WM Pi3 DIL IL IL JIL JIL IL JL J Pi LIL JL IE IL IL IL IL IL IC IMC oIL ICL IL ee 0 1i 2 3 4 5 6 amp 6 7 6 9 E NC 15 14 15 a t 2 3 4 E E 7 2014 Vital Systems Inc 12 www vitalsystem com Vital CNC Control User Guide The I O mapping can also be checked from the Mach3 Diagnostic Tab If the Mach3 signals do not correctly activate in response to the state of the Digital Input then you may need to check the Status Window to see if the Digital O state works or is wired correctly If the signal polarity is incorrect the active low setting can be changed in the Ports and Pins Config Mach3 CNC Licensed To Abdul Rufi File Ker Function Cfgs view Wizards Operator PlugIn Control Help Program Run Alt 1 MDI Alt 2 Tool Path Alt4 l Offsets Alt 5
15. to be wired manually and configured by the user to suit the target machine For a more detailed guide on using HiCON with Mach3 please refer to the Mach3 Software Integration Manual for HiCON Open Mach3 using the default profile provided You should then see this window popup at the start of Mach3 Select M3HiCON as shown in the picture Motion Control Hardware Plugin sensed Your system is showing more than one control device Please pick the one you would like this profile to use Normal Printer port Operation Ni3dsphic dsphdlc Plugin 4 D 10 VITAL Io Device A A Mo Device Dont ask me this again A message like the one below should appear in the Mach3 Status Bar indicating that communication has been established between Mach3 and the HiCON O 2014 Vital Systems Inc 10 www vitalsystem com Vital CNC Control User Guide LERNEN Elapsed On Off inhibit Jog ON OFF Ctrl Alt G Codes M Codes 0 000 MUS HICON Plugin 1 36 1 Board 7766 FVV 2 24 Serial 259953 FPGA 787E IP 192 158 Digital I O can be configured by going to the Ports and Pins Menu then the Input Signals and Output Signals tab Mach3 CNC Licensed To Senge Function CFg s View Wizards Operator Plugin Select Native Units MDI At Tool P Forts and Fins Motor Tuning I ps Digital O Signals wired on the 7535 Breakout board inside the motion controller can b
16. trols 5 User programmable 6 Enable Button Function Buttons 7 Feedrate Override Slider 4 Error LED 8 ON OFF Button 3 EStop Button 2 CPU LED JE i 1 Operator Keyslot 9 Spindle RPM Override 10 Cycle Start Button 11 Cycle Stop Button Operator Enables the use of motion control or system enable Integra Keyslot P11 Input 14 Indicates the current status of the internal motion controller Integra 2 CPU LED If the HiCON motion controller is used a heartbeat blink pattern Edd RUED indicates that the motion controller is operational This LED will turn off during firmware upgrade by the user Disarms the current system and stops all motion The button can be Integra 3 Estop Button twisted clockwise after being pressed to remove the system from P11 Input 9 the Estop state 4 Error LED Turns on when the internal motion controller incurs an error Integra P11 Output 7 5 User These buttons are wired to specific inputs on the HiCON and can be Integra Programmable mapped to execute custom commands or macros in Mach3 FN1 P11 Input 12 Function FN2 P11 Input 11 Buttons FN3 P11 Input 10 Enables Arms the system Motion can only be performed if the Integra P11 Input 8 Enable Button system is armed Glows orange to indicate that the system is armed and ready for motion Overrides the current feedrate to speed up or slow down the Integra execution of a gCode file in Mach
17. up units Tool Change Ignore Tool Change C Stop Spindle wait for Cycle Start C AutaTool Changer Angular Properties Unchecked for Linear v Advis is Angular v B Asis is Angular Iv C Asis is Angular 2014 Vital Systems Inc Editor 3 Code E ditor Browse wWinMT Motepad exe Startup Modals Use Init String on ALL Resets Initialization Stin aso Motion Mode Constant Velocity Exact Stop Distance Mode r IJ Made Fam End or M30 or Rewind Absolute Inc Absolute C Inc gm End ar or Mewn mm dm m ll ll 15 Shuttle Wheel Setting Shuttle Accel 0 004 Seconds General Configuration Zis 250 on Output 6 IY Home Sw Safety Look amp head 20 Ignore M calls while loading M9 Execute after Block Lines www vitalsystem com Vital CNC Control User Guide 3 Enable the Vital CNC Control brain and the MPG Buttons Selector brain if using MPG To do this go to Brain from the Operator menu in Mach3 Contro Program Run Alt 1 2014 Vital Systems Inc File Config Function Cfg s View Wizards Plugin Control Help MDi Ait 2 Tool Pa Lock Unlock Auto Calculator Control OffLine Maintenance Hours VB Script Editor Edit Button Script Set Normal Condition Restore Settings Brain Control 16 www vitalsystem com Vital CNC Control User Guide III Operation Front Panel Con
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