CNC10 Installation Manual 050301
Contents
1. oc O3 7 Y X INTERMEDIATE CONTROL CABLE All key press data and optional MPG data is sent serially tothe See the E Stop section and the Schematic for E Stop circuit Control Panel cable plus an LED indicator status is sent back hookup Red and Blue wires from the pendant E Stop button 8 Revisions on 03 01 05 Manuals AJAX pmd 4 Software Ajax CNC motion control software CNC10 is a Linux based program 41 Software Hard Drive Installation Instructions The AjaxCNC software comes preinstalled on a 128MB solid state flash drive With no moving parts this type of drive is far more stable in a machining envirinment 1 Install the IDE Flash drive reader Install this component in place of the existing master hard drive If this is a new PC simply install the Flash card reader in the first IDE slot on your motherboard using the supplied cable 2 With the Flash drive and the CPU10 motion control card installed boot up the PC to make sure all of your connections are secure 3 All of your permanent unlocks have been turned on in your control Every system is given a 10 day demo code to allow the enduser to try out all of the AjaxCNC features and options To turn on the control demo mode follow the instructions below It is suggested that the demo not be entered until the comple tion of the installation to take full advantage of the 12. restart axis runaway check No Motion Encoder cabling is faulty or Check cables restart motor wiring encoder was plugged in with control PC this error latches power on and requires a cold restart axis encoder connection No Motion Encoder cable is not plugged Check encoder connections is bad encoder cable is faulty Strange sounds or rough PID parameters not correct Run autotune swap encoder motion encoder problem or motor with a known good unit to problem locate problem source Note will be either X Y or Z 11 Servo Motor Power The following steps should be taken to ensure accurate motion control after motors have been mounted on the machine 1 Check the encoder count settings in the machine setup screen Press F1 F3 enter password F2 from the main screen The encoder counts should be 8000 for Ajax CNC supplied motors 2 Make sure each jog key moves its axis in the desired direc tion See the Conventions section in Chapter 1 of the Ajax CNC user s manual for the recommended axis setup If an axis is moving in the opposite direction change the direction reversal settings in the machine setup screen 3 Setup the motor revolutions per inch for each axis Refer to tech bulletin TB036 for assistance 4 Autotune should be run to set up the motor PID parameters This can be reached by pressing F1 Setup F3 Config enter password F4 PID F5 Tune from the main CNC10 screen
3. 05 DC3IO SERVO DRIVE AND PLC FLOOD COM D FLOOD COOLANT OUT3 LUBE PUMP COM WAY LUBE PUMP OUT2 SPINDLE RESET 12NO SPINDLE RESET 15NC SPINDLE RESET COM SPINDLE CCW 13NO SPINDLE CW 13NC SPINDLE DIRECTION COM 5656000060 6 5VDC HIGH LOW RANGE IN9 ROTARY CLAMP ACK IN31 INPUT COMMON ROTARY HOME IN30 SPINDLE FAULT IN25 INPUT COMMON TOOL RELEASE IN25 LOW LUBE ALARM IN18 INPUT COMMON DP4 DETECT 115 DP4 IN14 0000000005000 Manuals AJAX pmd 14 Spindle Control The spindle control section of the DC3IO provides an analog output that is factory preset for 0 10v DC output to an inverter in 0 004v increments The internal Digital to Analog Converter DAC converts a 12 bit value for high resolution spindle speed control 141 Spindle Motor The Ajax CNC system is capable of driving a spindle motor using either an Inverter recommended or by using Reversing Contactors 14 2 Spindle Motor with Inverter A typical Inverter wiring diagram is shown on the schematic Figure 14 1 Exact wiring will vary from one Inverter to the next so refer to your Inverter manual for specific wiring instruc tions In the example shown on the schematic the supply voltage is routed through the Inverter and E Stop contactor before going to the spindle motor The Spin Forward Spin Reverse Inverter Common 0 10 VDC Input and the 0 10 VDC Common pins on the Inverter are all connected to H5 as shown on the schematic Figure 1
4. On screen instructions will tell you how to start the tuning process For more information on autotune results refer to TB045 and TB004 5 Run dragplot This feature will help reveal mechanical prob lems that may effect performance TB047 details running drag plot Technical bulletins can be found on the supplied CD or on the Veet Support section of the AjaxCNC website Revisions on 03 01 05 Manuals AJAX pmd 12 Low Lube Alarm Input 12 Automatic Lubrication Pump The lube pump should be connected to H10 as shown in the diagram below Figure 12 The 110 VAC supply for the lube pump should also be connected to H10 as shown in the dia gram and on the schematic After the lube pump is installed you must connect the Low Lube warning circuit Connect the pump alarm common to Common on H13 on the DC3IO Then connect the lube pump alarm NC to the Low Lube input on H13 on the DC3IO If you are not using a lube pump you will need to place a jumper between the Common on H13 and Low Lube on H13 13 Coolant Control The is capable of controlling a coolant pump using a coolant pump contactor 13 1 Coolant Pump Contactor Ajax CNC coolant pump contactors requires a 24 VAC supply to power the contactor coils You must connect the coolant con tactor coil to the Flood and Flood Common on H10 Supply power as shown on the schematic AC VOLTAGE FOR THE LUBE PUMP G NH LUBE PUMP ACH ACN Revisions on 03 01
5. lt F10 gt to save this screen and exit 14 6 Troubleshooting Spindle Output Parameters a Press Setup F3 Config F3 Param to enter the parameters screen b Check parameter 31 This should be set to 1 c Edit parameter 32 Enter the baud rate of 19200 d Edit parameter 33 Enter your spindle gear ratio e Press lt F10 gt to save and exit f Press lt ESC gt until CNC10 main screen appears 2 Make sure that the spindle is not inhibited by the PLC program a The E Stop must be released to start the spindle b The digitizing probe must be unplugged Manuals AJAX pmd Figure 14 1 Spindle Inverter Control Diagram DC310 SERVO DRIVE AND PLC IFLOOD COOLANT OUT3 LUBE PUMP COM WAY LUBE PUMP OUT2 SPINDLE RESET 15NO SPINDLE RESET 15NC INVERTER SPINDLE RESET COM VISPINDLE CCW 13NO SPIN FORWARD SPINDLE CW 13NC SPIN REVERSE SPINDLE DIRECTION COM FAULT RESET INVERTER COMMON E STOP MIST COOLANT OUT4 0 10 VDC INPUT COMMON ROTARY CLAMP 30NO O ROTARY CLAMP 30NC ROTARY CLAMP COM NORMALY CLOSED FAULT SPINDLE ENABLE 14NO SPINDLE ENABLE 1 4NC SPINDLE ENABLE COM NORMALY OPEN FAULT FAULT COMMON GROUND PHASE POWER IN HIGH LOW RANGE IN9 c PHASE POWER IN ROTARY ACK ING E INPUT COMMON L A x PHASE POWER IN ROTARY HOME IN30 ON 1 SPINDLE FAULT 1425 d E GROUND INPUT COMMON TOOL RELEASE IN24 M LOW LUBE ALA
6. 0 day period Note that after software installation it is normal to have errors displayed in the status window depending upon whether or not the DC3IO or Control Pendant are connected Revisions on 03 01 05 NOTE If you purchased one of our stocked control systems and ordered the Control Pendant in addition to the base kit you will need to update your PLC program The supplimental CD included with you Ajax CNC system con tains all of our standard PLC programs The read me file in the PLC Programs folder clearly explains what each PLC program is for Choose the correct PLC program for your application and follow these steps to update the control 1 Unzip and extract the PLC zip file to a blank floppy disk 2 Insert the floppy into the control computer 3 From the main screen press F7 Utlity F2 Update The files will automatically update the control You will need to reboot when you are finished This is the same procedure used for all control updates Manuals AJAX pmd 5 Electrical Panel System Schematic A D size AJAX system schematic is provided with every kit The schematic can also be found as an AutoCAD dwg file on the Ajax CD that came with your kit along with several other smaller schematics They are listed below for your reference Also provided on the Ajax CD is a program for viewing CAD files Included 8 1 2 X 11 Detailed Schematics nverter Power and Control Coolant Control Lube Pump In
7. 4 1 Again the schematic shows only a typical Invert er Installation for details on connecting your Inverter please refer to your Inverter Manual 14 3 Spindle Motor with Reversing Contactors On the Ajax CNC schematic you see a typical circuit diagram for wiring the spindle motor with reversing contactors For the DC3I0 to be able to control spindle direction Pins CW and CCW on H5 must be connected to the Reversing Contactor coils as shown on the schematic Terminal 2 on the 24 VAC supply must be connected to the Spin ENCOM pin on H5 as in the schematic Terminal 1 on the 24 VAC supply must then be connected to one side of the Revers ing contactor coils as shown The other side of the Contactor 18 Revisions on 03 01 05 coils must be wired as shown to allow the DC3IO to control the Reversing Contactors Itis essential that the 220 VAC supply for the reversing Contac tor and the Spindle Motor be connected to the output side of the E Stop Contactor and NOT the 220 VAC input side of the E Stop Contactor so that the E Stop circuit is capable of con trolling the power to the Spindle Motor and Spindle Speed Control with inverter 14 5 Spindle Speed Setup 1 Change maximum spindle speed to match your spindle and inverter a From the CNC10 main screen press F1 Setup F3 Config F1 Control b Change the value for maximum spindle speed so that it s the same as the specs for the inverter and spindle motor c Press
8. Ajax CNC CNC10 Installation Manual Rev 050301 2005 AjaxCNC Milesburg PA 16853 Table of Contents 1 Introduction 1 1 System Overview 1 2 AJAX Components 1 3 Installer Supplied Components 1 4 Optional Supplied Components 2 Motion Control Card CPU10 3 Control Pendant 4 Software 5 System Schematic 6 Electrical Panel Layout 7 Servo Drive DC31O 8 Motor and Encoder Cables 8 1 Motor and Encoder Cable Installation 8 2 Encoder Check 9 E Stop Circuit 10 Limit Switches 11 Motor Power 11 1 Troubleshooting 12 Lube 13 Coolant Control 14 Spindle Speed 15 Other Outputs 16 Digitizing Probe Revisions on 03 01 05 Manuals AJAX pmd 1 Introduction This manual describes how to install the Ajax CNC Computer Numerical Control system It is strongly recommended that you follow each step in order without skipping steps The PC based Ajax CNC system provides 3 to 4 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 and water jet cutters and other specialized applications The Ajax CNC system is intend ed for use by competent installers retrofitters and machine tool builders who want to do their own installation This manual is not intended for casual end users A separate operators manual is available for end users on CD ROM Figure 1 AJAX System Overview AJAX CONTROL
9. DC POWER SUPPLY SINGLE SECONDARY TRANSFORMER 110 VAC TO 83 VAC STEP DOWN TRANSFORMER FOR SERVO DRIVE DC POWER SUPPLY Revisions on 03 01 05 110 VDC POWER SUPPLY FOR DC SERVO DRIVE E STOP CONTACTOR DC3IO DC SERVO DRIVE AND PLC CONNECTOR HI cnn 110 VDC _ NOMINAL Title SERVO DRIVE DC SUPPLY Size Num ber Rev A Date 040903 Drawn by Filename DCPOWER S01 Sheet 1 1 Manuals AJAX pmd 11 Motor Power 111 Servo Motor and Encoder Troubleshooting CNC7 Error Message Motor Symptoms Possible Problems Solutions Axis position error Makes a quick jump when wires may be Reverse motor lead jog button is pressed reversed or A and B encoder connection channels have been swapped axis full power w o Moves full speed until error Encoder is not plugged in or Check connections for each motion condition is detected encoder is bad drive is axis an encoder is not powered up plugged into the axis but may not be from the correct motor replace encoder and check drive and E Stop connections axis home to close Will not home correctly Index pulse is missing Check Z and Z channel to switch wiring replace encoder if necessary axis runaway check No Motion Encoder cables for two axes Plug the cables into the motor wiring condition is detected are swapped correct locations and restart runaway is not on axis the control PC this error that was moving latches and requires a cold
10. EGND terminals are used for shield connec tions Plug the X Y and Z axis encoder cables into the X Y and Z encoder sockets on the PC s back panel Once again pay close attention to matching up each axis with its corresponding loca tion Wildly erratic motor motion will result if encoder and motor hookups are not correct Refer to the Ajax CNC schemat ic 8 3 Encoder Check Power up the PC but do not apply power to the drive DC3IO With the PC powered up and without any power to the drive and motors you can test the encoder feedback Go to the PID menu to verify encoder feedback From the main CNC10 screen press F1 Setup F3 Config enter password 137 gt F4 PID Turn each axis motor shaft slowly and watch the absolute position Abs Pos column for smooth counting Turning the motor shaft in the other direction should count down Ignore full power w o motion or Position Error messages in the message box Ensure that the correct readout changes for each axis motor SEE PC CONNECTIONS Z AXIS MOTOR DC310 SERVO DRIVE AND PLC CONNECTOR H2 SEE PC CONNECTIONS Y AXIS MOIOR PC CONNECTIONS X AXIS MOTOR Figure 8 1 Motor Encoder Diagram 12 Revisions on 03 01 05 AXIS ENCODERS ARE MOUNTED ON THE BACK OF THE SERVO MOTORS X AXIS ENCODER ENCODER Y ADIL CMOOICR LARE I 4935 CMCDICR ENCODER DEN COME CTI NC INTERNAL JOG 2 BLE RED Manu
11. PENDANT X 0 0000 Y 0 0000 Z 0 0000 MOTOR VOLTAGE PPLY INCOMING AC POWER DC SERVO MOTORS WITH ENCODERS 1 1 System Overview The Ajax CNC system is based on two main printed circuit boards and an optional control pendant Figure 1 shows 1 the CPU10 motion control card and 2 the DC3IO servo driver board 3 the jog panel pendant Also notice the DC brush servo motors and the DC motor voltage unregulated supply Servo motors and other CNC components are available from www AjaxCNC com 4 Revisions on 03 01 05 WB 005 CPU10 Motion Control Card DC3IO Three axis servo amplifier with PLC I O Control Pendant Provides control keys for the operator Manuals AJAX pmd 1 2 AJAX Components Qty _ Part No Description 1 10464 CPU10 motion control card 1 10250 Encoder Jog Panel Bracket w ribbon cables 1 10483 DC3IO Servo Drive 6 10234 5 fiber optic cables 1 10274 Jog Pendant 1 10237 Intermediate Jog Pendant Cable Ajax CNC CD containing manuals Linux Source CD 1 3 Installer Supplied Components Your PC should have the following minimum specifications A Pentium 400MHZ or better B 128MB Hard Drive or better provided C 128MB Memory or better D Linux Operating Software provided E 1 open PCI slot Electrical Enclosure 24 x 36 x 12 minimum recommende
12. RM 8 MO M RARE RESISTOR INPUT COMMON BRAKING RESISTOR DP4 DETECT N15 T N DP4 N14 T1 U 3 PHASE POWER 3 T2 V 3 PHASE POWER 2 T3 W 3 PHASE POWER OUT 2 14 7 Spindle Inverter Fault Input Refer to your Ajax CNC schematic 19 14 Spindle Speed Control 14 8 Spindle Hi Low Range Refer to your Ajax CNC schematic and Hi Low schematic found on the supplimental CD for wiring details if your ma chine is equipped with a Hi Low gear range Figure 14 3 Spindle Encoder Cable Hookup Diagram 1 N C 2 5V COMMON 3 Z 4 A 5 B 6 2 FHA 8 B 9 5VDC BODY SHIELD 22 AWG TWISTED PAIR ENCODER 20 Revisions on 03 01 05 Manuals AJAX pmd 14 9 Spindle Encoder Settings The Ajax CNC supplied encoder is a 2000 line encoder which yields 8000 counts per revolution of the spindle Spindle encod ers have to be connected directly to the spindle itself at a 1 1 ratio Other line encoders may be used 500 1000 1024 etc and the control parameter 34 must be adjusted accordingly The encoder cable used should be a shielded cable Ajax CNC spindle encoder cable spec Minimum 22 awg 4 twisted pair Attach shield wire to DB9 case typically soldered and other end to encoder case cover that is grounded to the machine Listed are some configuration parameters related to the spindle encoder Parameter Description P34 Spindle Encoder Counts Settings Must be set to the n
13. als AJAX pmd 9 ESTOP Circuit An effective emergency stop E Stop circuit is essential to any machine tool and is required by insurance carriers The E Stop circuit allows the operator to push an E Stop button and stop all axis motion and the spindle motor The E Stop circuit shown on the Ajax CNC schematic is based on a 24v AC voltage which is required to power the E Stop contactor coil As long as the E Stop circuit is not broken the system will operate The 24VAC coil voltage is routed through the DC3IO relay contacts la beled Drive Fault From there the E Stop coil voltage must pass through the E Stop button and then through the inverter fault contacts before returning to the 24VAC terminal E Stop may be tripped by pushing the E Stop button by a Servo Drive fault orby an Inverter fault 9 1 Blue Loop Installation The blue loop consists of two blue wires on the Intermediate Control Pendant cable These two wires must be connected to E Stop and Common on H14 9 2 Red Loop Installation The Red Loop is the 24v AC circuit that is required to power the E Stop contactor coil To complete the circuit connect the first red wire on the Intermediate Control Pendant cable tothe Drive Fault RLY2 pin on H11 on the DC3IO The other Drive Fault RLY1 pin on H11 must be connected to terminal 1 on the 24 VAC supply The second red wire on the Intermediate Control Pendant cable must be connected in series to A2 on the E Stop c
14. capacitor terminals There should be approx imately 120VDC across the terminals Notice the DC this is for servo motor power and is not to be confused with 120VAC input voltage If you intend to use lower voltage motors such as Pittman 24VDC motors then a suitable transformer must replace the 83 VAC secondary winding transformer referred to in the Ajax CNC examples Do not attempt to apply voltages above the servo motor s maximum rating of 140VDC If you have installed and checked everything up to this point you can now check axis motion operation without installing the other optional subsystems such as spindle coolant and lube controls Connect the DATA and SYNC fiber cables between the DC3IO and CPU10 cards See sections 5 and 6 if you have trouble locating the DATA and SYNC connectors on the cards Release the E Stop button and the E Stop contactor should make a clunk sound as it turns on If you re using an inverter you will have to power it up and clear any fault conditions to get the E Stop contactor to close Power should now be applied to the drive s Vm and GND con nections Jog each axis in both directions and verify smooth motion from the motors see section 11 1 if movement problems are encountered If the motors are not mounted on the machine yet mount them before continuing to section 11 2 Figure 11 DC Servo Motor Power Circuit INCOMING 110 VAC MAIN POWER DIS CONNECT 10 AMP TIME DELAY FUSE FOR SERVO DRIVE
15. d Misc Electrical components a Rotary electrical disconnect b Fuse Holders c Quencharc d Terminal strips e E Stop contactor E stop switch f Spindle inverter g E Stop contactor h Coolant contactors i Spindle reversing contactors j Limit Switches normally closed type Revisions on 03 01 05 Introduction 1 1 4 Optional Installer or AJAX supplied components Axis motors a 17in Ib 29in lb and 40in Ib DC brush motors with encoders are available from AjaxCNC com b Pre wired motor cables are available from AjaxCNC com DC Power Supply consisting of the following a Primary transformer with secondary 83VAC output provides 120VDC after rectification b Capacitor 12 000uf minimum 160VDC c Fuse Holders amp 15 fuses Suggested Source AjaxCNC com AjaxCNC com AjaxCNC com AjaxCNC com AjaxCNC com Automationdirect com AjaxCNC com AjaxCNC com AjaxCNC com Automationdirect com Manuals AJAX pmd 2 CPU10 Motion Control Card also passes PLC I O information to the DC3IO card through the The CPU 10 motion control card is an PCI PC interface card The fe ene CPU 10 card accepts encoder inputs from the servo motors and uses a DSP to perform the servo PID control algorithm The 2 1 CPU 10 card outputs torque commands serially down onto two Plug the CPU10 motion control card into a PCI slot in your PC fibers DATA and SYNC to the DC3IO board The CPU10 motherboard Notice th
16. d to set the limit inputs to 0 in the motor setup menu This is very useful for initial testing but always remember to push all the dip switches down when you want to install your limit switches See TB061 The AJAX system also supports software travel limits and Machine Home to Mark See Chapter 3 of the Ajax CNC opera tor s manual Figure 10 1 Typical Optoisolated Input SERVO3IO INPUT CIRCUIT Figure 10 2 Limits Input Z LIMIT SWITCH Z LIMIT SWITCH Y LIMIT SWITCH Y LIMIT SWITCH X LIMIT SWITCH X LIMIT SWITCH Revisions on 03 01 05 DC3IO SERVO DRIVE AND PLC CONNECTOR H14 Manuals AJAX pmd 11 Motor Power Warning Only a qualified electrical electronics person should perform these steps Install your main power connections Do Not Turn on the power yet just make and check all connections Check all Motor Supply Vm related connections on the Ajax CNC schematic 1 Main Disconnect 2 Step down transformer for Vm Motor Supply Voltage 3 Rectifier Bridge Vm 4 Capacitor Vm double check bridge vs capacitor polarity 5 Inrush limiter 6 Bleed down resistor 6 8k 5W 7 Vm fuse 15 8 Connection to E Stop Contractor 9 PC and DC3IO s 110VAC power supply connection 10 Ajax Power bridge Motor Power 11 With the E Stop pushed in apply the AC voltage to the input of the motor power supply Check the motor voltage Vm from the supply at the
17. e AjaxCNC CPU 10 requires only one PCI slot igure JOG PANEL RIBBON CABLE PLC VO JOG PANEL EXPANSION PROGRAMING axis 5 58828 HEADER J3 HEADER J4 HEADER J2 HEADER 8 axis 4 4 INTERNAL RIBBON CABLES TO BACK OF PC CPUI0 ENCODER INPUTS REV 040325 ISASLor DBISF lt J uj ENCODER JOG PCI stor PANEL BRACKET PC MOTHER BOARD WITH RIBBON CABLES Figure 2 1 CPU10 Fiber Optic Connections SERVO PC CA VOA casn E Woda fe need asa asiga Aswad IAIN a LNO NI FIBER OPTIC JACKS 1 3 NC NC 4 5 EXTEND THROUGH IOI IOI IOI IOI IOI 101 THE PC BACK 7 JOG DB15M ENCODER JOG PANEL BRACKET WTIH RIBBON CABLES Revisions on 03 01 05 Manuals AJAX pmd CPU10 2 2 2 Encoder Pendant Bracket Installation Install the backpanel connector bracket into the PC backpanel Connect the internal encoder ribbon cables to their respective axes on the CPU 10 before plugging into the PCI slot Revisions on 03 01 05 Manuals AJAX pmd 3 Control Pendant Installation Install the Control Pendant Intermediate Cable in your electri cal cabinet and plug the end WITHOUT the red and blue wires into the DB15 pendant connector on the back of your PC Figure 4 Control Pendant Cable Hookup SERVO PC TINOO CONTROL PENDANT oranv 19a aI 28 d zig T gt c
18. eries connection relay contacts 6 Dedicated limit switch inputs 24 General purpose inputs e 2 Dedicated inputs E Stop Drivefault AUX OUTPUTS 1 FLOOD COM FLOOD COOLANT LUBE PUMP WAY LUBE PUMP ura SPINDLE RESET NO SPINDLE RESET NC ows SPINDLE RESET COM SPINDLE CCW SPINDLE CW QUES SPINDLE DIRECTION COM DM RLY TSU ouverauur MIST COM 2A MIST COOLANT ours ROTARY CLAMP NO OUT 30 ROTARY CLAMP A SPINDLE ENABLE NO SPINDLE ENABLE NC SPINDLE ENABLE COM FIBER JACKS vec 8 ncok V COMMON SV COMMON ISV Is 5 ma 2 moo lt svp lo HIGH LOW RANGE IND ROTARY CLAMP ACK IN3I INPUT COMMON le ROTARY HOME N30 SPINDLE FAULT IN2S INPUT COMMON 6 TOOL RELEASE m24 LOW LUBE INI8 INPUTCOMMON DP4 DETECT INIS DP INI EXTERNAL ssvpc switch mais e E STOPINIL INPUT SPIN RESET ENABLE AND CWICCW RELAYS RATED FOR DSVAC 30VDC 60VDC SVAC FLOOD LUBE RLY 1 2 ROTARY CLAMP AND MIST RELAYS ROTARY CLAMP NC 10A 250 10A 30VDC RATEDFOR DC3IO ssvpc INPUT COMMON 5 7 1 Installing the DC310 board on your electrical panel Warning Do not hookup or apply motor voltage at this stage Motor voltage will be applied in Chapter 11 All systems m
19. ing is 1 5 to 2 P82 of degrees of rotation before bottom of rigid tap hole that the cycle will spin at slow rpm setting P68 Revisions on 03 01 05 Manuals AJAX pmd 21 Figure 15 1 Relay Output Circuit SVDC RELAY A 5VDC 5VDC 9 8 SPARE DRV OUT DRV 62 UT DRV 60 OUT DRV 37 a gt E 2 o OUT DRV 11 OUT DRV 10 OUT DRV 36 OUT DRV 35 OUT DRV 34 OUT DRV 32 OUT DRV 31 OUT DRV 29 OUT DRV 12 OUT DRV 61 gt E 6 OUT DRV 1 OUT DRV 3 OUT DRV 3 2 o AUX OUTPUTS 1 AUX OUTPUTS 2 AUX OUTPUTS 3 DC3IO SERVO DRIVE AND PLC CONNECTOR H4 H6 AND H7 Figure 15 2 Output Driver DC3IO Circuit OUTPUT DRIVER User Supplied 5 VDC lt amps RELAY COIL 22 Revisions on 03 01 05 Manuals AJAX pmd Figure 15 3 Ajax Dual Relay Board SUPPLY VOLTAGE FOR SOLENOID OR SOLENOID CONTACTER COIL OR FN CONTACTER COIL 23 Revisions on 03 01 05 Manuals AJAX pmd 15 Digitizing Probe Connector The Digitizing Probe connector allows the use of an optimal Digitizer Probe with the Ajax CNC system 15 1 The Digitizing Probe D P connector receives power through the attached Molex connector which must be plugged into the PC power supply on the DC3IO board Digitizing Probe Installation Visit our web site for free downloads of other PLC programs for specific machines www ajaxcnc com Keep in mind tha
20. ontactor Connect Al on the E Stop contactor to terminal 2 on the 24 VAC supply E STOP CONTACTOR Figure 9 1 E Stop Circuit without Pendant Revisions on 03 01 05 110VAC TO24 VAC STEPDOWN TRANSFORMER 3A SLOWBLOW 110 VAC QUENCH ARC DC31IO DC SERVODRIVE AND PLC CONNETOR H11 Figure 9 1 E Stop Circuit with Pendant CLAMP LE ENABLE DC3IO DC SERVODRIVE AND PLC CONNETOR H14 E STOP S WITCH IN JOG PENDANT DBISM DC310 DC SERVODRIVE AND PLC CONNETOR H14 E STOP CONTACTOR Manuals AJAX pmd 10 Limit switches are required to be normally closed NC switch es which are attached to header H14 of the DC3IO board Each limit switch input is actually pulling down on an optoisolator input on DC3IO board Figure 10 1 When a limit is reached the Limit switch will trip the optoisolator circuit Typical Limit switches are used for both overtravel protection and HOMING the machine at powerup Limit Switches A typical Limit switch hookup is shown in the diagram below Figure 10 2 Connect each Limit switch on the X Y and Z axis to it s respective pin on H14 on the DC3IO as shown in the schematic The AJAX system can be operated without limit switches To defeat the need for limit switches flip up on all the paddles on the LIMIT DIP Switches and place a jumper between each limit input and their respective common Also you will nee
21. puts and Outputs 110VDC Power Supply Indexer E Stop circuit Brake Control Pendant Probe Digitizing Connection 15 PIN TERMINAL STRIP E STOP CONTACTOR FLOOD COOLANT CONTACTOR 24V AC FUSE 110VDC FUSE STEP DOWN TRANSFORMER RELAY BOARD Electrical Panel 5 6 Electrical Panel Layout The illustration below is how we suggest you lay out your electrical panel This is only a suggestion however and you may need to modify this arrangement to better suit your needs Figure 6 Panel Layout Suggested POWER SUPPLY SERVO DRIVE AND PLC BOARD MOUTNT OVERTOP OF THE POWER SUPPLY EMI FILTER CAPACITER AND DIODE BOARD REV 040604 i DC310 de 2 EMI FILTER CAPACITER AND DIODE BOARD 10 Revisions on 03 01 05 Manuals AJAX pmd 7 Servo Motor Drive DC3IO The DC3IO combines a three axis brushed DC servo motor drive along with sufficient I O to control lathes mills or routers For example with suitable 29in 1b motors the DC3IO can easily drive a Bridgeport Boss Series I milling machine As the name implies DC3IO stands for 3 axis SERVO drive with integrated PLC I O Specifications of the DC3IO Board 3 DC brush servo motor outputs up to 15 at 120VDC 35 General purpose outputs recommended for but not dedicated to coolant brake and auxiliary controls 4 Dedicated outputs lube spindle enable CW and CCW Spindle speed control 12 bit DAC E Stop s
22. t just because a standard M code is labeled for a certain function that does not mean you have to use it for that purpose For example M8 is used for Coolant You can use this output to activate a Flood pump OR a mister solenoid You can use the M8 output to activate a vacuum pump a clamp etc M8 turns it on and M9 turns it off Figure 16 1 Probe Digitizing Connection D C AC INPUT 115 230V 6 60 SUUZ MODEL NO FSP180 50NK V MAX OUTPUT POWER 180W 13 3 V 16 7 ORANGE 1 V 16 0 A RED 12V 10 0 A YELLOW 12V 0 3 BLUE GROUND BLACK P G SIGNAL GRAY 5 Vsb 2 0 ACVIOLET DC310 SERVO DRIVE AND PLC CONNECTOR H13 DIGITIZER CONNECTOR CHASSIS GROUND Tue PROBING DIGITIZER CONNECTION E Date 040906 Drawn by Filename 501 24 Revisions on 03 01 05 Manuals AJAX pmd
23. umber of counts for the Spindle Encoder 1000 line 4000 counts 2000 line 8000 counts etc P35 Spindle Encoder Input selects which encoder port the spindle encoder is hooked to Settings 0 Encoder port 1 Encoder port 2 2 Encoder port 3 3 Encoder port 4 4 Encoder port 5 The 5th axis encoder input is primarily used for spindle encoder input Set P35 4 when connecting encoder cable to the 5th axis encoder input as per the Ajax CNC drawing P78 Spindle speed display Settings 0 Displays programmed spindle speed Displays actual spindle speed from the spindle encoder P31 Spindle output port Settings for all DC3IO systems P32 Spindle Output port Baud Rate Settings 19200 Recommended setting P36 Rigid Tapping Settings 0 Disable Rigid Tapping Enable Rigid Tapping 3 Enable Rigid Tapping and Do Not wait for Index pulse 5 Same as 1 but enable spindle override during tapping 7 Same as 3 but enable spindle override during tapping P37 Spindle deceleration time Settings Time in seconds for spindle deceleration during rigid tapping Typical time 3 seconds Note Your inverter should be set up with a braking resistor and set up to decel faster than this setting P68 Minimum Rigid Tapping Spindle speed Settings Typical setting is 500 to 600 rpm for Rigid Tapping P69 Duration for minimum spindle speed Settings Amount of time to wait when at speed set in P68 Typical sett
24. ust be checked out first Refer to the Ajax CNC detailed schematic Check the connections from the DC3IO to the power supply The DC3IO is supplied with 12 and 5VDC from the power supply via the J10 Ensure that J10 is connected to the power supply These DC voltages are used to power the logic of the servo drive and the logic of the PLC I O section 2 15 BRAKES isr OUTPUT DRIVER ij EXTERNAL REV 040604 Y FUSE VMGND 110VDC NOMINAL X FUSE INPUT COMMON 24 LIMIT INS z LIMIT INS INPUT COMMON Y LIMIT ING je v LIMIT IN3 INPUTCOMMON LMT X LIMIT IN x LIMIT INI Revisions on 03 01 05 Manuals AJAX pmd 8 1 Motors and Encoders Ajax CNC motors are DC brush servo motors and have 2000 line 8000 count per revolution encoders Differential line sig nalling is used for noise immunity Encoder cables should use shielded wire with twisted pair signal lines for noise immunity reasons See Figure 8 1 Reliable operation at distances up to 50 are possible Motors may be hard wired without the use of MS connectors for cost reduction reasons Fully wired ser vo motors with cables may be ordered from AjaxCNC 8 2 Installation Wire your motor cables to H2 on the DC3IO board The DC3IO board has labels next to each terminal on H2 to aid in the wiring The earth ground
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