Max32 User Manual
Contents
1. m La WWW KELLYWARE COM t leave the Max32 HOLIMS AVL 30 ONS Y f i H2J4IANSS TAYU 40 ONG Y inpu t HOLIMS 13 YHI 3O ONG Z e i HOLIAAS 13 YI 40 ONI Z B Z HOLIANS GAVEL 30 ONJ A HOLIMS BAVUL JO ONJA ZHOLIMS AVL 20 ONG X 4 HOLMS BAVUL 20 ONS X YOI ION t Moro muogodoid eaa aps e f i pona 9 gt pape HK USS e ILL LL mw t oS nape I i uss 150 Diagram 1 Typical Motor Connection CINONINOO VAYN eae ug DOW As ov Y Add NS d3aMOd HOLOW NOWOS 38vN3 i Hid EXON 4319 uv 7 J A kd NS BAMOd HOLON N x iagrams ll Q Q G C CT c G S lt s c O ke 5 he SC he 2 he S S 3S O 3 E 3 2 amp o S Q g W LINOWNOS 318vN3 D uio i Aid iS AIMO HOLON wg pen 319 L TVA JA INOWINOO a 31HvN3 Addis H35 Od MOLON wd 2l VC JU i MAE DOW g sug vx Note iring W Diagram 2 PC USB Port and Power Supply Connection O 2012 KellyWare M AXI 4X WWW KELLYWARE COM Circuit Board Mounting Pattern 2 89 in 3 68 in Diagram 3 Mounting Pattern Jumper Settings Jumpers JP1 and JP2 should both have shunts in place when using the 6 8i supplied AC Adapter to power the2. USB Step and Direction Pulse Generator User Manual 2012 Kellyware 1 15 2012 MAXIE Table of Contents TADEO GOMES saani i eee eee PIES ENG E E E E T A OE E E E E Key g udc4 diuani PAPO GOD aeie E E E E EE UO NET I E sl P Winnog FACIE NS E Eo T Circuit Board Mounting Pattern eeeeesseseeeeeeeessse d umpet Settings c easenteiuo eiie tuse re eso tot beg ara reiia fuso re tese etra no Encoder Parameters sessi Troubleshooting OPORTET o o T O 2012 KellyWare WWW KELLYWARE COM M AX 4 X WWW KELLYWARE COM WARNING Improper operation of CNC equipment can result Parts List Max32 board USB A to USB B Cable in severe injury Keep 525 VDC 3 Watt Mini USB AC Power Adaptor hands fingers loose clothing long hair and Key Features all other body parts a e 32 bit Processor for ultra fast motion safe distance away e Serial commands through USB Port from moving parts e 24 bit motion commands up to 16 777 215 steps per O 2012 KellyWare motion e Hzto 140 KHz adjustable step rate with 1 Hz resolution Four axis linear interpolation Hardware linear ramping in 1 to 10 Hz increments user adjustable User adjustable ramp up down for fast sequences 3k motion command buffer for fast sequences of motion Dual limit switch inputs per axis TTL or pull up E stop input TTL or pull up for in
3. x4 X Y AXIS XS ZA AXIS xg PE O 2012 KellyWare 4 AELLYWARE UI WWW KELLYWARE COM Installation 1 Connect the USB A to B cable to an open USB port at the rear of the PC 2 Plug in the mini USB AC power adapter to a wall outlet and to Max32 s I O 5 VDC connector 3 Connect the stepper motor drivers to the X Y Z and A axis terminals 4 Connect the E Stop switch to the terminals Setup 1 Start the KCam software 2 From the Setup menu select Port Setup 3 Select Serial Port Max32 v5 xx Figure 1 E Port Setup Port VO Controls maxStepper LPT Setup LPT info General Port Type Output Names Serial Port Max32 v5 xx v Spindle Cw Spindle Cw Spindle CCW Spindle CCW C Win95 98 Mist Coolant Mist E Win35 38 NT Flood Coolant Flood The 170 DLL one should choose Aude T depends on the Operating System 4 choice is given incase problems occur with ports on some PC s or Operating Systems i Apply Cancel Figure 1 5 Select the MaxStepper tab Figure 2 Buffer 3600 Rev 5 0 0 Date 11 05 2011 Hz 5 Port Setup N exa Port VO Controls MaxStepper LPT Setup LPT Info General Port Status General VO Encoders MaxStepper 2 Comm Port hd Max Inputs and Outputs Invert Direction X Limits Invert Spindle Cw D Spindle CW Invert Enable E Invert Spindle CCW v Invert Limit E Invert Coolant Mist D Spindle CCW 2 zr M Invert Y Direction T Y Lim
4. 2 dd 2 zl Invert Y Direction Y Limits La Sa Ree z Coolant Mist Dura ommunication Invert Y Enable EHE Present Invert Y Limit E x B E Coolant Flood OUTA Comms 40243 M high Milow Invert Z Direction Z Limits 7 B Limis Invert Z Enable D gt m e o 100 fio OUTS Invert Z Limit E PWM OUTG Invert A Direction A Limits C Limits INT OUT Invert Enable D g E NT OUT Invert A Limit Bi E E STOP Options Pw Output Ramp Rate 5 Hz step Maximum Spindle 10 Value Min Arc Length 0 00000 Invert PwM Output D Clear Reset DK Apply Cancel Figure 3 10 Close the Port Setup window 11 From the View menu select CNC Controls and test the motors with the jog buttons The motors should move as the jog buttons are pressed E CNC Controls Co a mm escesgggpsescsecsceessesscscsseg f Program Encoder Error Feed Overide ES UL Spindle C Spindle CCW RPM Coolant Mist Coolant Flood Auxillary Manual Automatic Timing Process Status YY AT A E ye y Single St b Y ingie im G01 x100 Y100 2100 A100 Goto Move to Move ta Re Tool Home NN MOTORS ENABLED Soo Moseo Figure 4 Setup is complete and you are now ready to use KCam O 2012 KellyWare 6 ur 1 Im n x 0000000 Be amp cu i PH a I TR a o0000000 F 1 SSS S25 22222 Sees xr eoocooceo ik m xn oooooooOQ
5. Isolated Inputs and Outputs If you wish to power the Inputs from a separate power supply than the Outputs remove the shunts from JP1 and JP2 and connect a separate 5 VDC power supply to X7 s 5 and CM terminals Note that the 5 and CM terminals are bussed between X4 X5 and X6 They are also bussed between terminals X7 X8 and X9 Jumpers JP1 and JP2 connect the two busses together One or Two external power supplies connected to the X4 and X7 terminals may also be used if the supplied AC adapter is not desired X Jumper JP3 allows removal of the filter capacitor and resistor from the PWM output When the shunt is placed across Pins 1 and 2 the PWM output is converted to a 0 to 5VDC analog signal When the shunt is placed across pins 2 and 3 the PWM output is not filtered and can be sent to a device requiring a digital signal Note that the 0 5 volt filtered analog signal is not buffered It will not source low impedance loads m O 2012 KellyWare 8 MAXIE Encoder Parameters Read Enable option will turn on the encoder software in Max32 WWW KELLYWARE COM Stop on Fault option will cause Max32 to halt motion operations when the encoder position error exceeds the Max Error Mode parameter sets the encoder quadrature count mode Typically 1X mode is used e 1X quadrature count mode one count per quadrature cycle e 2X quadrature count mode two counts per quadrature cycle e 4X quadrature count mode four counts per quadratu
6. its ee z Coolant Mist ommunication Invert Y Enable D rd T Invert Y Limit E l gt l Coolant Flood OUTA omms Errors 0 Invert Z Direction Z Limits Elfen Mu le ae 0 Invert Z Enable M e ol 100 fior Durs Invert Z Limit all Las r C Limits rd E Invert amp Direction A Limits t Enabl E nvert amp Enable Sj CBytel 0 dis iow CByte2 0 Invert amp Limit EAS Dptions Pw Output Mere Ramp Rate 5 7 Hz step Maximum Spinde 10 Value md Ind 0 Min Arc Length 0 000007 Invert PWM Output Clear Reset DK Apply Cancel Figure 2 6 Under Port Status select the MaxStepper Comm Port that Microsoft Windows created when the USB cable was connected to Max32 You may need to open Microsoft Device Manager to determine the port number 2012 KellyWare 5 AELLYWARE UI WWW KELLYWARE COM 7 Make appropriate adjustments to the Max Inputs and Outputs and Encoders to suit your stepper motor driver requirements 8 Click Apply to save your parameters 9 You should see the MaxStepper firmware Rev and Date information in the Port Status group E Port Setup Port VO Controls MaxStepper LPT Setup LPT Info General N Port Status General VO Encoders MaxStepper 2 Comm Port hd Max Inputs and Outputs Aux JB Invert x Direction x Limits Invert Spindle Cw D wetEnebe M BB InvetSendeco jy 90 I Invert X Limit Tass Invert Coolant Mist T Spindle CCW Dur
7. re cycle C Factor is a multiplier used to recalculate the Encoder Counts so that Encoder CPR will match Step Counts The Encoder Counts C Factor x Encoder Pulses Max Error is the maximum allowed error between the encoder position and the step count before a position fault is set Position faults are latched on and must be cleared manually Position faults can be cleared by setting the axis position setting the encoder position or homing the table Port Status MaxStepper Comm Port 2 zl x Encoder Read Enable lv Stop on Fault E Y Encoder Read Enable lv Stop on Fault SASF n e Mode x v Mode 1 Communication C Factor 2 m C Factor l Fresen Max Error ho Max Error ho Fellas 0 Enc Cnt 0 EncCnt 0 cs Step Cnt 800000 Step Cnt 800000 Len Er 0 Buffer 755 Encoder Enc Faults ev D Date 11 05 2011 Read Enable Iv n ux X Fault NH Hz Stop on Fault Stop on Fault Y Fault NN Bte 0 Mode x z Mode 1X 0v Z Fault EH d l C Factor f1 C Factor 1 A Fault EN dir is Max Eror 10 in Max Eror 10 Enc Cnt 0 Enc Cnt 0 Clear E Step Cnt 800000 Step Cnt 400000 Apply Cancel Figure 5 Example 1 Stepper Motor Axis Specs full step mode 200 Steps per Rev 2000 SPI Encoder Specs 200 CPR in 1X mode Modez1X C Factor Motor SPR Encoder CPR 200 200 Mode 1 Max Error 10 steps 10 1 2000 0055 Example 2 Stepper Motor Axis Specs 1 4 step mode 800 S
8. stant stop opindle clockwise and counter clockwise digital outputs for solid state relays Flood and mist coolant digital outputs for solid state relays User configured digital output for solid state relays One pulse width modulated or 0 5VDC un buffered analog spindle speed output for spindle motor speed control One auxiliary digital input TTL 5 VDC for monitoring KCam 4 compatible X Y Z A Axis outputs Step Direction Enable X Y Z A Axis inputs Forward Limit Switch Reverse Limit Switch Stable motion with any operating system including Win98 Windows 7 32 64 bit Output frequency is smooth and consistent regardless of PC operating system load All inputs and outputs isolation interface ICs with a 1KV rating for protection between the I O terminals and the controller PC for noise immunity and safety 32 bit Hardware Quadrature Encoder Counters for all four axis to verify position MAXI AX WWW KELLYWARE COM Introduction Max32 is a PC controlled USB step and direction pulse generator that provides exceptionally smooth operation at a reasonable price It interfaces a PC running Microsoft Windows and a set of four stepper motor drivers and uses a microcontroller to convert USB serial commands to pulses MaxStepper can control auxiliary devices such as relays It has inputs for monitoring devices or auxiliary switches Encoders may be used to verify motor position on each axis 2011 Model Max32 v5 0 1 KellyWare S N XXXXXXX INPUTS
9. teps per Rev 8000 SPI Encoder Specs 1000 CPR in 1X mode Mode 1X C Factor Motor SPR Encoder CPR 800 1000xMode 8 Max Error 10 steps 10 1 8000 001375 Example 3 Stepper Motor Axis Specs 1 4 step mode 800 Steps per Rev 8000 SPI Encoder Specs 1000 CPR in 1X mode Mode 4X C Factor Motor SPR Encoder CPR 800 1000xMode 2 2012 KellyWare 9 M AX 0 oe 4 X WWW KELLYWARE COM Max Error 10 steps 10 1 8000 001375 Troubleshooting just installed Max32 The Status bar shows Make sure Max32 is connected properly to a working MaxStepper Failure and the Port Setup USB port on the PC Verify and correct the KCam Window shows an increasing number in the communication port configuration that matches the port Error status in the Microsoft Device Manager When I press the jog buttons the position Check and correct any mistakes with the wiring to the displays show change but the motors do not stepper motor drivers move Is the enable wire connected Drivers may need this to operate the motors The enable output may be inverted If so reverse the setting in the Port Setup window Make sure power is applied to the stepper motor drivers If the axis limit switches are displayed as set and limits are not engaged reverse the Invert Axis Limit as needed Check the E Stop switch circuit It should be closed during normal operation The stepper motors move but one or more are Reverse
10. the Invert Axis Direction in the Port Setup running backwards window as needed The stepper motors move but one or more do Verify the Limit Switch wiring by manually testing the not stop with limit switches switches and reviewing the limit buttons in the Port Setup window Reverse the Limit Switches Disabled in the Table Setup window occasionally goes in the wrong direction driver for that axis The spindle speed output does not work with A special type of SSR is required for spindle speed my Solid State Relay SSR control A Crydom MCPC1225A Proportional Controller SSR or similar model along with JP3 set correctly will convert the PWM signal on terminal X6 to a variable 110 VAC power source for a spindle motor or Dremel tool A Max Fault occurs when jogging Turn off the Stop on Fault option in the Port Setup window until encoder feedback is verified or increase the Max Error parameter Encoder feedback can be corrected by adjusting the C Factor until Enc Cnt matches the Step Cnt when jogging Use the Set Encoder Position or axis Zero button prior to jog tests to match the step and encoder values 2012 KellyWare 10
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