C6 – VARIABLE SPEED CONTROL Rev. 6 User manual Rev.1.1

C6 – VARIABLE SPEED CONTROL Rev. 6 User manual Rev.1.1
C6 (Rev. 6) User Manual
C6 – VARIABLE SPEED CONTROL Rev. 6
User manual Rev.1.1
1. Overview.
This card lets you control your spindle with
step and direction signals, as if it was an axis
motor. It converts the step signal into an
analog (0-10VDC) and by using the onboard
relays you can control the direction
(CW/CCW) and enable the drive (On/Off).
A Variable Frequency Drive or Inverter works
by modifying the frequency for AC motors.
You can control most of these devices with
an external analog signal (0-10VDC). That is,
if there is 5VDC coming into through the
control signal, the motor will run at 50% of full
speed, if there was 10VDC, the motor will run
at 100% of full speed. If there is no signal
coming out, then the motor will stop.
This unit can also be used on many DC
motor
controllers
by
replacing
the
potentiometer that controls the speed.
Fig. 1. C6 Variable Speed Control
2. Features
•
Inputs a frequency (step) and
outputs an analog 0-10VDC.
•
Has two relays that can be used to
control the direction and enable
and disable the drive.
•
Optoisolated output signals. The
analog and CW and CCW signals
are optically isolated, so this board
can be used with drives that make
grounds common with the mains that
drive the VFD or motor.
•
All TTL +5VDC or +3.3VDC
Signals. Interface directly with
parallel port interface products and
other cnc4pc.com cards. 5VDC
(TTL) signals are very common
among automation devices.
•
Screw-On connections for all
terminals. You only have to screwon the wires to make all your
connections.
•
Flexible design. It works with
cnc4pc’s products, directly through
your parallel port, or through many
other parallel port control products.
•
RJ45 Connector. This connector is
for connecting the boards directly
using a standard RJ45 cable,
allowing can be used to carry input
signal
and
power
line.
3. Specifications
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C6 (Rev. 6) User Manual
INPUT SPECIFICATIONS
On-state voltage range
Minimum on-state input current
Maximum off-state voltage
Maximun operation frequency
Minimum on-state pulse width
Signal Type
2 to 5V DC
16 mA
0.8V
50KHz
3uS
Active High
ELECTROMECHANICAL RELAYS SPECIFICACTIONS
Maximum Current (AC)
[email protected]; [email protected]
Maximum Current (DC)
Dimensions
External power
[email protected]; [email protected]
GENERAL SPECIFICATIONS
Millimeters: 105L x 75W x22D
12V DC @ 200mA
4. Functional Block Diagrams
Fig. 2. C6 Analog Output Block Diagram.
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C6 (Rev. 6) User Manual
Fig. 3. C6 Relays Outputs Block Diagram.
5. Dimensions
Fig. 4. C6 dimensions
All dimensions are in Millimeters.
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6. Installation instructions
Fig. 5. C6 Interface Components
Requirements:
It requires a [email protected] or [email protected] power supply to
operate.
To keep the output signals optoisolated, these must not
have common ground or current with other circuits you are using.
WARNING:
You will require a voltmeter to fine tune your system.
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C6 (Rev. 6) User Manual
Wiring:
Before connecting anything, please be sure to read your VFD’s manual and
make sure you understand all the safety issues.
Please check the wiring guide and wiring samples here:
http://cnc4pc.com/Tech_Docs/C6R5_WG.pdf and
http://cnc4pc.com/Tech_Docs/C6R5_WS.pdf
WARNING: The jumpers must be kept on the OPTO position, unless
you are using an optoisolated VFD.
Fig. 6. Optoisolation configuration jumpers
WARNING: Check the polarity and voltage of the external power source and
connect the 12V or 15-24V, and GND. Overvoltage or reverse polarity power
applied to these terminals (X1) can cause damage to the board, and/or the power
source.
Configuring the Control Software:
It is strongly recommend you read your control software’s manual. You need to
configure your control software to control the spindle as if it was an angular axis.
This card requires a 25 KHz input signal to deliver 10VDC. So you have to set the
speed of the motor (spindle) at maximum. For acceleration values adjust them to
where you feel comfortable. Keep in mind the acceleration of the motor must also
be set in your VFD.
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For configuring Mach follow these steps:
1. Go to Config / Ports&Pins / Motor Outputs. Enable the spindle and select the port
and pins you wired for step and direction.
Fig. 7. Ports&Pins configuration screenshot
2. Go to Config / Ports&Pins / Spindle Setup. In the motor control box, check Use
Spindle Motor Output and Step /Dir Motor. Under Pulley Ratios set the pulley
ratios of the machine.
Go to Config / Motor Tuning / Spindle. On Steps per unit put 1,000, set velocity to
Fig. 8. Spindle Setup screenshot
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maximum. For Acceleration, choose the acceleration that you feel comfortable
with. Start slow, increase acceleration as you test your system. Under Step Pulse
length, use a number from 3 to 5, but start with 3. This number is directly
proportional to the final voltage you will get in the analog output. Use this number
and the fine tuning pot to adjust the voltage you want to get at max speed.
Fig. 9. Motor Tuning and Setup screenshot.
After configuring the Mach, these steps should be followed.
Step 1. Ensure that all external power sources are set to OFF.
Step 2. Connect the power supply to the Power Inputs Connectors (X1).
Step 3. Connect the input signals to the Inputs Connectors (X3).
Step 4. Turn on the external supplies
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Step 5. Connect a multimeter in the analog outputs connectors (X4) and make and
fine tune this output:
Make sure that when you reach the max speed in the
control software you get 10VDC out (X4). This voltage
can vary depending on many things, including the
electrical properties of parallel port or breakout board you
are using, the length of the step pulse your software is
delivering, and the normal hi or low status of your step
pin. Play with the fine tuning pot in the card (X5), the
normally hi or low status of your pin, and the pulse width.
Step 6. Turn off the external supplies
Step 7. Connect the analog output (X4) and external Relay contacts (X6 and/or
X7).
Step 8.Turn on the external power supplies.
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RJ45 Connector:
The RJ45 connector (X3) is for connecting the boards directly using a standard
Ethernet cable A standard Ethernet cable with RJ45 has straight through wiring.
That means that Pin1 = Pin1, etc…
This connector eases the installation process by eliminating the screw on
terminals. The RJ45 connectors are used not just to carry the I/O signals, but also
to power the external board. That way you will have it all in one connection.
Pin4 carries the step signal, and Pin5 and Pin6 control the relay 1 and relay 2,
respectively.
Replacing a Potentiometer:
This circuit can be used to replace a potentiometer of DC
motor speed control circuits. This speed controller circuits
are very commonly used by SIEG, KB Electronics, and many
other oriental machines. Before explaining how to do it,
please first keep in mind that it can be done if the voltage
that goes though the pot is +12vdc or less. This circuit
cannot be used for AC currents.
In most cases the terminals that go to the potentiometer will
carry these signals:
P1 = GND
P2 = WIPER
P3 = REFERENCE VOLTAGE
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These are the steps for replacing a potentiometer:
1. Measure the voltage difference between P1 and P3. Make sure it measures
under +12vdc.
2. Fine tune the analog output to the output voltage you got from step 1.
3. Connect the ground from the analog output to the ground of the
potentiometer (P1).
4. Connect the analog output to the wiper connection of the potentiometer
(P2).
If the reference voltage from pot is between +10 and 12vdc, you can use it to
power the analog circuit (not for the C6, because the relays might draw too much
power). In this case, connect P1 to the ground of the power terminal, and P3 to the
+12vdc power connector.
7. Troubleshooting.
SYMPTOM: THE BOARD DOES NOT REACT TO THE SIGNAL.
POSSIBLE CAUSE
POSSIBLE SOLUTIONS
-
-
Pin conflict or mach3 configuration.
It is possible that the port address
used for the pin is not right, or that
there is a pin conflict with the. That is
that you are using that same pin twice.
(it could be assigned to a different
function).
The signal or frequencies are not
getting to the board. It could be the
cable or that you are passing the
signal through the same breakout
board that you are enabling/disabling,
so the outputs could be disabled, so
they will not get to the breakout board.
Revision: 9/28/2009
-
Go to the device manager in windows,
and check the memory address used for
the parallel port you are using. Usually it
will be 378 for LPT1. Check also that
the port does not have a conflict. Then
in mach3, go to Ports & Pins / Port Setup
and Axis Selection. Check the memory
address is correct.
-
Check that the pin you are using is not
been used anywhere else in your setup.
Got to motor output and output signals,
and check all the entries.
-
Try a different cable.
-
Test the pins in the cable (before they
reach the breakout board) with a
multimeter.
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-
-
Problems
with
Mach3
Pulse
Generation.
Mach3 could have
installation problems (you did not
restart immediately after installation),
or there could be something creating a
conflict. Some dongle devices might
cause this, other software, like
QuickTime or drivers for touch screen.
-
Test this in a different PC.
-
Follow Art’s suggestions for optimizing
up WinXP:
http://www.machsupport.com/downloads
/XP_Optimization.txt.
The inputs signal does not have
enough strength. Modern PCs come
with parallel ports that have very low
amperage signals, the pulse stream
has to be able to provide at least
16mA signals.
-
Use a breakout board to buffer and
boost the signals.
SYMPTOM: THE ANALOG OUTPUT DOES NOT REACH THE 10VDC.
POSSIBLE CAUSE
POSSIBLE SOLUTIONS
-
Insufficient pulse width. It is possible
that the signal pulse width is not
enough to activate the optocouplers.
-
In Mach X, go to Config / Motor Tuning /
Spindle. Under Step Pulse length
increase this value, use a number from 3
to 5, but start with 3.
-
The signal is set active low or the
breakout board could be inverting
the signals.
-
In Mach X, go to Config / Ports&Pins /
Motor Outputs. Change the active low
status of the pin used for step.
Disclaimer:
Use caution. CNC machines could be dangerous machines. DUNCAN USA, LLC
or Arturo Duncan are not liable for any accidents resulting from the improper use of
these devices. The C6 is not fail-safe device, and it should not be used in life
support systems or in other devices where its failure or possible erratic operation
could cause property damage, bodily injury or loss of life.
Revision: 9/28/2009
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