BladeRunner AIO User Manual CandCNC

BladeRunner AIO User Manual CandCNC
BladeRunner AIO User Manual
CandCNC
With BladeRunner AIO SERVO Addendums
UPDATED 3/15/14
Covers BladeRuner AIO, BladeRunner Dragon-Cut
including new Dragon-Cut with DTHC IV
Unit pictured is a Bladerunner Dragon-Cut 630-4
withe DTHC IV upgrade and C3 Bus 4 port hub
All Content Copyrighted 2008-2014
CNC and motion control involves equipment that can cause serious injuries.
CandCNC assumes no liability for ANY damages to any person or property
from the proper or improper use of any equipment CandCNC sells or from any
advice verbal or written. Use the equipment at your own risk. Practice good
safety precautions. Be smarter than the machine.
Read full copyright notice on page 7
CandCNC
Page: 1
A
INTRODUCTION: BladeRunner AIO
INTRODUCTION
The BladeRunner AIO is a complete CNC motion controller in a single enclosure that consists of
1. Advanced logic Interface electronics to connect the signals from a PC and provide bidirectional communication for controlling motion, operator feedback and expanded Input/ouput
(I/O). UBOBIII with Port Expansion for single Parallel Port operation
2. Safety monitoring and auto-shutdown circuits controlled via embedded processors.
Monitors DC (motor) voltage, DC load current and internal temperature. Values displayed on
screen. Less than 1msec total shutdown to out of spec conditions. Fault shutdown codes on
Front Panel and on screen.
3. Exclusive Driver Interface design monitors each axis independently and protects drives from
shorts and overloads. Reports faults with flash code and on-screen in text. Driver interface card
has input high speed opto isolation (step & dir).
4. High quality Gecko stepper drivers with X10 microstepping and tuned anti-resonance for
smooth motion.
5. High capacity toroid linear power supply provides low noise DC power with large surge
capability. AC input has two levels of ON/OFF. AC side fusing (breaker) DC side Electronic
fusing and conventional fusing. Operation on most AC power grids in the world.
6. Wired and tested motors are specially designed to match Gecko Drivers for optimized
performance
7. Unit is expandable for up to 5 motors and drives (4.5 axis configuration one axis hardware
slaved) for adding double Z motion or rotary axis.
8. Warranty covers labor and parts ( returned to factory) for a full 2 years. All components
including motors and drivers.
IN ADDITION to the Above the BladeRunner AIO DRAGON-CUT offers:
1. Fully integrated Digital Torch Height Control with:
» Dynamic Fault and anti-dive detection
» On-screen display and setting of all Torch Height Parameters
» Full high speed digital response
» Total electrical isolation for safety and noise rejection
» Advanced PWM digital pickup at the plasma via a single cable
» Exclusive HyT-Connect™ SINGLE CABLE plug-n-go interface for all
Hypertherm 45/65/85/105/125. Direct Connection kits for most other brands.
» Industry first DCP-01 (digital current probe) option shows actual cut current on
any plasma cutter!
» Instant recall Stored Settings Library. A Cut Profile that is a dynamic Cut chart
stored by material type/thickness.
» More precise control than any other THC (ATHC; AVHC; AVC;THC) on the
market.
» Only THC with DCC™ and TAP™ for storing and adjusting plasma cut
parameters while cutting
2. High quality electronics and same 2 year warranty.
CandCNC
Page: 2
INTRO
A
INTRODUCTION: BladeRunner AIO
Familiarize yourself with the controls on the BladeRunner Front Panel and with the loading and
operation of MACH3 with the proper profile. The SOFTWARE part of this manual is devoted to
getting MACH3 properly installed with the right CandCNC support files and profile to run the
BladeRunner AIO Plasma and Router. After you have the software installed and the cables and
satellite cards hooked up, you will be guided through a series of tests to determine if everything is
working. We ask that you go through the setup and manual in the order presented. If at some point
you cannot get the expected results and check your connections and setup with no success, then
call our tech support person at 903-364-2740 during normal business hours (posted on the
CandCNC website). Often an email to [email protected] will get a response after hours or on
weekends. Another valuable source of help is the CandCNCSupport Group at
http://www.candcnc.net/supportforum
You must have a yahoo membership and you must request to join the CandCNC forum. The Group
is open to all persons interested in CNC cutting and/or CandCNC products.
Installation and setup of your BladeRunner AIO....OVERVIEW
There are a series of steps you must complete to setup and interface the
BladeRunner AIO with your PC and Your Plasma torch
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Install and setup the Primary Parallel Port in your PC
Setup and configure the first serial port (COM1) on your PC *
(DTHCIV models use USB to RS485 serial connection)
Install MACH3 software (proper version)
Install MACH3 license into the MACH3 main folder
Run menu driven CandCNC Master Installer program from the
CandCNC Support disk to load selected custom screens and setup files
and Plug-ins
Open MACH3 and check screens and configurations.
Connect the 2 PC port cables (one 25Pin, one 9 Pin) to the side of the
BladeRunner *
Run a quick series of tests to confirm the ports are working and that
MACH3 is configured correctly
Tune and Calibrate the motors on each axis.
Setup and Test Inputs and Outputs for Homes and Limits
Check for proper motion
Fire up the machine and cut a test file.
Proceed to the DTHCII setup (Dragon-Cut versions).
* Serial port (COM Port) install and setup on the DTHCIV is not used. Use instead the
Setup and config for the C2BUS USB to RS485 4 port hub (required for DTHC IV
operation) 9 Pin cable is not used and unit will ahve an RS485 (CAT 5) jack instead
CandCNC
Page: 3
INTRO
A
The setup of the BladeRunner AIO Series Interface involves the installation of MACH3
software and some support files on the PC to be used for the machine controller.
UPDATED MANUALS CAN BE FOUND AT: http://www.CandCNC.com/manuals.htm.
Always check that location
BladeRunner AIO Table of Contents
TOC
BLADERUNNER AIO TABLE of CONTENTS
PART 1, SETUP, CALIBRATION . {CONT)
A. Introduction - Table of Contents
B. Detailed Install & Setup - PC Hardware
1. PC Requirements & Prep
a. Not Supported List
b. Limitations
c. Profile Copies
d. PC hardware requirements
e. Windows Optimization
f. Unused NIC - Disable
2. PC Hardware: LPT (printer) Port - Motherboard
a Install and Setup Printer Port- Motherboard
b. Using Windows Device Manager to display Ports
c. Check Hex Address
3. PC Hardware : COM (serial) PORT
a. Using Windows Device Manager - COM setup
b. Setup details
4. PC Hardware: LPT (printer) Port - Expansion Card
a. Using Mfg’s disk to setup expansion card
b. Using Windows Device Manager to display Port Address
C, Detailed Install & Setup - Software
1. General Concepts
a. The 3 C’s: CAD- CAM-CONTROL
b. Definitions
c. MACH concepts Profiles and Screen SETS
d. G-Code Definition
2. Installing MACH3 from the Support CD
a. CD file structure
b. Running the INSTALL FILE for MACH
3. After the MACH Install
a. Sample Folder Structure
b. Folder Contents Defined
4. MACH3 License Install
5. CandCNC Support Files
a. General Info
b. BladeRunnerAIO-UBOBIII Install Defined
6. Installing CandCNC files from the Support CD
a. CD file structure
b. Running the INSTALL FILE Screen shots
7. Working with MACH3 PROFILES
a. Starting the Profile from the Desktop ICON
b. Starting the Profile from the MACH LOADER
c. CREATE a new PROFILE
CandCNC
A
Page: 4
BladeRunner AIO Table of Contents
TOC
BLADERUNNER AIO TABLE of CONTENTS
PART 1, SETUP, CALIBRATION
D. The BladeRunner Hardware Setup
1. C3Bus USB-RS485 4 Port Hub Install
2. Making the External Connections
a. PC parallel & Serial Ports
b. Power cables
c. Motor connections
3. Front panel Controls
4. Front Panel Dashboard
E. Configure and Testing BladeRunner with MACH3
1. The MACH3 / CandCNC Screens
a. DTHC Screen Details - Main Screen
b. Diagnostics Screens
2. Getting Motion from the BladeRunner AIO
b. Powering up the system
c. Keyboard Hot keys
3. Using the MACH Configuration interface (Menu)
a. Motor/Axis Calibration and Tuning
1. Table Physics
2. Fine Tuning the calibration
b. Axis Slaving
c. Homing & Limits
F(A) ADDENDUM - BladeRunner SERVO system
1. Physical Differences between Stepper & Servo
2. Servo motor and Gearhead Dimensions/specs
3, Setup and Motor Tuning - Servo
4. Gecko G320X default settings
5. Calculations & Formulas
6. Recommended Settings (Typically setup)
CandCNC
A
Page: 5
BladeRunner AIO Table of Contents
CandCNC
TOC
G. Detailed Install and Setup - BladeRunner Hardware
1. Table I/O card
a. Card location in the BladeRunner
b. Making the wiring connections
2. The Charge Pump (CP)
3. E-STOP and it’s variants
a. EPO jumper on Table I/O
b. Power on Detection
c. Hardware E-STOP Options
4. Setup and testing INPUTS - HOMES
a. Z axis setup and testing (required for DTHC)
b. Optional XY & A homes
c. Other inputs
5, Setup and Testing INPUTS - LIMITS
6. Setup and Testing OUTPUTS
a. How Outputs work in the BladeRunner
b. Things that trigger an output
b. Testing OUTPUTs
H.. Final system checkout
1. Bringing it all together
a, Final Motion Test
b. Doing an “Air Cut”
A
Page: 6
A NOTE ABOUT RUNNING A PC WITH MACH3
There is a tendency to treat the PC used for the CNC machine as a general purpose workstation
and use it for other purposes when it is not cutting. We strongly urge you to resist the tempation to
use the PC on the CNC table for ANY other purpose than as a DEDICATED CONTROLLER
running MACH3. With the requirements of the PC being modest, an older or refurbished PC
makes a nice machine to dedicate to the task. You will NOT get better performance from a new
super-duper, quad processor PC with 8G of RAM and a 500G HD! Optimize and treat the PC with
MACH as a CNC controller and you will have fewer issues and a better use of your equipment.
Use you hot new PC/Laptop to Draw and do the CAM work. Take it to the Controller PC and us it to
cut the job
THE FOLLOWING CONFIGURATIONS ARE NOT SUPPORTED:
?Any Windows 64 bit install
?Any non-parallel port pulse card or control (e.g. Smooth Stepper, USB drivers, etc)**
?Laptops (even with a parallel port)
In addition: While WIN7 is supported by MACH we do not currently support WIN7 running the
BladeRunner. The problem with WIN 7 is usually the drivers for the hardware on the PC and
not something we can help troubleshoot. In other words: You can try to use WIN 7 and it
MAY work but if it does not, please don’t call us for support.
** In Jan 2014 CandCNC introduced the DTHC IV and the Ether-Cut™. The limiitations
listed above do not all apply to thsoe newer models.
Other Limitations:
We have included a version of MACH3 on the Support CD that has been tested and certified
to work with our plug-ins and screens. If you have already installed a LATER version then it
MAY work. If you experience problems with a version newer than our version on the CD then:
[SEE THE “BEFORE YOU UNINSTALL MACH.....” BELOW]
1. Uninstall the newer version of MACH using Windows Software Install/remove program
2. Open the Hardware Manager on the PC and uninstall the MACH PULSING ENGINE
device in the hardware list.
3. Do a fresh install of MACH3 and re-install the CandCNC files (INSTALL) off the CD
BEFORE YOU UNINSTALL MACH OR DO A REINSTALL OF THE CandCNC INSTALL OFF
OF THE CD
If you have settings you would like to preserve from the earlier install make a copy of the
MACH3 folder on your drive using another name or roll it over to a memory stick. The
important files will be the specific PROFILES (all have XML extensions on the file name). You
can copy the older XML profile over to the new install BUT if there is a bad setting it will
transfer that too. One way around this it to open MACH Loader and CREATE a new Profile
with a New Name and CLONE it from the profile you are using .You can then copy the Cloned
CandCNC
Page: 7
B
PC HARDWARE
PC Requirements & Preparation
PC Requirements & Preparation
PC HARDWARE
B
TO run MACH3 with the Bladerunner and Bladerunner Dragon-Cut™ Systems:
1. Pentium 4 PC
2.4 to 3.4 GHz Processor
512M to 1G RAM
20G Harddrive
1280 X 1024 SVGA (no shared system RAM)
1ea 25 pin LPT (Parallel) Port
1ea 9 pin SERIAL(COM) Port
Windows XP SP2 or SP3
Keyboard
Mouse
2. Optimized Windows setup
No automatic updates running
Disable Remote Assistance
No Virus Checker or background file checkers
No unconnected Ethernet cards (disable NIC if not connected to a cable/hub)
Turn off all non-essential background processes in Windows
3. Disable Startup Items in Registry
1. Click Start button.
2. Click Run.
3. Type MSCONFIG and press [ENTER].
4. Click Startup tab.
5. Uncheck everything
6. Click OK.
7. Exit MSCONFIG.
4. Disable Indexing on all NTFS drives
1. Double click My Computer.
2. Right click on hard drive and choose Properties.
3. On bottom, uncheck "Allow Indexing Service to index this file for
faster searching".
4. Hit OK.
5. Disable Power Management
1. Right-click on your desktop, and then click Properties.
2. Click on the Screen Saver tab.
3. Set Screensaver to None.
4. Press the Power button near the bottom.
5. Set all options to NEVER shut down automatically!
6 Disable Wallpaper
1. Right-click on your desktop, and then click Properties.
2. Click on the Desktop tab.
3. Where it says Background, scroll all the way up and choose None.
4. Click OK.
CandCNC
Page: 8
PC Requirements & Preparation
PC HARDWARE
B
7. Disable any unused network cards.
1. Open Control Panel/System/Hardware/Device Manager
2. Scroll list to Network Adapters
3. Click to show list of adapters
4. Right click unused Network Adapter
5. Select DISABLE.
6. Select Yes
Note: The PC can be used in the network or with a wireless card but it is important that if the
network is not available (card is not connected to a cable and hub) that it be disabled.
Ethernet communications will interrupt MACH (and the pulse stream). An unconnected card
will continually search for a hub every few seconds even if it has no traffic for the network.
When connected to a valid network it no longer will “beacon”. Do not transfer files or use
any Windows utilities when you are running code!
CandCNC
Page: 9
B
PC HARDWARE
INSTALL and SETUP PRINTER PORT (LPT)
Motherboard Port
In WINDOWS:
1. Go to START (lower left) CONTROL PANEL
and select SYSTEM from the list You will see a
screen simialr to the one on the left
2. Select HARDWARE Tab.
3. You will see a window like the one below.
4. Select DEVICE MANAGER
5. A list of all the hardware devices on your PC
will appear.
see next page to continue
CandCNC
Page: 10
In WINDOWS:
6. Scroll down the list until you find the PORTS (Com & LPT)
line
7. Expand the line (+ button).
8. Find the PRINTER PORT (LPT1) and click the line to open
the TABS.
9. Click the RESOURCES Tab. You should see the screen
below and the I/O Range should start at 0378.
If you do not see that LPT port in the list or you have another
address for LPT1 under the RESOURCES proceed to the
next section
If you have the screen shown you have a Motherboard
Parallel Port at the default address and your Bladerunner
default install will use that address. You can move to the
COM port setup page.
CandCNC
B
PC HARDWARE
INSTALL and SETUP PRINTER PORT (LPT)
Motherboard Port
Page: 11
NOTE: USE THIS SECTION ONLY IF YOUR PC DOES NOT HAVE A BUILT-IN
PARALLEL PORT and/or SERIAL PORT
Use the same procedure to install a primary (PORT1) Parallel Port (if your PC does
not have one) or a secondary port (PORT2). Do not attempt to use two separate
parallel port cards of the same type to get two ports. For two ports use a Dual
Parallel Port card.
Make sure the card you install has drivers for the version of Windows you are running.
Win2000 drivers may or may not work in XP (or visa versa). When you install the card in
your computer and turn it back on, it should find the new hardware and when prompted,
you should use the disk that comes with the port card to install the correct drivers. There
should be instructions with the card on the proper way to install the drivers.
After you install the parallel port and Windows recognizes the port(s) then open the device
manager from the Hardware section under Windows /Control Panel/System and open the
Ports icon and find the Port entries. Open that and click on the resources tab.
WRITE PORT
ADDRESS HERE
Write down the first number in the Input/Output range (DE00 in this case above). We will have to enter
that number in the MACH3 setup procedure later
CandCNC
Page: 12
B
PC HARDWARE
INSTALL and SETUP PRINTER PORT (LPT)
Expansion Card Port
NOTE: COM Port is used ONLY with
DTHCII. DTHCIV models use C3
BUS USB to RS485 HUB. Skip this
page if you have the DTHCIV Dragon
Cut model.
You will have to setup the COM1 serial port in Windows. It should be setup with 9600 baud, 8
bits, no parity, 1 stop bit, no Flow control
Testing: We will test the functionality of the com port after we hook up the BladeRunner
to the computer
CandCNC
Page: 13
B
PC HARDWARE
PC hardware - COM Port
SOFTWARE INSTALL
SETUP
BLADERUNNER AIO SUPPORT CD.
! Contains Master Installer (Auto Install File) to automatically load Drivers (Plug-ins),
Custom Screens, and Custom Profiles for router and plasma.
! Contains (This) Complete Manual for BladeRunner and all associated Manuals for
internal cards.
! Contains tested rev level of MACH3 software (Unlicensed DEMO VERSION).
! Contains MACH3 SheetCAM and Hyt_Connect RS485 Licenses if purchased with
the Bladerunner. Auto installer allows any one or all to be automatically installed from
the CD if they are on it.
! Contains sample artwork for plasma and router (CDR format).
! Contains freeware drawing program (Inkscape) that will open and let you edit the
CDR sample files.
! Contains Demo version of DXFTools for smooth arcs and curves from CorelDraw
DXF export.
!Contains Demo version of SheetCAM.
!Contains Support Installer for SheetCAM. Adds in custom POSTS and Tool Sets
CandCNC
Page: 14
SOFTWARE
INSTALL
C
GENERAL CONCEPTS
READ THESE NOTES!
It helps to have a basic understanding of how MACH operates, what it does and how it combines with
the BladeRunner Hardware to generate motion.
! There are 3 distinct parts (legs) of CNC: CAD(Drawing), CAM (Toolpathing) and CONTROL
(operation of the hardware and operator interface. MACH is the third and last (CONTROL). It does
not generate toolpaths from a file; it cannot be used to draw or edit artwork. It runs a specific “dialect” of
G-Code.
! Specific software programs are used for the CAD(drawing) to generate the base artwork in vector
format. For simple shapes a pure CAD program can be used. For artistic, decorative or signage type
cuts, a drawing program that allows drawing in vector format (lines) will better fit the needs and is a lot
faster than pure CAD. It will allow import of several Vector type formats to allow you to use vector clipart
(like the files found at www.VectorArt.com) The two most popular drawing programs are CorelDraw (any
version after 11) and Adobe Illustrator. A FREE alternative is Inkscape and is included on our Software
CD. You can download it from http://inkscape.org/download/?lang=en
! The CAM process takes a drawing file and allows the user to import it in line format, define the
objects to cut and in what order, with which tool and what type of cut. Better CAM programs have
automatic lead-ins/outs (essential for plasma) and cut type settings. The most essential piece is the
“POST” processor that translates the CAM program’s native toolpath data to standard G-Code in a form
that matches your control program (MACH3). The best value and most flexible CAM for 2 D or 2.5D
cutting is SheetCAM. It is available at www.SheetCAM.com. SheetCAM TNG is a part of our Software
Bundles
! Some programs combine CAD and CAM or CAM and CONTROL but they typically are a
compromise and one or more section will not be as robust as the other. To maintain maximum flexibility,
and not be placed in a position where you have to change out an expensive tool (or quit using a section),
it is recommended you run separate applications for each “leg” of the CNC Triad. You can then pick and
choose the features from each one that best suit the type cutting you do.
! MACH uses setup “Profiles” stored in the main MACH3 Folder as an XML file. It stores all of the
settings about the hardware and interface (input pins, output signals and pins) motor tuning and travel
directions. We use a term called “mapping”. It refers to defining a specific function to a specific port and
pin setting in MACH. The BladeRunner Install copies the “profiles” needed to the MACH folder to run the
Bladerunner Hardware. Certain settings that are specific to you machine (motor tuning, travel
directions.etc) have to be entered during setup. The settings get stored in the current running PROFILE.
!The screen presentation for the BladeRunner is in the form of a custom screen “set”. The file is
stored in the MACH3 Folder and has a .set extension. It controls what buttons, readouts (DRO’s) and
bitmaps (pictures) are on the screen. The visual look is controlled using custom bitmaps. Bitmaps used
with CandCNC screens are all stored in a folder located in the Bitmaps Folder (under MACH3) and in a
sub-folder named CandCNC. With the exception of certain custom objects in a screen there is no setup
information. Certain operations on the Bladerunner (parameter feedback and DTHC or Spindle Speed
functions) MUST use the associated screen set to operate properly.
!The G-code runs in MACH and gives it moves in absolute (measured from a beginning zero point) XY
and Z coordinates. It’s up to MACH to process the file, do the math and based on the settings in the
Profile, issue the proper number of pulses (steps) and proper direction (dir) to the motor drive modules
(hardware). There is no positional feedback between MACH (software) and the table position
(Hardware). MACH is not “closed loop”. It issues the signals at the rate set by the motor tuning rules
and it’s up to the hardware to move to that location.
CandCNC
Page: 15
SOFTWARE
INSTALL
C
SOFTWARE INSTALL
OVERVIEW
SOFTWARE
INSTALL
C
Installing MACH3 and the custom BladeRunner files
The actual installation of MACH3 software is straight forward since the file is downloaded
from CandCNC support CD and the file when clicked on will take you through an install of
the software on your machine. We have included an unlicensed version (demo) of MACH 3
that is needed to use with the BladeRunner series of devices DO NOT TRY TO USE AN
OLDER (EARLIER) VERSION THAN WHAT IS INCLUDED ON THE SUPPORT CD
While we can answer questions about the proper interface of our BladeRunner with
MACH3, the actual setup and use of MACH3 on a specific PC may better be handled
through the actual software provider or the support list. Our custom files provided on our
install disk should setup the PC to work correctly with the BladeRunner, but be aware that
changes you make to setup parameters after the install make changes to the profile. Make
a copy of the BladeRunner XML files in the MACH folder (backups) when you have
finished setting up the unit. It will save you a lot of time and frustration if you ever
need to recover from PC hardware problems. Any time you make setup changes to a
profile then refresh the backup. Store it and your MACH license file on an external device.
We have included a version of the MACH3 Manual on the CD. Do not use it as you primary
manual for the setup and realize there are settings in the BladeRunner that should not be
changed or it may cease to operate. In most cases you will not need to referernce that
manual. For plasma cutting most of the information is not needed and if there is a conflict
between a plasma specific setup or procedures, (this) Bladerunner manual should prevail.
The following pages will take you through the install and setup of you CONTROL PC. First
you will install MACH3 then run the Master installer to do a custom setup for MACH for the
BladeRunner and the DTHCII or DTHCIV. Detailed setup and testing of the DTHCII is a
separate manual on the CD titled DTHCII Manual. Detailed setup and testing of the DTHC
IV is a separate manual on the CD titled DTHC IV Setup and Config Manual.
NOTE: THE MP3000 products use the same interface electronics and DTHC as the
BladeRunner
This manual may contain typo’s and outdated information. Newer
Manuals may exist. Always check www.CandCNC.com/manuals.htm
for the latest version of product manuals
CandCNC
Page: 16
INSTALLING MACH3
INSTALLING MACH3 FROM THE SUPPORT CD TO YOUR CONTROL PC
1. Locate the Support CD (same one this manual is on) and open the Main Folder
(Root) of the CD drive. Use Windows File Explorer or My Computer and navigate to the
CD Drive onthe PC
2. Open the CD and the folling structure should be displayed:
3. Navigate to the MACH Program Folder
4. Double Click the Mach3Version3./042.029.exe line. The sutomated install of MACH
will start
CandCNC
Page: 17
SOFTWARE
INSTALL
C
INSTALLING MACH3
SOFTWARE
INSTALL
C
MACH will ask you for
the default installaion
Disk and folder to use.
SELECT THE
STUCTURE IT SHOWS.
DO NOT CHANGE IT
OR OTHER INSTALLA
MAY NOT WORK
CORRECTLY
Several Features will be
selected by default
(checked) Turn off
Wizards, LazyCam You
can turn off Screen sets
unless you want to use
the Default MACH
screens to build your
own screens
(experienced MACH
users ONLY)
Make sure you leave
Parallel Port Driver
checked . Hit the NEXT
button
CandCNC
Page: 18
INSTALLING MACH3
SOFTWARE
INSTALL
C
Do not create any
profiles in this
screen. All of the
Profiles you will
need for the
BladeRunner
System will be
automatically
created in the next
section of the
software install
section
THIS IS AN
IMPORTANT
SCREEN. It indicates
that MACH is adding in
the Parallel Port Driver.
This is a Hardware
Driver installed into the
Windows Hardware list
and is used to
generate the high
speed outputs and
inputs needed for
proper operation of the
BladeRunner and the
CandCNC
Page: 19
MACH3 SOFTWARE
Basic Structure
SOFTWARE
INSTALL
C
MACH FILE STRUCTURE
SAMPLE FOLDER STRUCTURE:
Some folders are added for
specific options so your folder view
will not have all of the ones shown
on an initial install. The important
ones are listed below
This is located on the C:/ drive of
your Control PC.
FOLDER
From time to time if you add
features or certain upgrades are
installed there can be added
folders and/or changes to files. We
make available specific files that
upgrade files in this structure. In
some cases the user must open
the specific folder and copy the
new file into (or overwrite an
existing file) in a folder. Being
familiar with the structure makes
this process easier
CandCNC
CONTAINS
Bitmaps
Contains Bitmaps (custom backgrounds
and Buttons) for the custom screens.
CandCNC has a Folder under Bitmaps
for the specific bitmaps for our screens
GCode
Sample G-code for ROUTER. Do not
use except for testing motion it will not
work with plasma
Macros
Contains Sub-folders of macros for
EACH generated Profile. In the specific
sub-folder that are macro files. When
you call a macro by number from
code or internally it uses the specific
macro in the folder of the same name
as your running profile.
Plugins
A folder of plugins installed. The base
plugins for CandCNC are the ccc_comm
and the ccc_ubob. Others are installed
with options like the PN200. Every
plugin the folder will be “seen” by MACH.
The Configuration of a plugin
including enabled and disabled is
stored in the specific XML (profile) so
they can be differnt configurations in
different profiles
xmlBackups
Backup copies of the Profiles XML’s for
your system. Can be renamed and
copied back to the MACH main folder to
bring back a damaged XML. You should
STILL perform file backups onto another
media source of your XML files anytime
you change settings.
Page: 20
MACH2 LICENSE INSTALL
Manual Method
INSTALLING THE MACH 3 LICENSE *SEE UPDATE NOTES
1. Locate your Software Support CD. It is a separate CD from the Support
CD. If you purchased either of the CandCNC Software bundles you should
have the Software Support CD
A NOTE ABOUT THE
MACH3 LICENSE FILE:
The Mach1Lic.Dat is an Encrypted
file. You CANNOT open it. It
must be copied intact using the
steps below. Each License file
has a unique serial number issued
to CandCNC. We keep a
database of all licenses and in the
event you misplace your license
contact us and we can issue a
replacement.
2. Open the Software Support Cd to the top folder (root) and click on the README
FIRST .txt file. It will open in NOTEPAD. It will explain the licenses and the way
CandCNC can issue licenses.
If you already have a MACH license or have bought from another source the
procedure is the same but the location of the license file will be different
3. Select the Licenses Folder and then the MACH folder under that
If you have purchased a MACH3 license or Software bundle from CandCNC then In
that folder you will find a single file.
NOTE the new Master Installer V and later
To license MACH3.
1. Use File Explorer and RIGHT CLICK on the Mach1lic.dat file and select COPY
(this copies it to the Windows clipboard)..
2. Immediately Use File Explorer to navigate to the C:/MACH3 folder on your
system Hard drive (C:). Right click the MACH3 folder in File Explorer and select
PASTE from the menu. That will copy the file in the MACH3 main folder on your
control PC.
3. Open the MACH3 folder and display a list of the files in the righthand portion of
the Screen. Make sure the Mach1Lic.Dat was copied.
NOTE: MACH will load and run in DEMO mode without a license. It is fully
functional with the exception it will only run about 500 lines of code and advanced
features like the THC logic are not functional. You MUST have a valid license
loaded before you can use the DTHCII in MACH
CandCNC
Page: 21
SOFTWARE
INSTALL
C
MACH2 LICENSE INSTALL
AUTO Method
This method of install covers customers that have purchased a Software Bundle
at the same time as their equipment. The MACH3 license and SheetCAM license
can be installed automatically using the MASTER INSTALLER. As part of the install
you can select to install either or both licenses. You can come back later and use the
Master Installer to install other options including the software licenses
NOTE: WE DO NOT recommend installing SheetCAM on the same PC you
use to run MACH3 and your table if you are using the Parallel Port setup.
MACH3 needs 100% of the available resources and having other
applications or their related run-time drivers may cause problems with the
pulse train out of the parallel port. You can use the same CD and Master
Installer Menu to Install the SheetCAM Support Files and SheetCAM TNG
License on the PC you draw and use CAM.
CandCNC
Page: 22
SOFTWARE
INSTALL
C
CandCNC SUPPORT FILES
Install
THE FOLLOWING PAGES COVER THE INSTALL OF THE BLADERUNNER
CONFIGURATION FILES FROM A MASTER INSTALL (EXE) FILE
The Master Installer Auto Installer Files will automatically load all of the CandCNC support
files for MACH3. You must have MACH 3 (version 3.43.067) off this CD installed and
running first THEN run the appropriate selections off the Menu.
The installers will load both the Router and Plasma profiles and both ICONs will show up on
your Desktop. Each profile for MACH (XML) stands alone so if you want to use both you
must setup both profiles with the Motor Tuning and any other parameters that are exclusive
to your machine
For reference the full MACH3 Manual is in the Manuals Folder. You will also find the
BladeRunner AIO Manual there as well. We also post the latest manuals on our website
http://www.CandCNC/com/Manuals.htm. Expansion Cards (DTHC II & DTHCIV) have their
own manuals for install, setup and use.
If you have purchased the BladeRunner AIO Dragon Cut for plasma cutting you will also
need to refer to the DTHCII _Setup-Config .pdf
All Manuals are in PDF format. You will need to have the Adobe PDF Reader Or something
like Foxit) installed (Free) to view or print the manuals.
IF YOU DO NOT HAVE THE SUPPORT CD or it is more than 30 days since you received
your BladeRunner you should check http://www.CandCNC.com/Manuals.htm for the Master
Installer (ZIP) at the bottom of the page. You can download, unzip and run that installer
STRUCTURE OF THE SUPPORT CD.
Version of Master Installer is a Roman Numeral (”V” in this case = 5 decimal) and
will increment with each release. Check the website Manuals Page for the latest
release. NOTE THE WHAT TO DO FIRST-READ.txt. open that file with
Notepad and it will give you the latest basic instructions or changes
CandCNC
Page: 23
SOFTWARE
INSTALL
C
CandCNC SUPPORT FILES
Install
Master Installer, What it DOES:
1. Copies two PROFILES (XML’s) to the MAIN MACH Folder for each product
selected
2. Copies several Screen SET files to the MAIN MACH Folder depening on the
Menu selection
3. Creates a folder under MACH3/Bitmaps named CandCNC
4. Copies all of the bitmaps for the MACH screens to that folder
5. Copies the custom drivers (PLUGINS) to the MACH3/Plug-in folder
6. Opens the MACH3/macros folder and creates a folder for each Mach Profile
added in step 1
7. Removes default MACH profile links (Icons) from the Desktop
8. Installs any specail drivers like the C3BUS Hub and the Hub Utility for products
that need that
WHAT IT DOES NOT DO:
Load or install MACH3
Load or install any other software
Setup the MACH3 Profile (i.e motor tuning, axis slaving, etc) for your specific
table/machine
TO START THE INSTALL FROM THE CD OPEN THE CD TO THE STRUCTURE
in the ROOT folder of the drive and double click the MasterInstaller[V].exe file.
The install will start with a series of windows. In most screens you will just hit
NEXT.
CandCNC
Page: 24
SOFTWARE
INSTALL
C
CandCNC SUPPORT FILES
Install
Basic information
about the
CandCNC
software and
programs. Take
a couple of
minutes to read
the text (as
boring as it is) so
you will know the
details about
your CandCNC
products. We
have made the
custom drivers
and our software
as non-restrictive
as possible. It
does not limit the
resale or use by
a legal owner.
If you installed
your MACH3 in
the C:/ drive on
your Control PC
as we suggest in
the MACH Install,
Then just hit the
NEXT button on
this screen.
CandCNC
Page: 25
SOFTWARE
INSTALL
C
CandCNC SUPPORT FILES
Install
SOFTWARE
INSTALL
C
Master Installer Menu System
Starting with Master Installer the same installer is used for all CandCNC
products and a MENU selection system is used In version IV and higher the
menu has been expanded and the options to load licenses (if you purhcsed
them) is included. You will see a much expanded list of products reflecting
recent additions to our product line.
You may see this dialog if you have previously installed any components.
Select YES
CandCNC
Page: 26
CandCNC SUPPORT FILES
Install
SOFTWARE
INSTALL
C
SELECT NEXT
Select “Install”
CandCNC
Page: 27
SOFTWARE
INSTALL
C
Another screen of
information we
think you should
know so humor me
and please read it !
FINISHED!!
Once you have installed the Master Install file then you can start the final setup, calibration and basic motion
tests of your BladeRunner. You can always get back to the basic default values for a BladeRunner if you simply
rerun the install again, BUT BE AWARE that any configuration changes (including motor tuning etc) will go
back to the install defaults. The following page will cover how you can start the specific PROFILE
CandCNC
Page: 28
Starting The MACH PROFILE
SOFTWARE
INSTALL
STARTING THE BLADERUNNER PROFILE
From the the Desktop on the computer
Look for the C3 Icon and select the Plasma or
Router Profile to run. If the C3 icons are not
present you may find it installed them with a
generic icon like this
it will run from either Icon
HOW TO RUN FROM THE MACH LOADER:
The MACH LOADER ICON should still be on the desktop. It gives you
access to a MENU of installed profiles that exist on your setup.
Your display may have
more or less profiles than
the screen here. You need
to see at the products you
have selected in the install
menu. The DTHCIV will
have it’s own profiles and
screens
Your screen may look
different depending on
what you installed
There are several things you can do at this point.
1, You can highlight and delete unused profiles.
2. You can highlight and RUN a specific profile by clicking OK after you
highlight the file name in the list.
3, You can Create a NEW profile (see next page)
CandCNC
C
Page: 29
TO CREATE A NEW
PROFILE:
1. Select Create from the
previous screen you will get
a window similar to the one
on the left.
2. Type a new name in the
input box under New Profile
Name. Leave the Default
Profile Values Box
UNCHECKED
3. Find a Profile in the
Clone From List you want
to copy all of the settings
from.
4. Highlight the File you
want to Clone From.
5. Click OK
6. The new PROFILE will
appear in the selection list.
It will have all of the settings
of the PROFILE it was
Cloned from. It also sets up
a folder under the MACROS
folder with all of the same
macros the original had.
To make new profiles or to change the Profile Name DO NOT simply rename the
PROFILE (XML) in the MACH folder. It will show up the list as a new name but
there will be no corresponding MACROs folder so you may encounter problems
trying the run form that profile
.
IF YOUR RESTORE A PROFILE FROM A BACKUP or ANOTHER SOURCE of
the same name it will overwrite the exiting PROFILE and chagne all of the settings
to those of the backup.
NOTE: While a profile of another name contains all of the settings you may need
to run MACH it lacks the matching Macro Folder created during a Clone. You
should first create a Clone of an existing profile using the same name as the file
you wish to transfer in and THEN overwrite it with the imported file.
Page: 30
CandCNC
C
SOFTWARE
INSTALL
Working with
MACH PROFILES
C3BUS
INCLUDED IN THIS KIT:
1.
2.
3.
4.
5.
USB to RS485 4 Port Hub Module
Universal WallPlug Power Supply. 100VAC to 240VAC in, 5V DC out
USB A to USB B interface cable (6ft )
Installer/driver CD **
User Manual (PDF) **
** May be on Master Support CD in RS-485Hub4 Folder
Any trademark or logo used in this manual is the property of the trademark owner
CandCNC
Page: 31
D
BR HARDWARE
INSTALL
USER MANUAL RS485 4 PORT HUB
Setting Up RS485 4 port hub for use with
C3BUS
DTHC IV Ultra Fast THC
USE THIS SECTION TO INSTALL THE C3BUS RS485 3 PORT
Hub if you have the DTHC IV, Hypertherm Advanced Connection
Kit (Hyt-Connect RS485 SIM kit) or the PN200 48 function Hand
Controller. The C3BUS will be the universal BUS for CandCNC
equipment. New products from CandCNC will utilize the C3BUS.
YOU ONLY NEED ONE HUB PER SYSTEM. It is sold bundled or
separate. It is REQUIRED for the above listed products.
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
BR HARDWARE
INSTALL
D
C3BUS USB to RS485 4 PORT HUB
Handles all secondary (backside) communications to and from
the DTHC IV to MACH3. All screen readouts and all settings to
the DTHC IV are handle by the C3BUS. The HUB UTILITY
uses the same C3BUS to communicate with all the RS485
modules including the DTHC IV. It is essential the C3BUS be
installed and running BEFORE you attempt to setup the
DTHCIV.
RS485 4 PORT HUB (TOP VIEW)
PWR
Con ACT
USB
RS485 4 PORT HUB
(END VIEW)
RS485 4 PORT HUB (FRONT VIEW)
CandCNC
Page: 32
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
PWR
USB ACT LED shows
valid connection to PC
on USB channel
Con ACT
USB
To EPO on ESP front panel
or EPO on Table I/O
ACTIVITY MONITOR
LEDS
Standard CAT5 UTP up to 50ft
When a device is plugged into a
port on the hub the LED will light
if it has proper communications.
It does not mean the device is
operating correctly (see later
pages for using the Hub Utility).
The Activity Monitor shows send
and receive activity on the port
ARC
OK
Z
ON
SENSOR INPUT
DTHC
Steps
RESET
HOLD
To PWM Module
CandCNC
Electronic Controls for CNC
DTHC IV Digital Torch Height
To HUB
RS485
Port1 INPUT
C3BUS
CP PWR UBOB III™ Technology
To PC
CandCNC DTHC IV (parallel port) system shown
CandCNC
Page: 33
BR HARDWARE
INSTALL
Universal AC Power Plug
100VAC to 240VAC 50/60HZ
Regulated 5V @ 1A out
D
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug
Locations and
Layout
CONNECTION
EXAMPLES
The CandCNC C3BUS ™
USB to RS485 4 Port Hub
C3BUS™
RS485 4
Port Hub
CONTROLLER
PC
Mount close to PC
USB
6ft max
CAT
CAT5
5
up to 50
ft
up
CA
T5
to
t
f
50
PN200
DTHC IV
Mark IV
CAT5
HYPERTHERM
65/85/105
with RS485 Port
EZPlug II
SERVO
CandCNC
CandCNC
RS485
Cards
up to 50ft
CAT5
UBOB
Mark IV
48 function
Hand Controller
Relay
4X4 Driver
card
Relay
4X4 Driver
card
CandCNC
RS485
Cards
Spindle
SSpeed
Mark IV
NOTE: Example ONLY some of
the examples are not available
yet. Only ones in Yellow are
currently available. Names may
change and release dates are
not yet scheduled.
Page: 34
BR HARDWARE
INSTALL
D
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
1. Plug the USB-RS485 4 Port Hub wall plug power supply into an AC outlet.
NOTE: While the wall plug power supply has pins for standard US AC
120VAC sockets the power supply will work and run from any AC power
source from 100 to 240VAC 50/60HZ. You can purchase plug adapters from
several on-line merchants including Amazon.com for less than $2.00.
No voltage conversion is necessary.
2.. Using the included USB A to B adapter cable plug the B plug into the
matching jack at the end of the hub and the other end into any open USB jack
on the control PC.
Note: For testing you can load the drivers and CandCNC Hub Utility on any
PC or Laptop, but for operation you need to have the hub installed and
working in the PC that runs MACH and controls you machine
3... Windows will see the new hardware and will launch the Hardware Install
Wizard. Use the following screens to finish the hardware install.
First Screen of
Hardware
Install(Update)
Wizard.
Leave the radio
button set on the
“No, Not this time”
option and hit the
Next Button....
CandCNC
Page: 35
BR HARDWARE
INSTALL
D
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
BR HARDWARE
INSTALL
D
Next Screen of
Hardware Install
(Update) Wizard.
Leave the radio button
set on the
“Install the software
automatically”
option and hit the
Next Button....the
driver has already
been installed in the
earlier steps so you do
not need try to find the
driver manually
This screen
indicates the
software and driver
install for the
CandCNC USB to
RS485 4 port Hub.
has been
successful
See the following
pages for checking
the install and to
use the CandCNC
Hub Utility (Admin)
CandCNC
Page: 36
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
BR HARDWARE
INSTALL
D
4. To confirm that your USB-RS485 4 PORT HUB drivers have been installed, open the
System Application in Control Panel in Windows and then the Hardware Tab and the
Device Manager. You will see a “Tree Structure” of hardware devices. Scroll to the
bottom and Find the UNIVERSAL SERIAL BUS DEVICES and under it you should see
the CandCNC USB to RS485 hub device. IF YOU DO NOT then unplug the USB
connector (either end) and wait 5 seconds and plug it back in. You should NOT get the
Hardware Install or Update Wizard . The Device Manager should update and show you
the screen below. The CandCNC USB to RS485 hub device will only show up when it is
plugged in.
CandCNC
Page: 37
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
The USB Active (ACT) LED only comes on
when there is a valid USB connection to the
PC. Drivers have to be loaded and active.
USB ACTIVE LED
PWR
Con ACT
USB B plug to PC
USB
INSTALLING CandCNC RS485 Devices to the USB-RS485 4 PORT HUB
The USB-RS485 4 PORT HUB has an advanced processor that can communicate
with several RS485 devices. RS485 is a robust and noise-immune communications
standard used in industrial electronics for years. Because of its differential signal
methods it is unaffected by external or ground based noise and reliable
communications of several hundred feet are common. RS485 is a multi-drop
topology meaning there can be multiple devices on the same pair of wires as long as
all of the devices operate at the same speed (BAUD RATE) and have a unique
address. Since USB is a common port on most PC’s it is a logical choice for
communications that do not depend on precise timing.
You will note that the USB-RS485 4 Port Hub has four independent channels and
each channel can talk to multiple devices, Because of different Baud Rates or
special signals the 4 port hub has two special jacks:
1. Hypertherm RS485 Port. This channel runs at a much slower speed and can
only talk to a Hypertherm Plasma Cutter equipped with an RS485 port (optional) and
through our HyT-Connect RS485 interface. If you already have the HyT-Connect
RS485 SIM Kit installed and have the older single port (dual jacks) RS485 module
you need to unplug the existing setup and plug the RJ45 (Cat5) cable FROM the port
on the rear of the Hypertherm into the jack 1 marked “To Hypertherm Rs485 PORT.
CandCNC
Page: 38
D
BR HARDWARE
INSTALL
Plug
Locations
Layout
RS485
4 PORT
HUBand
- DEVICE
CONNECT
INSTALLING
RS485
PORT HUB
USB- RS485
4 PORT4HUB
Plug Locations
TAPand Layout
BR HARDWARE
INSTALL
D
This page shows connection of the optional
HYT-Connect RS485 SIM Kit. More
detail can be found in the HyT-Connect
RS485 SIM Manual. The RS485 option
to control plasma cut current is part of
the TAP product
Plugging RS485 Hypertherm into RS485 PORT on back of
Hypertherm 65/85/105
See HyT-Connect Manual for details on installing and
using the RS485 remote control for the Hypertherm
and the DCC (Dynamic Cut Control).
CandCNC
Page: 39
USB- RS485
4 PORT4HUB
INSTALLING
RS485
PORT HUB
Plug Locations and Layout
2. PN200 Hand Control. The PN200 hand control uses normal high speed baud
rates but the special “dead man” E-Stop to the EPO of any CandCNC controller
requires a special jack. The PN200 MUST be plugged into the PN200 jack to be able
to use the E-STOP safety (recommended). The PN200 has to be the last device in a
group of devices. The PN200 will worked plugged into other jacks on the 4 PORT
HUB (except JACK 1) but you cannot use the E-STOP option. You can also use the
PN200 jack on the hub for other RS485 devices if you do not have a PN200. While
the PN200 would work with other devices on the channel that have loop through (pass
through) jacks the E-STOP to EPO DOES NOT PASS THROUGH OTHER DEVICES.
3. DTHC IV High Speed Digital Torch Height Control. The DTHC IV uses the
RS485 (C3BUS) for the following:
, Transfer of screen information to MACH3 like Torch Volts, Torch Amps and the
status LED’s for Torch UP, Torch DOWN and ARC OKAY. Unlike the DTHC II that
uses defined parallel port inputs for the UP, DOWN and ARC OK, the DTHC IV sends
the data across the RS485. The only “hard” input from the DTHC IV to MACH3 is the
HOLD signal (mapped to INPUT 1 on Ports & Pins).
, Communication to the plug-in in MACH3 to update Z position when DTHC is
active(tells MACH3 where the DTHC has moved the Z while under THC mode)
, Pass parameters and settings in MACH to the memory of the DTHC IV. This
includes all of the DTHC Cut Profile Settings either from the screen or from the Gcode when using DCC
C3BUS MANAGING THE HUB
During the install the CandCNC Hub Utility was
added and an ICON was placed on your desktop.
Click on the icon to open the Hub Utility.
IMPORTANT: The purpose of the HUB UTILITY is primarily to confirm proper
communication with each device and to be able to do some base level testing . You
cannot run the Hub Utility at the same time as MACH is running.
The following screens show the CandCNC Hub Utility displaying information about different
devices connected to it. The Hub is “smart” and automatically detects any compatible device
connected to it. Review the screens that follow and understand what each section of the
screen is used for.
CandCNC
Page: 40
BR HARDWARE
INSTALL
D
USBRS485
4 PORT
C3
HUB
MANAGEMENT
INSTALLING
RS485
4HUB
PORT HUB
HUB
UTILITY
USING HUB
UTILITY
Application
DEVICE DETAILS
Provides the:
Device Name
Device Code: Each
CLASS (type) of device
has a different Device
CODE. Codes can be
from 1 to 99.
Device Address: The
unique address of a device
within a class (values from
1 to 8). Devices of the
same type must have a
different Device Address.
Future cards will have
address jumpers to allow
multiple cards of the same
type to work on the same
hub.
Firmware Version: This
displays the current
DEVICES:
Shows a list of
connected
devices. As a
device is
connected and
sensed by the
hub it will appear
in the list. If you
connect a device
and it does not
show up
immediately,
stop (close) the
application and
restart.
Hub Connected
(to USB on PC)
Displays current
firmware of the HUB.
This MUST show
connected status
before any other of the
functions will display.
TEST DEVICE
Action button that
opens a new
dialog window.
You must have a
device
highlighted in the
Devices List to
use the
Setup/Test
Device
Update Device Firmware.
This allows you to update
each module with new
firmware. New firmware
will be designated by a
REV number. Firmware
updates will be available
for down load in a special
download section of the
CandCNC website and on
the Yahoo
CandCNCSupport Forum.
The Hub Utility is an application provided to manage the C3BUS USB to RS485
4 Port Hub and the devices attached to it. With the utility you can:
Update the Hub Firmware (Firmware is the program that runs the hub)
Update Firmware in the Devises attached (like the DTHC IV)
Test basic communications
Test device functions
Device level diagnostics
Set some device settings
What you CANNOT DO:
CandCNC
Page: 41
BR HARDWARE
INSTALL
D
USBRS485
4 PORT
C3
HUB
MANAGEMENT
INSTALLING
RS485
4HUB
PORT HUB
HUB
UTILITY
USING HUB
UTILITY
Application
IMPORTANT!! This section covers some setup and testing of the DTHCIV module.
While the DTHC IV Setup and Config Manual should be used to do the actaul DTHC
IV part of the install you should do the minumum tuning listed to setup the Z motion
DTHC INFORMATION is direct feedback from the DTHC IV module and indicates the current status of the
unit . You cannot make changes or do inputs from this section. Since you cannot run MACH and the Hub
Utility at the same time these settings are primarily used for off-line diagnostics at the factory.
BR HARDWARE
INSTALL
D
Z MOTOR SETTINGS. This section is the most important because it sets the base motor
settings for the Z motor under DTHC control. You will find that the Max Velocity and
Acceleration will be much higher than your settings in MACH for the Z motor tuning. This is
normal because of the DTHC IV controlling the motion directly under THC. You should set this
as high as possible. Move the settings up and test the Z motion using the Full Speed Jog
buttons on the screen. The motor should move smoothly and rapidly both up and down. Lose
steps (or faults on a servo system) back the numbers off by 25%. The settings here are for a
stepper system with a 620 oz-in motor running a 5 TPI leadscrew. Your settings will vary but
you should be able to hit about double the velocity and acceleration of the Z motor tuning in
MACH. IT IS IMPORTANT THAT THESE SETTINGS BE OPTIMIZED for best response under
DTHC control. They will effect the Gain and Tracking settings for the DTHC.
THIS IS THE ONLY PLACE TO SET THE Z TUNING FOR DTHC IV . A MINIMUM INSTALL
REQUIRES YOU PREFORM THIS ONE FUNCTION IN THE HUB UTILITY.
DTHC SETTINGS. These settings are covered in the DTHC IV Setup and config Manual
CandCNC
Page: 42
USBRS485
4 PORT
HUB
MANAGMENT
C3
HUB
MANAGEMENT
INSTALLING
RS485
4HUB
PORT HUB
HUB
UTILITY
HUB
UTILITY
USING HUB
UTILITY
Application
Only the
devices you
have purchased
and have
connected will
show up in this
List Box
Opens choice to
update firmware.
This is the first
step in updating
the HUB
FIRMWARE.
Current Firmware Version
Select the highest release number.
New firmware can be found on the
Candcnc website (manuals page)
CandCNC
Page: 43
BR HARDWARE
INSTALL
MISC:
D
USBRS485
4 PORT
HUB
MANAGMENT
C3
HUB
MANAGEMENT
INSTALLING
RS485
4HUB
PORT HUB
HUB
UTILITY
HUB
UTILITY
USING HUB
UTILITY
Application
DEVICE TESTING: PN200 48 Function Hand Control
IF YOU DO NOT HAVE THE PN200 the device will not show up
in your devices list and this screen will not appear.
Joystick shows XY
position when stick
on the PN200 is
deflected. Confirms
operation or joystick.
L1 - L5 (lamps)
are indicators. You can
click on the L numbers
to turn on an indicator
on the PN200 to test.
Checking the box under
it will cause it to flash.
Multicolor LEDS will
change colors if you
click the L button again.
LED Fast Flash
changes.
ROTARY ENCODER
TEST
Enc1 (DTHC
PRESET) encoder
status. Rotating the
encoder will increase
the count clockwise
and decrease counter
clockwise.
Enc2 (FeedRate)
Does the same.
5 X 5 keypad
reflects button pushes on the PN200
keyboard and displays key number in the
Last Key DRO
IF YOU DO NOT
HAVE THE HyTConnect RS485
options the device
will not show up in
your devices list
and this screen will
not appear
CandCNC
Page: 44
BR HARDWARE
INSTALL
D
D
BR HARDWARE
INSTALL
BLADERUNNER AIO Dragon-Cut w/ DTHCII
BLADERUNNER AIO RIGHT SIDE VIEW
INPUTS FOR UBOB III AND EXPANSION OPTIONS
CLOSE UP VIEW UBOB MODULE
RIGHT SIDE
CandCNC
Page: 45
Connecting up the BladeRunner Control box. Take a look at the block
diagram, that gives an overview of the control box. Note that there are two
cables that run from the PC and connect to the BladeRunner box. These are
labeled Port 1, and Serial It's important that you connect the first parallel port in
the computer (normally the existing printer port or LPT1 port) to Port 1 on the
BladeRunner Controller box There are also other cables that connect three
satellite cards (Table I/O, and THC Sensor Module/VFD Interface Card) to the
BladeRunner-DTHCII or Spindle Speed as well. The Table I/O is connected
Internally and is not part of the connections to the PC.
1. Install a DB25 Male to Female extension cable (All pins straight through)
between parallel port (PORT1 on the PC to the part marked Port 1 INPUT
(Orange highlight below) on the front of the MP3000-DTHC controller unit.
2. Install a straight through DB9 Male to Female cable (not a null modem
cable) from your Com1 port on the PC to the Serial port on the
BladeRunner
PC Parallel Port 1
Serial Port
PC
DB25 M-F
15 ft MAX
DB9 M-F
15 ft MAX
CandCNC
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BLADERUNNER AIO Dragon-Cut w/ DTHCII
C3BUS HUB for DTHC IV interface to PC
D
BladeRunner Basic Connections when using Parallel port
and DTHC IV Ultra Fast THC
BR HARDWARE
INSTALL
BLADERUNNER AIO Dragon-Cut w/ DTHC IV
RS485 POR
T
T5
CA able
C
DB25 M-F
Cable
PC
C3BUS USB to RS485 HUB
USB
PORT
PORT1
Parallel Port
CandCNC
BladeRunner Dragon-Cut DTHC IV OPTION:. Uses
existing Parallel Port
(PORT1) DB25 cable connect and
C3Bus USB to RS485 (USB port) connection. See
section on installing and testing the C3Bus 4
Port Hub in this manual. Hub must be installed
before you can access the motor tuning for Z
Page: 47
BladeRunner Hardware
MOTOR CONNECTIONS
NOTE: For BladeRunner Servo system
please see the end of the F section for
the differences in the motor connections
A
Z
A1 A2 B1 B2
A1 A2 B1 B2
Y
A1 A2 B1 B2
X
A1 A2 B1 B2
HW SLAVE
A1 A2 B1 B2
IMPORTANT:
Screw Terminals
Face UP
1
!
It is important that the stepper motor wires are wired correctly. When
shipped from the factory the motors are wired right and each one is
tested with the unit. Because motors for other products we sell are
wired differently it’s possible a motor you order after the unit has
been shipped could be wired differently. DO NOT ASSUME THAT
THE COLOR OF THE WIRES IS CONSISTENT. We order wire from
different sources and cannot always define the wire colors. If you
take the connectors off for any reason either mark the wires by
position or use an ohmmeter to test for coil pairs (see Bladerunner
Manual PartII Service Manual). If you use any other motor or rewire
for any reason CHECK TO MAKE SURE THE COILS ARE
COLOR CODE MAY VARY
MOTOR SIDE
BladeRunner ESPII box
CandCNC
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BladeRunner Hardware
MOTOR CONNECTIONS
BLADERUNNER G251-4 MODULE FRONT PANEL FUNCTIONS
A
Z
Y
A1 A2 B1 B2
A1 A2 B1 B2
A1 A2 B1 B2
HW SLAVE
X
A1 A2 B1 B2
A1 A2 B1 B2
IMPORTANT:
It is important that the stepper motor wires are wired correctly. When
shipped from the factory the motors are wired right and each one is
tested with the unit. Because motors for other products we sell are
wired differently it’s possible a motor you order after the unit has been
shipped could be wired differently. DO NOT ASSUME THAT THE
COLOR OF THE WIRES IS CONSISTENT. We order wire from
different sources and cannot always define the wire colors. If you
take the connectors off for any reason either mark the wires by
position or use an ohmmeter to test for coil pairs (see below). If you
use any other motor or rewire for any reason CHECK TO MAKE
SURE THE CONNECTIONS ARE CORRECT USING THE METHOD
BELOW.
1
!
COLOR CODE MAY VARY
TESTING FOR PROPER MOTOR HOOKUP
Motor DC resistance per coil is
less than 50 ohms
Low OHMS
0.0
OHMS
Low OHMS
OPEN (no OHMS)
On OPEN most DVM’s show “OV”
Put meter on lowest OHMS scale
CandCNC
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BladeRunner Hardware
Block Diagram
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SWITCHED POWER
48V 12A MODULAR
POWER CONTROL
See next page
UBOB
AC Line Cord
Universal
Power
Pak
G251-4 Card
AXIS I/O
TABLE I/O
Table I/O
Multiple Inputs
Switches, probes, sensors
Connections to Motors
Expansion Module Option
DTHC
or
ISS-02
TO PC Port1
CandCNC
To PC Serial
(See Text)
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BladeRunner Hardware
MOTOR CONNECTIONS
OLDER PHOTO
D
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INSTALL
Some modules may have changer appearance or position
CrossFlow FAN
OPTION
BladeRunner AIO Cover Removed Inside View
UBOB III Advanced
Breakout Card
TABLE I/O
CARD
G251-4 Motor Driver
G251-SOLO
5th Axis OPTION
CandCNC
DTHC EXPANSION
MODULE OPTION
FAN-FUSE
END PLATE
Page: 51
BladeRunner Hardware
MOTOR CONNECTIONS
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CandCNC
ESP II
Enhanced Smart Power
ON
OFF
ON
OFF
DRIVE +5VDC TEMP POWER DRIVES TEST
FAULT
FAULT FAULT
OK
OFF
BLADERUNNER AIO FRONT PANEL
[Enhanced System Power II]
Located on the Front Cover of the ESPII Enclosure, the FRONT PANEL is
the Operator Interface for the ESPII and provides tactile pushbuttons to
turn the DC power to the Motors ON/OFF. The FRONT PANEL is a
SMART CONTROL utilizing a powerful microprocessor that monitors and
controls the power section of the BladeRunner AIO. The ESPII monitors
critical parameters, controls ON/OFF, and will automatically shutdown in
microseconds in the event of a fault. The ESPII monitors/controls:
1. System DC status
2, System Driver Status (enable/disable drives)
3. DC voltage level (overvoltage shutdown)
4. DC current (load) level (overload shutdown)
5. Internal Temperature (overtemp shutdown)
6. System Fault Indicators (LED’s and Screen Text)
CandCNC
Page: 52
BladeRunner Hardware
Normal Power up sequence:
1. Operator turns on MAIN POWER SWITCH. +5VDC LED comes on; RED OFF LED
comes on; DRIVES OFF LED comes on. All LEDS may sequence on once during processor
turn on.
2. Operator pushes ON Button. ON LED turns Green OFF LED goes off. Power comes up
on DC bus. Approx 2 sec later Drives OFF LED goes off and MOTORS LOCK
ON Button:
OFF Button:
Sends Signal to
Processor to turn
on DC Power to
the Motors.
Sends Signal to
Processor to turn
OFF DC Power to
the Motors.
CandCNC
ESP II
Enhanced Smart Power
ON
OFF
ON LED
OFF LED
On Green
whenDC power is
on.
On RED when DC
power is OFF
ON
OFF
DRIVE +5VDC TEMP POWER DRIVES TEST
FAULT
FAULT FAULT
OFF
OK
CandCNC
Multi-Axis Controller
Power Dashboard. Displays status and FAULTS
See Chart on next page to decode FRONT PANEL
indicators
IMPORTANT INFORMATION: The ESPII provides multiple levels of
protection for the system and the motor drivers. Electronic fusing will
shutdown power in milliseconds as opposed to conventional fuses.
The Primary AC has two levels of control. The MAIN POWER
SWITCH and the in-line SAFETY RELAY (controlled by the FRONT
PANEL. The Safety RELAY controls AC power to the DC power
supply section. Besides Electronic fusing the system also provides
failsafe conventional fuses/breakers. There are two levels of
conventional fusing on the DC power side. The locations and values
of the conventional fuses are in the ESPII service Manual.
CandCNC
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FRONT PANEL LED LEGEND
Note: LED!s flash several times on intial power up. Pushing
recessed TEST button will test all LED!s and show common
patterns for comparison
INDICATOR
Color
DRIVE
FAULT
RED
DRIVE
RED
DRIVE
RED
DRIVE
STATE
1 flash
/pause
MEANING
X Drive Fault
NOTES
A Drive Fault indicates a shorted
motor/cable or a failed Motor
Driver.
Z Drive Fault
RED
2 flash
/pause
3 flash
/pause
4 flash
/pause
DRIVE
RED
5 flash
/pause
5th Drive Fault
+5 VDC OK
GRN
ON Steady
+5 is ON/OK
Shows power on and logic
supply OK
TEMP FAULT
RED
1 flash
/pause
Case Temp
Fault
Internal Case Temp is too high.
Check fans and filters
POWER
FAULT
RED
Fast Flash
Power
Overload
DC POWER
Too Much Current drawn Auto
Shutdown. Overload of power
Module(s)
POWER
FAULT
RED
Slow Flash
Over Voltage
DC Volts Exceed max for safe
operation. Line surge or back
EMF. Auto Shutdown
DRIVES OFF
YEL
ON Steady
Drives
Disabled
Only on BladeRunner. Shows
drives are freewheeling
(disabled). Normal condition
during.power up and
faults/shutdown
TEST
YEL
ON Steady
Test Mode
Unit is in self test
TEST
YEL
Flashing
Config Error
MODE Configuration error or
unplugged module.
CandCNC
Y Drive Fault
A Drive Fault
May indicate misconfigured
Slave Axis Setup
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BladeRunner Hardware
MOTOR CONNECTIONS
BladeRunner Hardware
MOTOR CONNECTIONS
Load and Testing MACH
After you have installed MACH and run the BladeRunner INSTALL on the Support CD, open
MACH3 using either the MACH Loader and the BladeRunner selection from the list OR using the
BladeRunner Icon created in the desktop.
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You should see the following screen or something very close. If you are missing the Desktop icon or
it’s not in the selection list, re-run, the INSTALL again. If you have the Profile (BladeRunner) listed in
the MACH LOADER and the screen does not display, go to the top menu bar and select VIEW/Load
Screens and navigate to the MACH3 folder and select BladeRunner-Router.set. If it is missing any
of the Bitmaps (picture buttons and/or backgrounds) then confirm the Installer created the CandCNC
folder under the MACH3/Bitmaps Folder and there are files in that folder. We have included a Zip
file on the CD of all the bitmaps and the ZIP file is on the CandCNCSupport Forum site in the
FILES/BladeRunner Support Files Folder. You can UNZIP the files in the Bitmaps.ZIP file directly to
the MACH3/Bitmaps/CandCNC folder. Along with bitmaps and other features the BladeRunner
screens contain several custom functions embedded as code behind certain buttons. If you elect to
use another screen SET file with the BladeRunner be aware some functions will not work. The
DTHC screens have specific functions and the DTHC functions will not work on other screen
sets.
Typical Router Screen with TAB Flyout
CandCNC
TAB OPTIONS
Page: 55
BladeRunner Hardware
MOTOR CONNECTIONS
CUSTOM CandCNC Screen SET provided with
BladeRunnerAIO UBOB3 Profile from the Master Installer
file. Some features may change over time. DTHCII
specific functions are covered in detail in the DTHCII User
Manual Added controls can be accessed with TAB
(flyout)
BladerRunner DTHC
PLASMA PROFILE SCREEN
CandCNC
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BladeRunner Hardware
Screen Sections explained
MOTOR CONNECTIONS
MACH3 TOP MENU. POPS up windows on top of the screen to access various settings. Three most
used are: 1. Files 2. Config 3 View. This menu row is visible and can be accessed from all screens
MENU SCREEN SELECTION. Consists of tabs to select different screens. In normal run mode the
PROGRAM RUN screen is the most used. The DIAGNOSTICS screen is used to confirm proper settings
and functions and will be covered later
DRO (Digital Readouts) for axis position and for manual referencing and zeroing the DRO’s
REF buttons move an axis towards an associated HOME switch. When the axis hits the switch
It will stop and backup slightly. If it moves the wrong way or does not move at all see the section
on CONFIG/HOMING & LIMITS
Current G-Code File Loaded or running
RUNNING PROFILE Box Shows the current MACH PROFILE you have running.
Function Buttons allow
control of the G-code,
Loading and Closing Gcode and a rewind to the
start button
REF XY Button,
performs a REF move
on XY at the same time
but not on Z. Useful on
plasma after the first
REF has been done to
locate 0.0
JOG ENABLE Button
Turns keyboard jog on/off
(should stay on normally)
FRO Feedrate Override
changes feedrate on all
Axis at the same time
CandCNC
Loaded/Running G-code
screen shows g-code as it is
executed. Stopped code can
be scrolled and new start points
selected. The code can be
Edited using the Edit G-Code
Button
Function Buttons allow control
of the G-code, Loading and
Closing G-code and a rewind to
the start button
LOAD MATERIAL button
initiates a move to a preset
postion
OUTPUTS ON/OFF Buttons
Turns on/off the two AUX relays
(table i/o Card). Bladerunner AIO
has two wired AC sockets that are
controlled from these buttons
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BladeRunner Hardware
MOTOR CONNECTIONS
DTHCII SCREEN SECTION.
A detailed breakdown of all the buttons
functions and readouts on the DTHCII section
are covered in the DTHCII User Manual
(separate manual) Only general descriptions are
covered here.
UP/DWN and Send to DTHC Button. Any value
typed into the PRESET VOLTS and ENTER is
used to lock the value inthe DRO is instantly
transferred to the DTHCII memory when the
Send to DTHC button is hit. The User/operator
can quickly change the PRESET VOLTS before
or DURING a cut and change the ARC GAP in
the process
TORCH AMPS Displays the action Cutting AMPS
IF the CandCNC DCP01 Digital Current Probe
has been installed. Otherwise it reads zero. IT IS
NOT USED FOR THE CUT CURRENT PRESET
value.
THC ON/OFF turns the THC function In MACH
ON or off. The DTHCII can turn this on
automatically when the torch fires (setting in the
Cut Profile) Operator can turn the THC on/off
manually. When THC is off MACH ignores any
commands from the DTHCII to move the Z
INDICATOR LED’s
TIP SAVER (turns on when TIP
saver is active. TIP SAVER is a
dynamic anti-dive that keeps the
torch from diving on corners or when
crossing a void or existing kerf
UP/DOWN/ARC OK shows the
statues of those inputs from the
DTHCII. These are the
COMMANDS from the DTHCII to
MACH.
DTHC ONLINE shows the
communication status of the DTHCII
module to MACH3. It MUST be on
to allow MACH to display screen
values and to allow Cut Profiles to
transfer to the DTHCII
CandCNC
TORCH ON/OFF toggles the torch (OUTPUT1)
on/off manually from the screen. The torch can
be turned on or off at any time MACH is out of
RESET....even during a run
STORED SETTINGS (CUT PROFILES). This
button opens a window that displays a range of
values and settings for the DTHC to use. The
initial display is of the CURRENT SETTINGS in
the DTHCII memory. Profiles by material can be
recalled. selected and added. Detailed use of the
CUT PROFILES is covered in the DTHCII User
Manual
IMPORTANT: There are Self-Tests that can be
preformed on the DTHCII modules and other
modules in the setup. They establish that the
modules are functional and sending data to
both the parallel port inputs and the PC serial
input. If you do not have proper display of
values while cutting or the DTHC ONLINE is
not ON you are missing critical signals. See
the DTHCII User Manual to run the tests
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BladeRunner Hardware
MOTOR CONNECTIONS
STOP Stops Gcode execution
instantly (dumps
buffer) Turns off
ouputs
RUN (Cycle Start)
runs g-code that
is loaded . Will
restart g-code if in
PAUSE or STOP
NOTE: To stop gracefully (no lost
position) use the FEEDHOLD and
after machine motion has ceased use
the STOP.
CandCNC
RESET (Toggle
ON/OFF) Stops all
code, Turns off all
ouputs, Stops any
macro. Turns off
Charge Pump
Toggle turns
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FEEDHOLD Pauses
G-Code at end of
buffer. Leaves outputs
active
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BladeRunner Hardware
MOTOR CONNECTIONS
FAULT - ERROR Message box. Scrolls FAULT messages from CandCNC ESPII and other
“smart” devices. Shows drive faults, Power Faults and Hypertherm Fault messages for
units equipted with otions RS485 port and optional HyT-Connect RS485 SIM Kit.
ERROR messages are information and critical messages from the MACH system.
Diagnostics Tab
Used to test and diagnose general Input and output problems and to do test runs.
CandCNC
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BladeRunner Hardware
Diagnostics Tab Controls
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AXIS CONTROL Diagnostics: Has the same DRO’s the same Axis ZERO buttons
and manual REF buttons as the Program Run Screen so the User can see the
numbers without have to flip back and forth. When troubleshooting you can see
activity on an axis and do setup if needed.
INPUT STATUS BOX: Shows the Inputs as they are mapped in MACH. The Inputs are
YELLOW when ON (active). The inputs should all be OFF (grey) when the system is first
turned on and MACH is out of RESET. There MAY be an Emergency (E-STOP) on if the DC
power to the motors is off on the BladeRunner. The Limits will seldom light because as soon
as a LIMIT goes active, to puts MACH in RESET and the INPUTS are no longer displayed
correctly. It turns the LIMITS OFF as soon as the LIMIT goes active. The indication a LIMIT is
working is if when hit it puts MACH into RESET. The setup or HOMEs and LIMITS will be
covered in later in this manual. Use the INPUT Status to test the individual inputs. Please
note that Inputs FIRST hit specific pins on the parallel port and the MACH PROFILE
determines what each one does so if you have inputs that are not correct the first thing to
check is the RAW PAORT INPUT BITS on the following pages.
OUTPUT STATUS: Displays the status of the OUTPUTS/ Active outputs FLASH RED
(not on steady) It uses the mappings in MACH to activate a specific out NAME. The
physical output that is matched to is set in the PROFILE (Ports&Pins/Ouput Signals)
When you activate an output like the TORCH Output or Outputs 1 and 2 you should see
them start and flash in the OUTPUT STATUS BOX. It does not mean the actual output
signal name is active only that the signal is active and if mapped properly should activate
the specific output on the BladeRunner. See the section on setting the OUTPUTS
CandCNC
Page: 61
BladeRunner Hardware
Diagnostics Tab Controls
NOTE: The number of output relays can be expanded by adding in a Quad Relay
Expansion card but is seldom used so connections and setup are not covered here
On a BladeRunner Dragon-Cut (with DTHC) OUTPUT 1 in MACH is used to turn on
the TORCH Relay located out in the THC SENSOR PWM. Operation is covered in
depth in the DTHCII User Manual but it is easy to simply plug in the THC SENSOR
PWM module to the DTHCII module using the 25ft UTP Cable and test the TORCH ON
by toggling the TORCH button on the Diagnostics Screen and watching the TORCH
LED on the front of the THC SENSOR PWM module. You can test the other two AUX
outputs by plugging in the AUX AC cable and plugging in an AC load (table lamp,
120VAC FAN . etc) and toggling the individual outputs on and off.
The AUX outlets can also be turned ON and OFF from G-code using an “M” command.
What M command is used to turn on/off an OUTPUT is a setting in MACH and comes
defaulted so a M03 or M04 turns on OUTPUT1 (Torch on the Plasma Profile, Spindle
on the Router Profile.) M05 turns OFF either. In a full Spindle Speed System the M04
turns ON the REVERSE RELAY.
The two AUX Relays (See Setting Outputs Section) are located on the TABLE I/O.
Control OUTPUTS
from
DIAGNOSTICS
SCREEN via the
Toggle Buttons for
each output,
NOTE: Only 3 Outputs are availaible on a BladeRunner AIO
Dragon-Cut (Large buttons above). The Router setup only has
2 outputs available.
CandCNC
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OUTPUT Status (Cont). There are two AUXILLARY OUTPUT Relays on a
BladeRunner AIO unit. They are designed as Output 1 and Output 2 on the Buttons
and they toggle ON/OFF the AC Outlets A and B on the end of the BladeRunner Box.
These AC outlets are wired to the AUX AC line cord on the BladeRunner. That cord
must be plugged in before the outlets can be used. CAUTION there is high voltage
(120VAC ) at the Relays and the Outlets. DO NOT OPERATE THE BLADERUNNER
WITH THE AUX AC CORD PLUGGED IN AND THE TOP COVER REMOVED.
BladeRunner Hardware
Diagnostics Tab Controls
Diagnostics Screen allows you to LOAD
and RUN G-CODE files and to see the
scrolling G-CODE. To load a G-Code file
move to the top tool bar and FILES/Load
GCode and select the file to load. It will
appear in the G-Code window. There is a
small Toolpath display under the G-CODE
window and the dispaly can be turned
ON/OFF with the buttons under it.
To RUN, Feedhold, STOP, Rewind of
SINGLE STEP from the Diagnostics
Screen use the Buttons shown.
There are status LED’s for UNITS and to
show running status and Dwell.
USING SINGLE STEP TO TROUBLESHOOT
CODE:
Often a mistake in G-Code or the setup is hard to
spot because it runs faster than you can watch the
machine and the code execute. The SINGLE
STEP can help with that. It puts MACH in “Single
Block mode” which means it will execute ONE
LINE (block) of G-Code at a time. It does this by
clicking the RUN button each time you want the
next line of code to execute. On a plasma we
recommend you turnoff the plasma and disable the
AUTO THC ON (Cut Profile) before using the
SINGLE button. With the SINGLE Button on (LED
ON) you can run a line, watch the moves, take a
measurement if needed and see if the motion is
correct.
CandCNC
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BladeRunner Hardware
Diagnostics Tab Controls
Other things you can control from the Diagnostics Screen:
1. JOG ON/OFF (unusually left ON)
2. Set the SINGLE STEP Jog Increment (Cycle Jog Step)
3, Change the JOG MODE from CONTINIOUS to STEP. STEP MODE only
moves the axis the JOG INCREMENT each time you hit the Jog button.
4. Change the SLOW JOG rate (no SHIFT with a JOG KEY = Slow jog).
You can use the UP DOWN buttons or type in the value in the DRO (hit
enter to “SET” the value)
5. Turn the THC Logic in MACH ON/OFF
6. Enter a new TIP VOLTS (PRESET VOLTS) value [Enter Key to Set] and
then SEND to DTHC (change the running value in the current DTHC
configurations
While most of the controls are on the Program Run Screen of MACH the
DIAGNOSTICS SCREEN lets you monitor inputs/outputs and position while
running manually or via code. While there is a lot of information and buttons it
offers the feedback you need when doing the intital setup or troubleshooting of
a system. Earlier in the PC Hardware Section you see how the RAW PORT
INPUT BITS shows if the Parallel Port is properly configured and respondiing.
CandCNC
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BladeRunner Hardware
SETTING UP MACH3 FOR BLADERUNNER
For systems using Parallel Port primary interface
When you install the BladerunnerAIO-UBOB3-using the Mastger Installer (auto
installer) it idiomatically sets up two profiles in MACH, One for Router and one
for Plasma with DTHC interface. The following pages will go though how to
test and change any of the default settings for your specific table.
There are several sections of the MACH CONFIG that we will cover. The
access the MACH3 direct configuration menu find the TOP Menu on the
screen and click the CONFIG select in the Drop Down Menu
The selections in the CONFIG
Drop Down Window (DDW)
consists of several sections.
Most of them are not used
setting up a BladeRunner
Profile. If you don’t know what
a function is DO NOT change it
unless you make a copy of
your Profile and perform the
changes on it. Making changes
to see what it will do is
dangerous because cetain
settings are critical to the full
operation of UBOB III.
A note here about configurations and MACH3
The config menu is a user interface to make changes to the current MACH3
PROFILE you are running. Each Profile has it’s own file with settings. Virtually
every setting is stored in that PROFILE. Things like Motor Tuning, Ports & Pins
and even which Screen Set it uses are stored. If you make a change in one
profile it DOES NOT propagate over to another profile’s settings!
If things get really messed up you can reload from the INSTALL file off the CD
but if the PROFILE name is the same then the settings go back to the Defaults.
Each time you make a change in CONFIG it gets stored in an XML file with the
same name as the displayed Profile in the Program Run screen. IT ONLY
SAVES THE RUNNING PROFILE WHEN YOU CLOSE MACH NORMALLY.
MACH only reads the Profile when you start it up to a specific profile. Some
settings will change the RUNNING profile (what you are currently running)
OTHERS DO NOT. Plugins are only read once when MACH is started so a
chage to a plugin config will require you stop and restart MACH3.
CandCNC
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CHECKING MACH3 CONFIG for Proper PORT1 ADDRESS
In the PC Hardware Setup Section of this manual the PORT 1 Address was
determined. Use the CONFIG/Ports&Pins menu to check the address and if
needed change the settings. Note PORT #2 is disabled. Default Kernel Speed is
45000HZ which will work with most PC’s and will provide pulse rates for any
BladeRunner setup except perhaps the Servo system. Seethat section for more
details
CandCNC
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BladeRunner Hardware
CHECKING AXIS MOTION (4 Motor systems)
Setting up the Software Slaved Axis. BladeRunner 300-4 and 620-4 are shipped with 4
motors but the A axis is NOT SLAVED in the default setup. You will need to decide
the axis naming convention you will be using for X & Y. There are several schools of
thought here. The old convention is to call the “long” axis X and the short axis “Y”.
This can make for some confusion as to how to layout files to be cut if the operator
station is not facing perpendicular to the long axis. Our approach has always been to
use the computer screen layout where the vertical (UP and Down) on the screen is Y
and the horizontal on the screen (side to side) is X. That is the way the software will
want to designate the axis on the computer by default. In the following pages we show
typical setups and operator position. The goal is to have the toolpath oriented the
same way as it shows on the computer drawing in relation to where the operator stands
at the table. The recommend placement of HOMES is based on the fact that normally
the lower left corner of the drawing is defined as the 0, 0 (origin) of the drawing and the
resulting G-code from the CAM if it follows the same convention.
!
NOTE: IF YOU HAVE A 4 MOTOR SYSTEM, the A axis should be software slaved
to the axis you have designed as the Gantry motion axis (X or Y). We do not have
that setting as a default because we do not know which axis you will designate as
the gantry motion axis.
To slave the axis in software: Open MACH3 CONFIG/AXIS SLAVING
Select the Axis you wish to slave the A to (X or Y and click the A radio button on that
axis.
If you have a 5 motor system. A 5 axis slaved (sometimes called a 4.5 system)
Hardware slaves the 5th motor/driver using settings on the UBOB card. Factory
default is for the 5th axis to be slaved to the Y motor and turn in the opposite
direction. The above Slave Axis Selection is set to None on all axis (no slaving).
The A axis then is independant and is activated for testing with the numeric pad +
and - keys by default.
CandCNC
Page: 67
BR HARDWARE
INSTALL
D
BladeRunner Hardware
TABLE SETUP SUGGESTIONS
D
X, Y Homes
0, 0
Typical rectangular
table setup
4 motor setup (dual drive
on the gantry)
Z axis w/ torch holder
X axis
If you stand here to run the machine
then 0, 0 is lower left corner from your
location. X is cross axis (long axis)
BR HARDWARE
INSTALL
Set your table and control console up so you
cut in the same orientation that you draw in
where side to side is always X
Master
Motor
Slave
Motor
GANTRY
Z axis w/ torch holder
(alternate mounting)
X, Y Homes
0, 0
If you stand here to run the machine
then 0, 0 is lower left corner from your
location. X is cross axis (short axis)
X axis
CandCNC
Page: 68
ONLY USE THIS PAGE IF YOU HAVE A 5th AXIS CARD INSTALLED or INSTALL ONE LATER
Even if you decide not to use the 5th axis the unit is shipped from the factory setup to use the
5th axis as the default Slave axis (HARDWARE SLAVE) If you decide NOT to use the Hardware
Slave and instead want to use the A axis as a software slave then YOU MUST break the Hardware
Slave using the Jumper Settings below. If you elect to ignore the instructions and leave the settings
as a Hardware Slave and try to use the A axis hardware slaved also, you will get DRIVE FAULTS on
the (unused) 5th axis.
5 AXIS SYSTEM
FACTORY DEFAULT
Hardware Slave shown in “Y” Position
Both OPTION BLOCKS MUST be jumpered
the same.
1-2 External drive FROM PORT2 card
3-4 Slave 5th Axis to X
5-6 Slave 5th Axis to Y
1
2
J63
2
Factory Default setting if
5th axis not used. Do not
change unless you are
going to use a 5th driver
and motor.
1
4
3
5
6
5
6
DIR
5
1
2
1
J63
2
4
3
6
5
6
Axis Slave
STEP
4 AXIS SYSTEM
FACTORY DEFAULT
AXIS I/O
1
In order to run 5 separate (independant) axis (not hardware slaved)
you have to install and setup a 2nd parallel port card in your PC
and interface it through our OPTIONAL Port2 Interface Card. See
the addendum section for information about the Port 2 Interface
THE UBOBIIII card in the drawing is located in the Top of the
BaldeRunner AIO unit, The PORT1 and COM1 connecors stick
through the apnel on the right side of the enclosure, see the photo on
page ___tp locate the UBOB Card
CandCNC
Page: 69
BR HARDWARE
INSTALL
D
ONLY USE THIS PAGE IF YOU ARE GOING TO DRIVE A 5th MOTOR FROM THE
MTA150 Card. or in the BladeRunner It sets up what that output (B) does. If you want to
SOFTARE slave an axis that is done in MACH3 in the Axis Slaving under CONFIG.
TABLE I/O
1
26
Pull pin 26
+9 FLT
U55
+
1
U1
J53
1
PLUG
U7
J53 REAR
SERIAL
U10
C5
+
CandCNC
UBOBIII
REV5
U5
AXIS I/O
1
GND +12
DTHC
AXIS
I/O
Pull pin 26
EXPANSION
+
16
15
J4
2
R6
RN1
1
J63
+12
J9
AXIS
OUT
J65
POWER
PORT2
SIP2
EPO B-PASS
J6
RN2
+
+
25
U2
SIP1
U3
1
1
J2
24
See previous
page for Hardware
slaving option
jumpers
PORT2 INTERCONNECT
J57
FAN
1
TABLE I/O
J3
C11
J1
1
14
PLUG
PPORT1
+
PARALLEL
U51
SERIAL
+5
+
CandCNC
UBOBIII
1
SIP4
DIR OPTION
NORM REV
J5
1 2 3
REV5
SKT
J29
DIRECTION POLARITY JUMPER
(New on UBOBIII REV5 cards)
This option is used ONLY if you are hardware slaving the 5th axis option from the X or
Y. It allows you to change the direction of rotation of the 5th motor if needed. You can
reverse a stepper direction at the motor simply by swapping the polarity of one coil
(out of the two) Wile that works for steppers you cannot reverse the direction of a
servo that way. We have added the Direction Polarity Jumper to allow you to reverse
the DIR signal polarity in hardware. To reverse the direction simply move the jumper
from 1-2 to 2-3 position,
DIR OPTION
NORM REV
J5
1 2 3
CandCNC
Page: 70
BR HARDWARE
INSTALL
D
D
BR HARDWARE
INSTALL
REV14 UBOB used with DTHCII based
Systems
CandCNC
Page: 71
D
CandCNC
BR HARDWARE
INSTALL
REV14 UBOB used with DTHCII based
Systems
Page: 72
TABLEI/O
TABLEI/O
J67
J66
1
J3
REG1
1
26
L1
1
SIP4
4
2
GND +5
10
1
GND+12
J7
SerialtoFP
DTHC
IV
+
2 3 4 J53
1
DTHC
SELECT
C11
J12
SIP5
J13
14
EXPANSION
J68 DTHC
4
3
2
1
J11 ZAXIS
OPTIONS
U7
3
MUXSELECT
DTHCIV
U1
5
6
D20
6
5
1
J15
J56
PORT2
J11
6
IV
3
DTHC
II 1
+
AXIS I/O
4
+ DTHC5
DTHC
J4
26
+
1
U53
1
2
DIROPTION
REV NORM
J5
3
1
3
2
+
C20
PCSERIAL
+
J6
1
+
II
1
1
16
15
Y
3X
1
AXIS I/O
BPort
PORT2
2
Y
X
B
2
2
+
STEP
J65
+12
POWER
C
T1
OPTIONS
DIR
J63
J8
R65
SIP2
U9
5thAXIS
+10FLT
SIP1
U2
UBOBIII
REV15
R7
D17
PPORT1
+5
CP
+
EPOB-PASS
ONforByPass
SIP3
CandCNC
12/13
SKT
J29
DTHC IV Conventional Single Parallel Port
DTHC
IV Conventional
Parallel
Port5th axis
J63 and
J65 used
same way to Single
hardware
slave the
TABLEI/O
TABLEI/O
J67
J66
1
J3
REG1
1
26
L1
6
U7
3
SIP4
10
1
1
4
2
DTHC
IV
DTHC
GND+12
EXPANSION
J7
SerialtoFP
1
+
2 3 4 J53
J68 DTHC
SELECT
3
2
1
J11 ZAXIS
OPTIONS
C11
J12
SIP5
26
+
1
U53
1
2
DIROPTION
REV NORM
J5
3
1
D17
CP
+5
2
3
+
C20
PCSERIAL
UBOBIII
REV15
R7
PPORT1
6
5
DTHC
IV
3
DTHC
II 1
4
J13
14
U1
5
MUXSELECT
DTHCIV
J15
J11
1
4
+
DTHC
J4
+
AXIS I/O
2
J56
PORT2
1
+
+
J6
1
1
II
1
AXIS I/O
BPort
16
15
Y
3X
+
2
Y
X
B
2
PORT2
+12
POWER
C
GND +5
T1
STEP
J65
D20
6
5
OPTIONS
DIR
J63
J8
R65
SIP2
U9
5thAXIS
+10FLT
SIP1
U2
+
EPOB-PASS
ONforByPass
SIP3
SKT
J29
CandCNC
12/13
DB 25 mounts to front panel for port 1
to PC cable
DB25 MALE
CandCNC
Page: 73
D
BR HARDWARE
INSTALL
UBOB REV15 used in all DTHC IV Bladerunners,
MP3100 systems
BR HARDWARE
INSTALL
D
UBOB III REV 15 Standard Cables
used on ALL configurations
TO TABLE I/O CARD
TABLEI/O
TABLEI/O
J67
J66
1
J3
TO DTHC CARD
Table I/O Card located inside
BladeRunner and Plazpak
products
REG1
1
DTHC IVL1 Interface cable
1
U7
3
3
DTHC
II 1
4
U1
5
14
1
10
DTHC
J7
SerialtoFP
1
+
2 3 4 J53
C11
J12
SIP5
26
+
1
PPORT1
DTHC
IV
SELECT
4
3
2
1
ZAXIS
OPTIONS
J13
EXPANSION
J68 DTHC
MUXSELECT
SIP4
2
GND +5
6
IV
J11
4
D20
6
5
1
+ DTHC5
DTHC
J4
J11
6
DTHCIV
+
+
AXIS I/O
1
2
J15
1
1
J56
PORT2
1
AXIS I/O
+
U53
1
2
DIROPTION
REV NORM
J5
3
1
D17
+5
3
+
C20
PCSERIAL
UBOBIII
REV15
R7
CP
2
+12 from
system bias
supply
+
J6
PORT2
II
2
Y
3X
16
15
Y
X
B
2
J65
+12
POWER
C
T1
STEP
BPort
AXIS I/O TO G251-4 or
MTA 150 Card
SIP1
OPTIONS
DIR
J63
J8
SIP2
U9
5thAXIS
+10FLT
R65
+
EPOB-PASS
ONforByPass
U2
GND+12
26
SIP3
SKT
J29
CandCNC
12/13
AXIS I/O STEP & DIR Signals
See previous pages for
Jumper settings and cables
for different configurations
On MP3100 and MP3500 systems the
Axis I/O ties to the MTA150 card either
internally or via a DB25 cable connection
depending on the model
CandCNC
Page: 74
1. Make sure the PC connections have been made and the PC Hardware ports setup
as per previous sections.
2. Plug in all the motors. Orient them like they are going to be mounted. Label them
if they are not on the table.
3. Turn on the main power switch on the end of the BladeRunner ESPII box.
4. Turn on Motor DC using the Front Panel ON (White ) button.
5. Check to make sure the motors “lock” and that you have a Green ON LED
6. Start MACH3 with the plasma or router profile (desktop Icon).
7. Switch to the DIAGNOSTICS TAB in MACH
7. Jog the axis in turn using the keyboard Jog keys
a. Left and Right Arrow --> and <-- should jog X axis
b. Up and Down Arrow should jog Y axis
c. PageUP and PageDown should Jog Z axis
8. STOP! If you cannot get an axis to move or or it only moves in one direction:
a. Check to make sure the associated DRO is changing on the screen
b. If it is then check all of your cables from the parallel port
c. If you have DRO action and still fail to get motion in both directions, turn to
the Service Manual Section. See the section on troubleshooting port problems.
9. If you have motion on all attached motors then proceed to the next section
DEFAULT HOTKEYS (BladeRunner Profiles)
F1
Esc
~
!
1
`
Tab
@
2
Q
Caps
Lock
Shift
Ctrl
F2
F3
#
3
$
4
W
E
A
S
Z
F4
%
5
X
^
6
R
D
T
F
C
F5
G
V
Alt
F6
F8
&
7
*
8
(
9
Y
U
I
H
B
F7
J
N
M
F9
F10
F11
|
\
)
0
_
+
-
=
O
P
K
L
<
,
>
.
{
[
:
;
}
]
Print
Scrn
SysRq
Scroll
Lock
Insert
Home
Page
Up
Num
Lock
Delete
End
Page
Down
7
8
9
Home
p
PgU
4
5
6
1
2
3
Pause
Num
Lock
Break
"
'
?
/
Alt Gr
F12
A Axis JOG
(unslaved)
Z JOG KEYS
Shift
End
Ctrl
Caps
Lock
/
*
Scroll
Lock
-
+
PgDn
0
.
Ins
Del
Enter
AXIS DRO’s
ENTER KEY
XY JOG KEYS
AXIS DRO’s
CandCNC
Page: 75
D
BR HARDWARE
INSTALL
INITIAL MOTION CHECK:
After you have powered up the BladeRunner and checked the power on sequence
and checked the motors on each axis the next step is to plugin all motors and run an
intial motion check. You can wait to do this after you get the motors mounted on your
CNC table if you want or you can set the motors on the table oriented like they will be
mounted to check inital motion and direction.
BladeRunner Hardware
LINEAR MOTION WITH RACK & PINION
Pressure Angle
Pitch Diameter
R
OD
D
BR HARDWARE
INSTALL
TABLE SETUP SUGGESTIONS
RACK
TYPICAL SPUR (PINION ) gears
Psr = Pinion Speed increase ratio = Pitch Dia [in inches] * PI (3.1416)/1
= Pitch Dia [in mm] * PI (3.1416)/25.4
Example: 1” Pitch Dia pinion will have a step up ratio (speed increase of 3.14
(approx 3)
Belt reduction decreases speed by Raw Speed /Belt Reduction Ratio
Belt reduction increases linear force by normal force X Belt Reduction Ratio
Raw Motor Resolution = 1/200 = .005” linear [.127mm]
Final linear resolution = .005/Belt Reduction Ratio
Belt Reduction Ratio =
R2/R1
Numbers for direct pinion drive are
:simply Psr * Motor RPM = IPM
(speed)
Torque(oz) = T1/ R3
P2
Linear Force
R1
R2
P1
R3
P3
FIXED
Forces:
T1= Rated motor holding torque (Oz-in) / R1
T2 = Shaft holding torque of P2 = motor holding torque * Belt Reduction Ratio
T3 = Torque(oz-in at pinion (teeth) = T2 * R3
Note: Motor torque decreases with Motor RPM so a number of about 50% of the holding torque
Motor constants: (based on stepper motors provided by CandCNC)
Typical RPM of hybrid steppers (moderate load) with different DC power
24 VDC = 300 RPM
48 VDC = 600 RPM
65 VDC = 800 RPM
Number of steps for 1 motor REV = 2000 (this a fixed number based on Microstepping X10)
CandCNC
Page: 76
BladeRunner Hardware
TABLE SETUP SUGGESTIONS
EXAMPLES
620 oz-in Stepper motor @ 48 VDC with 1” dia pinion gear & direct drive:
Max possible IPM = 600rpm X 3.142 = 1885 IPM
* 50% RPM linear force = 50% Stepper motor torque / pinion Radius/ Pinion Speed
Ratio = (310Oz-in/.5in) / 3 = 206.66 linear oz of force
Same design but with 3:1 belt reduction from motor to pinion shaft:
(310OZ-in/.5in)/1 = 620 linear oz linear force.
* in the above calculations the motor RPM and torque numbers of 50% were used
to operate the motor in the center part of it’s torque-RPM curve.
Calculating the beginning Steps per UNit on an AXIS
Use the following formala to get a ballpark steps per unit number in MACH
Psr = Pinion Speed increase ratio = Pitch Dia [in inches] * PI (3.1416)/1
Target Steps per Unit = (Psr X 2000)/Belt Reduction ratio
This will give you the required number of steps it takes to move 1”
Once you have the calcualted number of steps it takes to move the axis one inch
then put that number into the STEPS per UNIT of the motor.
Based on the speed numbers you have calculated from the previous pages set you
velocity to a vlaue of 60 to 80% of that number.
Set your Beginning Acceleartion to a low number like 10
To fine tune the calibration see the next pages.
CandCNC
Page: 77
BR HARDWARE
INSTALL
D
Setting the initial Steps per Unit in MACH3 motor tuning.
Every table will have different Steps Per Unit, Velocity (max speed) and Acceleration settings. To do
testing on the table you must determine the correct settings for your table. Use the following method:
For Steppers:
1. Determine the number of steps your motors need to make one full revolution (Normally
200 for most steppers)
2. Multiply by the Motor Driver microstepping rate (10 for BladeRunner/Gecko drivers) =
2000 steps for one motor revolution.
3. Determine the drive ratio of your mechanical drive (how far does the leadscrew or pinion
move the load with one revolution of the motor).
4. Convert everything to you Units (inches/millimeters) and same time measurements
(seconds or minutes).
Using 1 and 2 above we know we have to send 2000 pulses (step pulses) from MACH to rotate the
motor one complete revolution (360 Degs).
The rest of the math is based on the transmisson ratio(s) between the motor and the final drive element.
If it's Rack & Pinion you need to know the DP (diametric pitch) or the tooth count of the pinion gear and
the TPU of the Rack (Teeth per unit)
If it's a direct drive leadscrew you need to know the treads per unit (TPI for inch units)
We have to determine how far the load moves (in units) for each REV of the motor.
Lets do a direct drive leadscrew of 5 TPI :
It takes 5 turns to move the load one inch of linear movement so the steps per inch (unit) of the axis is
simple: 2000 [number of steps for one rev] X 5 [number of Rev to move one inch] = 10.000 steps per
th
inch. (.0001”) resolution. About 6 to 7 times the torque. 1/5 the motor Speed.
Now let's do a R & P direct drive and an R & P with a belt reduction transmisson:
For a R & P the distance traveled per rev of the pinion is given by the DP of the pinion X PI [3.1416].
Ifwe use a 1” DP pinion the distance traveled is 3.1416” per rev of the pinion So a direct coupled motor
gives us over 3” of travel per rev. To get it back to a Unit (1 “) it would be the number of steps (2000 from
above) / 3.1416 or 636.6183….as you can see, the resolution at .00157 per step is MUCH courser than
the 5 TPI leadscrew. The max velocity (speed would be over 8 times the leadscrew but with 1/3 the
torque of the motor specs) is over 2000 IPM.
To gain back the lost resolution and torque you should belt reduce between the motor and pinion. With a
5:1 ratio you would see the numbers change to:
2000 /3.14165 X 5 or 3183.1 steps per inch (.000314 inch). Torque would be 1.66 times greater than
motor rated torque.
NOTE: DO NOT use the microstepping in a “true” resolution calculation for accuracy. Microstepping is
for motion smoothness and cannot be counted on to actually position the motor shaft at a fraction of a
motor pole (between poles). It can be off and the faster the motor spins the less effect microstepping
has. The only true resolution will be the 200 steps per rev of the motor. In practice it will be somewhat
better especially at slower RPM but it varies.
CandCNC
Page: 78
BR HARDWARE
INSTALL
D
For proper tuning of MACH3 please refer to the MACH 3 manual. The exact
tuning of the software is beyond the scope of this document.
Motor Tuning Screen in MACH3
Testing the BladeRunner for motor control
. In order to get motion and you need to have MACH3 running with it out of E-stop and the CP
LED on the front panel active (ON). Without CP active, you will not get motion.
•
•
•
•
•
•
•
•
•
Make sure all of the cables are connected.
Power up the BladeRunner
Load Mach3 with the proper profile (BladeRunner) and Screen
Turn on DC Motor power using the ON button on the Front Panel
Motors should “lock” when power comes on to the motors
Hit the Reset button. The LED over the Reset in MACH will turn solid Green
The CP LED on the front panel of the BladeRunner will turn solid Yellow
Use the keyboard arrow keys to jog your machine. Don't worry if they jog the wrong
way with the keys or the wrong axis jogs. We will fix that later.
The Optional test Step and Direction Monitor will confirm that the signals are getting
out to the EzPlug G251-4 Driver card. If the LED's flash and you are not getting
movement the problem at and the motor drivers. Check your cables and connections
carefully. The DB connectors need to be seated and the holding screws tightened for
each cable. Sporadic motor movement or direction changes (without changes at the
Step & Direction Monitor indicates one winding on a motor may not be making good
connection
CandCNC
Page: 79
BR HARDWARE
INSTALL
D
At this point you should have motion on all axis using the Keyboard keys to scroll with.
In this section we will set the direction of motion for each axis and match the keyboard
keys to that motion.
IF YOU HAVE THE MOTORS ON THE BENCH AND LABELED YOU WILL NEED TO
ORIENT THEM LIKE THEY WILL BE MOUNTED ON THE TABLE AND WATCH THE
DIRECTION OF TURN OF THE SHAFTS. IF YOU DECIDE TO MOUNT THE
MOTORS ON THE TABLE YOU SHOULD DISENGAGE THEM FORM THE TRAVEL
MECHANISM UNTIL YOU GET ROTATON DIRECTION RESOLVED. THIS IS
ESPECIALLY TRUE FOR THE SLAVED MOTOR ON THE GANTY AXIS
1. Load MACH and the BladeRunner Plasma or Router Profile
2. Load the Diagnostics Tab
3. Power up the BladeRunner AIO and the DC to the motors
4. Move Each axis several inches away from the Table 0 (home switch) positions5. Zero
each DRO with Zero Button next to each axis.
5. Jog the Z first. Note the Z DRO as it moves UP.
a, If the numbers are INCREASING in value then the direction is correct.
b. If the numbers are DECREASING then the DIR is wrong. See the next page to
change the DIR of a motor
c. The key may not match the direction of jog...do not worry it will be redefined
7. JOG the non-slaved axis next and do the same DRO check and change if it is scrolling
the wrong direction.
8. The Slaved Axis is a little different. You must FIRST setup the slaving (See Page ___
earlier in this section) using the 4 axis or 5 axis instructions.
9. The DIR setting on the SOFTWARE Slave (A is slaved to Master axis) is opposite the
Master axis (motor faces the other and spins opposite to move the same direction)
Hardware Slaving is set via jumper on UBOB III
10. If in the setup you need to change the Master Axis DIR to make it move correclty
you will also need to change the Slave Axis on a 4 axis (Software Slave) setup.
CandCNC
Page: 80
BR HARDWARE
INSTALL
D
SETTING MOTOR DIRECTION
Setting up the proper axis direction and motor tuning
While the Profile file (BladeRunner.XML) provided with the unit sets up all of the
pins there are several things we don't know about your machine and so certain
parameters have to be set based on your specific machine. .
Note each axis has a Step and Direction pin.
At this point do not worry if the axis moves in the wrong direction, simply that
you have the axis as you define them correct.
The next step is to make the axis movement agree with the DRO and g-code
commands for that axis. The DRO (Digital Read Out) for each axis is at the top of
the screen. You will need to take MACH3 out of E-stop by pressing the Reset
button.
•
Jog your machine so the cutting head is away from the Homes (approx
center of the table is good). Don't worry if the jog keys aren't correct or that
the DRO's are running in the wrong direction.
•
If your machine is setup so that one corner is X0,Y0 (lower left corner?) then
all moves from 0,0 should be a positive number.
CandCNC
Page: 81
BR HARDWARE
INSTALL
D
•
The MDI is a line to allow you to type in direct g-code commands to make
the machine make specific moves. You don't need to have a deep
knowledge of g-code to use it for testing.
Diagnostics Tab
(Your MDI may look different)
•
•
•
•
•
When you type in a g-code command it is not case sensitve but be sure to
use zeros's and not “O's” for the numbers! At this point do not worry
about which hotkeys are assigned to a direction.
With the machine out of e-stop and power on, type the following into the
MDI Frame:
o Move the screen cursor to the MDI frame and click on it. The frame
background color should change to yellow meaning it is ready for
input. No other movement keys work when the MDI frame is
selected.
o G00 X3.0
o Enter key activates command
The X axis should move 3 inches in some direction It should have moved
away from your established X zero and the DRO numbers should have
increased. If it did not then you need to reverse the direction of axis
travel.
To reverse the direction of any axis open the Ports and Pins/ Motor
Outputs and change the polarity of the Dir LowActive setting for that axis.
Clicking the Green Checkmark or the Red X will swap the definition. Red
X is posiive and Green Check is negative polarity.
Work with each axis to establish that the movement direction is correct.
Use the MDI frame and change the axis letter from X to Y then Z. Do
NOT change the polarity of the step signal (Should always be Red X
for BladeRunner
CandCNC
Page: 82
BR HARDWARE
INSTALL
D
FINE TUNING the calibration using the “tape measure” method
Once you have a ballpark of the number of steps it takes to move your machine 1
inch then you can fine tune that using a simple tape measure and a calculator
1. Establish a zero spot you can precisely mark on your table. On a plasma table
you need to remove the torch and either mount a laser pointer at tool center or use
a sharp pointed tool in a holder. You can also tape a small drill bit or pointer to the
torch nozzle if your mount has enough room. You want something small enough you
can see errors of .032 on the marks of the tape.
2. Setup up the axis you want to calibrate with the pointer sitting at the zero point
and zero that axis DRO.
3. Write down the Steps per Unit value you have for that axis.
4. Open MACH to the Diagnostics Page and find the MDI window
5. Type in a distance to send that axis out using the following G-Code (example is
for moving X out 30 inches) HIT THE ENTER Key to execute the line
G00 X30.000
6. Measure the ACTUAL distance you went with your tape measure from zero to
where it stopped and write down the distance to as close a decimal value as you
can (estimate the distance if it’s less than a 1/16 (.063).
7 BEFORE YOU make ANY changes move the axis back to the start point by using
the MDI and typing G00 X0.000 (for the example above)
8, Use the formula On the next page and calculate the new Steps per UNIT. Then
open the motor tuning in MACH and make the change. Run the same test again
(you should be MUCH closer. Once you are as close as you can see by eye at 30
inches do one final test at the longest point on that axis. Typically if you are within
.032 at the end of the move, you will be within 4 decimal points at 1 inch.
CandCNC
Page: 83
BR HARDWARE
INSTALL
D
CandCNC
D
C
B
2
1
3
4
437
B
8
N.cm
/PHASE
N.cm
A/PHASE
2 ±10
/PHASE
3.5
FF46-1/0.5
±10
A/PHASE
5.0
FF46-1/0.5
400
B
3.5
V
SERIES CONNECTION
PHASE
2
°/STEP
1.8±5
.265
V
3.969
4
RED A
Page: 84
TAG PLACE
5
PROC.
CHECK
DESIGN
CHANGE
APPROVE
STD.
6
NAME
B B D D
WHT PUE BRN GRN
EIGHT WIRING CONNECTION
BLK C
YEL A
BLU C
A
A
B
B
DATE
NR
DESIGN
BIPOLAR & UNI-POLAR
7
PAGE:
BR HARDWARE
INSTALL
MASS PLATE SCALE
SERIES CONNECTION
COLORS OF LEAD WIRES
Use # 8-32 mounting screws (4mm)
2.351
1.856
2.351
.172d
1
INSULATION CLASS
LEAD STYLE
NO. OF LEADS
HOLDING TOGQUE
RESISTANCE
CURRENT
VOLTAGE
3.5
1.8±5°/STEP
STEP ANGLE
PHASE
EIGHT WIRING
PHASE
2
unit=mm
CONNECTION WISE
V
SPECIFICATIONS
.940
.058
.375
DIMENSIONS
Dimensions in Inches
1.498
A
1.856
BladeRunner 620 Stepper Motor
Dimensions
8
D
Steps per unit in MACH
Current Setting in Steps per UNIT
= Sc
Actual Distance Traveled
= Dt
Commanded Distance (you entered) = Dc
New Steps per Unit value
= Sn
(Sc X Dc)/Dt = Sn
Sn is in steps and will probably a decimal number
Set the decimal amount to 3 decimal places
CandCNC
Page: 85
BR HARDWARE
INSTALL
FORMULA FOR CALIBRATING
Steps per Unit on an axis
D
SERVO HARDWARE
Addendum
E
ADDENDUM SECTION ADDED 11/15/12
For BladeRunner AIO Dragon-Cut SERVO
products
The following 6 pages are for the SERVO motor version of the BladeRunner DragonCut and cover the setup and tuning of a system with servo. The Drive tuning is done at
the factory and seldom needs to be changed but some mechanics may require some
tweeks to the driver tuning. Besides the change of the tuning in MACH (calibration)
and recommended settings for the servo system the Dragon-Cut will operate in the
same manner. The motor gearhead combinations were engineered for optimum
performance for plasma cutting. The wider torque range of the servo motors provides a
better platform for mixed cutting applications (router/plasma) but the typical issues of
cross contamination and change over still remain. The Servo system does offer higher
performance with increase upper cutting speeds at high acceleration rates. This does
put larger stress on the mechanics so full out maximum settings are often
counterproductive.
CandCNC
Page: 86
SERVO HARDWARE
Addendum
E
HARDWARE DIFFERENCES for
BladeRunbner SERVO system
EZPlugII Servo Drive Assembly
NOTE: Servo Motors use the same 4 wide
motor plug as the BladeRunner Stepper
systems but the pinout is different. Do NOT
plug a stepper into a servo unit or vive versa!
SERVO systems use a rotary encoder mounted on the
motor. Each encoder is supplied with a differential driver
(”pigtail”) that allows a standard CAT 5 cable to be
plugged in and transmit the encoder information back to
the servo interface sub-assembly. you MUST HAVE THE
ENCODER CABLES CONNECTED when a motor is
powered up! With no feedback to the electronics of
where the motor is it will “Run Away” We have color
coded the label and the cables to make it easier to
identify each motor/encoder pair. Do not get the pairs
mismatched/ The Inputs from the PC parallel and serial
port are connected the same way as the stepper version
as is the DTHCII connections (see DTHCII User Manual
CandCNC
Page: 87
ENCODER
6.0"
Page: 88
Overall length to flange
9.5"
SERVO MOTOR
3.54”
GEARHEAD 10:1
Different diameter pinion gears will yield different Speed and Force numbers
0.962"
Sh
a
Fla ft .3
ts 75
bo d
th X .
sid 88
es 2
Ce
n 1.4
Rin ter 98
Fla g .08
ng 0
e
4H
o
1.8 les .18
56 S
9
pac dia
ing
6
G
R
EA
H
Addendum
Approx Steps per Inch with 1”
DP Pinion gear SERVO
to rackHARDWARE
= 3183
Encoder Line Count = 250
Pulses per Rev = 1000
Resolution = .0001 per step
Combined Overall length 10.5 “
Diameter (max) 2.5 inches
Weight (combined 5.4 lbs)
PHYSICAL
1
54 : 1
0
D
EA
3.
Inp
u
.25 t sha
ft s
0“
ize
2.4
0
Planetary Gearhead
Front View
2.
40
1.8
5
2.40”
2.380"
CandCNC
Direct drive to 1” DP Pinion Gear:
Linear Speed = 1200 IPM max
Linear Force Cont = 900 oz-in per motor (4.69 Ft-lbs)
Linear Backlash at gear = <.0015”
Linear Resolution = .0003”
Gearhead:
Input (female) = .250 Output (Shaft) = .375 dia
Ratio : 10:1 reduction
RPM Max = 470 RPM
Torque Continuous = 450 oz-in
Torque Peak = 3200 oz-in
Radial backlash 10 Arc-minutes max
Servo Motor:
23 Frame flange mount 1/4” Shaft
Max RPM @ 60VDC = 4700
Continuous Torque = 50 oz-in
Continuous Current = 3.5A @ 50 oz-in
Peak Torque = 328 oz-in @ 20A
BladeRunner 23 Frame Servo
Motor & gearhead Dimensions
E
The BladeRunner Servo systems ship with 4 (or 5) servo motors and on the XY motors (3)
there are 10:1 gearheads. The following pages should be used to do the calculations for
the calibration and to determine the best velocity and acceleration. In addition to the
normal motor tuning in MACH the Gecko G320X drives have a PID set of pots that can be
used to do added response tuning of each motor. The PID settings are done during
final testing prior to shipping and seldom need to be adjusted. We have included
excerpts of the tuning process from Gecko but unless you are experiencing motion
induced fault issues, than doing adjustments just to see what it does will not “fix”
anything. While different loads can alter the response of the servo it will not effect the
accuracy. The servos are never at rest if they are powered up. As a result they WILL
make noise. If you attempt to tune them for no noise or minimum noise you will have a
“sloppy” system. Even a poorly tuned system will not allow a lot of error in position to
SERVO TUNING 101...Tuning by ear
If you don’t have a dual channel oscilloscope and the experience to use it, the easiest
way to tune a Gecko drive is by sound. The following covers that method and will yield
good results.
DO THIS ONLY IF YOU ARE CONFIDENT THAT THE MOTORS ARE EXHIBITING
SYMPTOMS OF IMPROPER TUNING! Most problems are mechanical (backlash,
loose gears/pulleys or settings in MACH) and cannot be helped with driver tuning)
This should be done ONLY if you experience any of the following:
1. Any motor that pulses slowly or is completely quiet qhen powered and not moving.
2. An axis that faults often when you are accelerating the motion
NOTE it is normal for a servo to fault and the ESPII to throw a fault when you do an
emergency STOP in MACH. The motor cannot stop instantly without causing a fault
Faults from other issues like overloads and noise cannot be fixed with motor
tuning!
The motors need to be mounted and under load to do tuning by ear.
1. Power up the motors. It may be easier to disconnect all but one motor and encoder
apir at a time so you can hear just that motor. if you accidently try to jog a motor that is
not connected the Gecko drive WILL fault.
2. Make sure the motor under test “locks”. If it starts to move than make sure the
encoder is plugged in for that motor. If the motor losses encoder pulses (either channel) it
will start to run away (spin at full speed huntting for a line on the encoder)
3. The motor should “hum”. The frequency is typically below 220 hz (octive 3 A on the
music scale). The important thing is that the motor does not sit and pulse indicating it is
way over dampened. The higher the frequency of the “hun” the tighter the tuning. There
are two main controls: The P and the D pots. The P is the gain and as you increase it the
hum frequency will go up.
CandCNC
Page: 89
E
SERVO HARDWARE
Addendum
ADDENDUM SERVO MOTOR SETUP AND TUNING
4. Start with the D pot turned all of the way counterclockwise (minumum) and slowly
advance the P pot until you either hit a point it gets unstable and the motor starts to
twitch (oscillate ) or you have it turned all of the way up. Make a note of the pot position
and back it off until the oscillation stops and then advance it to a position below that
point. Now increase the D (dampening) and listen to the frequency...it will drop. Stop
the D at about 1/4 turn and then advance the P past where it became unstable before. If
it starts to become unstable note the position and back it back down then advance the D
some
5. Start with the D and I pot turned all of the way counterclockwise (minumum) and
slowly advance the P pot until you either hit a point it gets unstable and the motor starts
to twitch (oscillate ) or you have it turned all of the way up. Make a note of the pot
position and back it off until the oscillation stops and then advance it to a position below
that point. Now increase the D (dampening) and listen to the frequency...it will drop.
Stop the D at about 1/4 turn and then advance the P past where it became unstable
before. If it starts to become unstable note the position and back it back down then
advance the D some more and turn the P back up. The objective is to have high gain
but with enough dampening to keep the loop stable under all conditions. Once you have
established the highest gain (P) that you can support at a given D then back it off a little
and leave the D where it is. Do not set the motor so that it is silent or pulses. After you
have the P and D set raise the I and that increases the dampening curve
Once you have the motor tuned in a static (non-moving setup) connect to load, than set
the tuning in MACH up to a high number (75 to 100) for acceleration and jog the motors
at full speed and change direction several times. If the motor driver faults that lower the
P slightly raise the dampening slightly by increasing the I setting. Once you have one
motor tuned correctly listen to the frequency of the sound. Use that as a guide to tune
the rest of the motors.
6. Setting the Torque Limit Trimpot. For 23 sized servo motors used on the
BladeRunner Servo system set the Torque Limit Trimpot to ½ range (centered between
full CW and CCW rotation. This limits current to 10A max. Leave Dip Switch 10 set to
OFF to prevent a 20A 1 sec peak cycle.
CandCNC
Page: 90
SERVO HARDWARE
Addendum
E
G320X Top View
P
I
D
Accessed
from rear
using small
flat blade
screwdriver
. Do NOT
force
Torque Limit
Trimpot
Dip Switch
Access with
Cover ON
SW1
Not used
SW2 Current or voltage mode select
ON – Current mode (default)
OFF – Voltage mode
SW3, SW4, SW5 Current mode servo gain
SW3 “ON”, SW4 “ON”, SW5 “ON” = Low gain (default)
SW3 “ON”, SW4 “OFF”, SW5 “ON” = Medium-low gain
SW3 “ON”, SW4 “ON”, SW5 “OFF” = Medium-high gain
SW3 “OFF”, SW4 “ON”, SW5 “ON” = High gain
SW6, SW7 Sets the G320X pulse multiplier
SW6 “ON” and SW7 “ON” = Step pulse times 1 (default)
SW6 “ON” and SW7 “OFF” = Step pulse times 2
SW6 “OFF” and SW7 “ON” = Step pulse times 5
SW6 “OFF” and SW7 “OFF” = Step pulse times 10
SW8, SW9 Sets the G320X following error limit
SW8 “ON” and SW9 “ON” = +/- 256 count following error limit (default)
SW8 “OFF” and SW9 “ON” = +/- 512 count following error limit
SW8 “ON” and SW9 “OFF” = +/- 1024 count following error limit
SW8 “OFF” and SW9 “OFF” = +/- 2048 count following error limit
SW10 Sets the G320X current limit trimpot behavior
CandCNC
Page: 91
E
SERVO HARDWARE
Addendum
Rotation Clockwise
(increase)
Max possible IPM = 4700rpm/10 X 3.142 = 1476 IPM.
* linear force = 100% servo motor continious torque X gear reduction / pinion Radius
= (50 Oz-in X 10) / .5 = 1000 linear oz of force
Same design but with 3:1 belt reduction from motor to pinion shaft:
* in the above calculations the motor RPM and torque numbers of 100% were used
since servo motor torque does not drop off with RPM. These are maximum numbers
and NOT recommended for normal cutting and rapids. High values of velocity and
acceleration put maximum stress on components for little benefit.
Calculating the beginning Steps per Unit on an SERVO AXIS
Use the following formula to get a ballpark steps per unit number in MACH
Psr = Pinion Speed increase ratio = Pitch Dia [in inches] X PI [3.1416]
Steps Per Rotation (SPR) of motor = encoder line count X 4; [250 line count =
1000]
Target Steps per Unit = (SPR X gearhead Reduction ratio/PSR)
1000 X 10 / 3.1416 = 3183.091 steps per inch
Once you have the calculated the number of steps it takes to move the axis one
inch then put that number into the STEPS per UNIT of the motor.
NOTE: IF you have the Step Multiplier on the Gecko set to 2X than you must divide
the Steps per Unit by 2
Based on the speed numbers you have calculated from the previous pages set you
velocity to a value of 50 to 80% of that number.
NOTE: MACH can only send the number of pulses per second as set in the Kernel
Speed in Ports&Pins. The number of pulses per second you need is the target
RPM (max) X the SPR/60. For a target RPM of 4000 and 250 line encoder you
need 40000000/60 = 66,666.0 steps per second (66 thousand) if your Kernel speed
is set to 45,000 (default) than you cannot achieve 4000 RPM. The step multiplier in
the G320X multiples the steps from the PC so a 2X setting makes the steps per
second required from the PC to be 33,333. The trade off is that it drops the
resolution by ½ as well.
Set your Beginning Acceleration to a low number like 10
CandCNC
Page: 92
E
SERVO HARDWARE
Addendum
EXAMPLES
50 oz-in Servo motor @ 60 VDC with 10:1 gearhead and 1” dia pinion gear & direct
drive:
SERVO HARDWARE
Addendum
E
Calculating the max IPM you can travel (limited by max motor RPM )
4500 RPM = 75 RPS
Kernel Speed / SPR = RPS
45000/1000 = 45 RPS
Final Speed is limited by the smaller of the above two numbers
Pinion RPM = (RPS/ gearratio) X 60
IPM = Pinion RPM X Psr
For 45,000 and 250 line encoder:
(45000/1000) = 45 RPS
Pinion RPM = (RPS/10) X 60 = 4.5 X 60 = 270 RPM
IPM = 270 X 3.1416 = 848,23
RECOMMENDED SETTINGS FOR BladeRunner Dragon Cut
with 23 Frame servo motors and 10:1 Gearhead reductions
Recommened pinion DIAMETER : 1” (25mm)
Recommended belt reduction to pinion : NONE
Maximum belt reduction to pinion 2:1
Velocity XY and slave : 500 IPM (12700 mm/min)
Acceleration XY and Slave 35 to 50 IPS/sec **
Steps per unit XYA 3183.091 (1” pinion)
Velocity Z (5 turn Leadscrew) 300 IPM (7620 mm/min)
Acceleration Z : 20 IPS/Sec
Steps per unit Z = 1000 X leadscrew TPI
THC Rate (Mach setting) 20 **
Recommended Span Voltage (Cut Proffile) 4 to 8 **
Recommended plunge rate (SheetCAM) 50 - 100 IPM
Recommend DTHC Delay (SheetCAM or Cut Profile) 1.5 to 3 sec
** These settings may need to be adjusted depending on your mechanics to get smooth
cuts. Always adjust one parameter at a time.
CandCNC
Page: 93
SETTING and TESTING INPUTS - HOMES
DTHC IV VERSION SKIP TO PAGE ##
The bulk of MACH3 and the Hardware has to do with Inputs and Outputs (I/O). In the BladeRunner AIO
system I/O takes several forms. Ultimately an INPUT is a signal coming INTO MACH3 from an external
source as a logic level (either Active High or Active Low) MACH is setup to “watch” certain Ports and Pins
(input points) and then using a term called “mapping” it assigns an INPUT to an ACTION. The BladeRunner
is unique in that it has double the number of normal inputs to a single Parallel (printer/LPT) port so you have
more than the normal 5 inputs to work with. This is essential when using the THC function in MACH because
it alone needs 3 dedicated inputs.
It is important to understand how the input Port Expansion works and how the mappings are used.
The UBOB III is the hardware I/O part of the BladeRunner. It takes outside inputs from the Table I/O card to
sense physical switches and sets up the “sharing” of the inputs. There are two PORTS defined in the setup.
PORT1 and PORT8. PORT 8 is the shared port to PORT1. The physical inputs are individual and each one
is opto-isolated and noise filtered. The circuit in the UBOB III takes all of the individual inputs and puts them
on TWO BANKS of signals.....4 on each bank (E-STOP is not shared). A special pulse is sent from MACH to
tell the hardware which BANK to read. This happens thousands of times per second in a process called
“multiplexing”. MACH alternately reads all of the inputs from BANK A (PORT 1) and then from BANK B (PORT
8). It is an effective way to increase the number of input signals without having to add more physical inputs at
the computer.
There are two things to keep in mind:
The shared inputs do not work when MACH is in RESET because all outputs are off and that includes the
special pulse from MACH to switch back and forth between the two BANKS of inputs.
The shared input process is controlled through a special DRIVER (plug-in) for the UBOBIII. It has to be
installed and enabled and set correctly for the shared inputs to work.
(versions of MACH3 before 3.41.020 DO NOT SUPPORT SHARED INPUTS even if the UBOBIII driver is
loaded. UBOB driver is ccc_UBOB.dll. It is added during an auto-install from the CD or the
BladeRunnerAIO-UBOB3-Install file.
The DTHC critical signals of THC ON (Arc OK), THC UP and THC DOWN and the Z home for the IHS (Initial
Height Sensing aka “Touch-off”) are REQUIRED for a Plasma setup. Other inputs are not required but highly
recommended to help in the cut process.
When you load the BladeRunnerAIO-UBOB3-Install file earlier in this manual it loads the right Drivers (plugins) enables them and sets their parameters. It also provides a default configuration for all of the INPUTS and
OUTPUTS that are common on the BladeRunner. The following screens show what the default settings will
look like. There may be differences in settings for inputs NOT ENABLED. Do not worry. A disabled input is
ignored by MACH3. Only the pins that are enabled count.
THE DEFAULT SETUP
1, XYZ&A Homes are enabled and set to the correct port/pin pairs
2. All LIMITS are disabled (see setting up LIMITS for details)
3 The THC INPUTS are all enabled and setup...even on a Router Profile since those
inputs can be re-purposed and used for other functions if desired.
4. The E-STOP cannot be disabled and the Active Low setting is critical (RED X
CandCNC
Page: 94
BladeRunner
Hardware
G
SETTING and TESTING INPUTS - HOMES
Each axis as a ++ and – which are the FAR and NEAR LIMITS. Each axis has a HOME
Each axis has an Enabled Column. Do not use Emulated ON (Red X for normal setups)
BladeRunner
Hardware
G
DO NOT USE THIS BUTTON!
The BladeRunner is unique in that it has two input PORTS (1 & 8). The pins are “shared”
so that PORT 1 Pin 11 is shared with PORT 8 PIN 11. That offers doubel the normal inputs
Note: A home is enabled by default. This may need to be changed if you do not software slave
A to another axis with a Home. See the setup of Homes & Limits section for details
E-Stop Cannot be disabled. The Active Low value is important. Note THC related signals are
on PORT 8. THC ON is the same as ARC OK.
Page: 95
CandCNC
CandCNC
Page: 96
INPUT PIN SETTINGS FOR DTHC IV
change from DTHC II based setups
CandCNC
Page: 97
THE CHARGE PUMP
THE CHARGE PUMP
The Charge Pump (CP) is an important safety signal in MACH and used by the BladeRunner. It is a ‘Keep
Alive” signal that is a waveform (approx 12 KHZ) and is generated by MACH and controlled by MACH and
the CandCNC drivers. If for any reason the power to the control system is turned on before the PC is
powered up it is possible that as the PC “boots” the parallel port can have signal changes (during POST)
that would might cause an output to go active.
Stepper motors require very specific signals to move making them inherently immune to random port
signals, The circuits in the BladeRunner do not allow any signal to pass to any of the drives unless MACH
is fully started and is functional and the operator has brought the system out of reset. NO CP, NO
OUTPUTS!
HOW IT WORKS:
MACH is programmed to turn on the CP only when MACH is loaded and has control of the PC and the
parallel port and MACH is out of RESET. While MACH controls the output signals through internal logic
there are hardware functions that act as a second level of safety. In the UBOB III based system the CP
signal MUST be present (not just a logic level) on the CP line from the PC or the internal buffers will be
disabled. No outputs will function. Without CP no Step signal will be sent to any motor drive (No
MOTION). Without CP no relay will fire.
If you start MACH and the BladeRunner and you get no motion the first thing is to check the CP LED on
the side of the BladeRunner. It detects and turns on the buffer circuits in the BladeRunner.
CandCNC
Page: 98
BladeRunner
Hardware
G
TABLE I/O CARD LOCATION
CHECKING INPUT SIGNALS:
The following sections detail how to use the hardware interface to use Inputs and
Outputs. Please review the section on the physical location of the internal cards and
then the section on the Table I/O card (where Homes and Limits and other Inputs are
connected. There are sections on using the E-STOP (either software or hardware or
both) Setting up HOMES and testing and optional LIMITS. Even if you do not plan to
use the XY or A homes it is important to at least test each input.
TABLE I/O MODULE LOCATION INSIDE BLADERUNNER AIO ESPII CASE
To access Inputs turn off power and remove fron cover. Locate Table I/O
Card and use detialed pages in this setion to make INPUT connections
25
1
C11
T10
ARC OK
J2
14 PLUG
ALT8
1
ALT7
K
K
D16
ARC OK
D15
ALT6
QUAD 6
RELAY
C14
C1
K
UP
10
R5
D20
R8 R4 K
Q6
C8
J13
ALT5
UP
C6
J14
T3
D18
DOWN
K
K
ALT4
C5
J10
C4
J8
C3
J12
ALT3
DOWN
C9
J9
LIMITS
AHome
D8
T2
T19
LIMITS
D7
D6
T17
ZHome
AHome
T5
K3
D5
T15
D4
C2
J7
ALT2
D21 K
R7
2 3
J22
1
K4
D3
K3
R1
D10
K4
T13
Q5
C12
R3
DANGER! DANGER!
YHome
ZHome
13
C13
K D11
J5
J18
K4
K3 R2
COM
J4
K4
Xhome
J11
EPO
NO
NO Com2
T21
T20
D2
YHome
Xhome
ALT1
EPO
C&CNC REV 1
TABLEI/O-16
INSIDE TOP VIEW
TABLE I/O or TABLE I/O II CARD
This area open fo
DTHC or ISS-02
Expansion
CARDS
UBOB III Universal Breakout Board
BLADERUNNER UBOB MODULE DETAILS
CandCNC
Page: 99
BladeRunner
Hardware
G
TABLE I/O CARD LOCATION
For Both DTHC II and DTHC IV
BladeRunner
Hardware
G
REV 10 and later
To “B” Socket HOT
terminal
To “A” Socket HOT
terminal
ToUBOB
10
MH2
K4
K4
K4
6
1
D10
J2
QUAD RELAY
COM
C&CNC
TABLEI/O
REV10
K3
J17
K3OUT
NO
J14
R1
D3
K3
FT-01
PWRIN
D12
T11
1
OK
++
J1
T20
EPO
T21
K3
D11
K3 R2
T2
T3
T7
T9
UP
DOWN
T6
LIMITS
T10
T5
T19
ARC
DOWN
1
AHome
ZHome
FT-01
LIMITS
T17
T16
T18
ZHome
AHome
T15
YHome
5
HOLD
T13
Xhome
T12
T14
Xhome
Yhome
InsideRow
COMMON
K4 J4
20A240VMAX
DANGER!
DANGER!
D2
J3
TABLE I/O or TABLE I/O II CARD
NO Com2
To AUX line INPUT
Hot side
DANGER!
Hot Feed
This area open fo
DTHC or ISS-02
Expansion
CARDS
UBOB III Universal Breakout Board
CandCNC
Page: 100
TABLE I/O CARD PINOUT
DTHC IV SIGNALS
If you have a BladeRunner with the DTHC IV option your
MACH profile maps the signals to the physical INPUTS
listed below.
P24 DC volts
for FT-01Input
TABLE I/O REV 12
XHome
YHome
ZHome
(touch off)
AHome
CHome
LIMITS
BHome
EPO
(Jumpered
for normal
operation)
HOLD
(do not
use)
CandCNC
Page: 101
BladeRunner
Hardware
G
SETTING and TESTING INPUTS - HOMES
Setting up HOMES.
Homes are used for establishing a known POSITION, Most often to define the
TABLE ZERO locations and be able to return to the same fixed spot. Much like the
address on your house versus the location of you RV at any given time. If you
establish a TABLE 0 and do all of your cutting in reference to the TABLE ZERO than
you can always re-establish your cut at anytime even after a power failure and ESTOP event that can cause the loss of position.
TESTING HOMES at the TABLE I/O.
If you have not yet mounted or wired your HOME switches yet, it is easy to test to
make sure of their operation:
1. UNPLUG THE AUXILLARY AC CORD THAT PROVIDES POWER FOR THE AC
SOCKETS BEFORE YOU RUN ANY TESTS! You will need to power up the
BladeRunner and the DC supply to run the INPUT tests but there is no AC high
voltage in the top of the unit UNLESS YOU HAVE THE AUX AC CORD PLUGGED
IN.
2. Open the BladeRunner up (remove the cover and place it gently off to one side
leaving the cables to the Front Panel plugged in. Expose the TABLE I/O in the top of
the case as shown in the illustration on page_73 Note the input terminal pairs are
side by side in two rows.
3. Power up the BladeRunner AIO with and turn on the DC (Front Panel). You do
not need the motors plugged in, but if they are it is okay. MACH will not come out of
RESET if the DC power is off. Inputs do not work right if MACH is in RESET
4. Make sure MACH3 is loaded and the BladeRunner Profile is selected. Open
the DIAGNOSTICS PAGE for the test
5. To test the inputs use a small screwdriver or metal object to short across a pair
of inputs. Start with X Home and go down through A home.
6. Note on the TABLE I/O Card there are small LED’s next to each pair. When
you short across a pair you should see the associated LED turn on. That indicates
the circuit is complete between the Input on the Table I/O and the UBOBIII. It also
confirms the 25 pin cable is working.
CandCNC
Page: 102
BladeRunner
Hardware
G
SETTING and TESTING INPUTS - HOMES
J2
CONNECTED TO
TABLE I/O HEADER
ON UBOB III CARD
K4
6
1
D10
K4
K3
QUAD RELAY
ToUBOB
10
MH2
K4
C&CNC
TABLEI/O
REV10
COM
J17
K3OUT
NO
K3
D3
K3 R2
J14
D11
J4
R1
K4
20A240VMAX
FT-01
PWRIN
D12
D2
T11
1
++
J1
T20
EPO
T21
DANGER!
DANGER!
K3
NO Com2
DANGER ZONE
WHEN AUX AC
CORD IS
PLUGGED IN
DANGER!
MAKE SURE THE AUX AC INPUT CORD IS DISCONNECTED FROM THE WALL
SOCKET BEFORE YOU RUN ANY TESTS
J3
HOLD
T9
ARC OK
BHome
T7
T19
AHome
LIMITS
T18
T6
UP
T17
ZHome
T16
T15
Yhome
T14
T13
Xhome
T12
InsideRow
COMMON
DOWN
T10
T2
1
T3
FT-01
T5
5
TO TEST:
SHORT
ACROSS
INPUT PAIRs
Example of testing X HOME input and indications on the
DIAGNOSTICS SCREEN. Test each input at a time and match up
the INPUT STATUS. The RAW PORT BITS shows the signal AT
THE PORT 1 input on the PC as MACH sees it. NOTE: You cannot
test the LIMIT input. The AUX 0 is NOT and input for the
BladeRunner.
Flashing INPUT
on RAW PORT
INPUT BITS
4 5
6 7 8
Checking the INPUTS
RAW PORT INPUT BITS
BIT 4 = A home/THC DOWN
BIT 5 = Z home/THC UP
BIT 6 = Y home/ARC OKAY
BIT 7 = E-STOP(EPO)
BIT 8 = X home/LIMITS
CandCNC
NORMAL INDICATIONS
With PORT1 unplugged from BladeRunner: All Bits (4 - 8} should
be ON STEADY
When MACH is out of reset then you should see the RAW PORT
BITS SHOWN ABOVE. Flashing inputs indicate activity on that
input (E-STOP MUST BE OFF - STEADY (dark))
Page: 103
BladeRunner
Hardware
G
SETTING and TESTING INPUTS - HOMES
EXAMPLE of HOME SWITCH
MicroSwitch Type switch with roller
lever actuator. Switch has .250 quik
connects and a NO and NC set of
contacts. Mouting in this case is drilled
and tapped AL block with High Strength
3M double-sided tape holding it to the
table frame Switch trips on bottom of
gantry frame but allows it to roll past if
needed.
Mount your HOME Switches so they define the X and Y zeros on your table. Mount some clips or
brackets (stops) on the cutting surface or edges to let you index a sheet of material in relation to the
table zero. Even if the STOPS are not exactly at table zero you can deal with the offsets in the CAM
layout. Having alignment stops on your table let you accurately remove then re-load a piece of
material. Having a defined table 0, 0 that can be referenced to makes the recovery of a loss of
absolute position easy to recover from. We have provided enough inputs to allow for up to 4
Homes.
The Z home setup is covered on the next page and depends on the type Floating Torch Holder you
are using.
The BladeRunner AIO enclosure is furnished with 2 access holes for routing switch wires into the box
for connection to the tabs on the TABLE I/O card. The holes are filled with two rubber knock-out
plugs that are easily removed. HOME switch wires carry very small amounts of current (< 15ma) and
low voltage (3 -5 volts DC) so the wire size is not critical. It is recommended it be stranded for
flexibility on any moving part of the table and for longer runs twisted pair(s) are recommended. Wire
from 24Ga to 18Ga works best. The smaller the conductor the more wire pairs will fit through the
access holes. Use the correct sized Crimp-On connector for the size wire you use.
Switch Wire Access
Plugs on End of
BladeRUnner AIO
CandCNC
Page: 104
BladeRunner
Hardware
G
Home Switch Connections: At least one Home (Z) is required if you are
using the BladeRunner Dragon-Cut for plasma tables. It is recommended
you mount and connect up HOMES for the X & Y but it is not required.
Z AXIS “Touch Off” SWITCH
Z HOME
WHAT IS A FLOATING TORCH
HOLDER and WHY DO I NEED ONE?
Example of a Z with the Floating Torch Holder for
doing the IHS for Plasma cutting.
The Floating Torch holder is a torch
holder mounted on a separate slide
from the Z axis and allows the torch to
move UP and DOWN independent of
the Z motion. In operation it uses the
end of the torch (torch tip) as a “Probe”
to find the Top-of-Material. Because
metal tends to warp and the slats may
not be perfectly level, the Z zero
changes (top of the material) as you
move around the table surface. The
DTHCII will track the rise and fall of the
material as it cuts to hold a constant arc
gap, BUT the absolute value of Z as
displayed by the Z DRO is based on the
LAST REFERENCE DONE. (Where it
started) Each pierce needs to be done
at exactly the right height above the
material so a method if Initial Height
Sensing (IHS) is needed. The Floating
Torch holder lets the Torch be the
sensing probe for the IHS. It is a
mechanical way to do the probe and is
more reliable than ohmic or capacitive
sensing. Using a Z homing sequence
generated by the G-Code (from
SheetCAM) the Z is lowered until the tip
of the torch touches the metal and the
floating mount allows the torch to be
pushed UP and that trisp the swtich.
Z AXIS FLOATING HEAD
SWITCH. Close up of
switch connections. Use
Normally Open Pair.
(Precision Plasma HD
Gantry and Z)
CONNECTED TO Z
HOME in BLADERUNNER
on the TABLE I/O
CandCNC
Page: 105
BladeRunner
Hardware
G
SETTING and TESTING INPUTS - HOMES
BladeRunner
Hardware
G
Using an Optional Salve
Side Home Switch;
Typical rectangular
table setup
It is advantageous to use a
HOME on the slaved axis
(in this case A). There is an
input for an A HOME. If you
set your inputs to have an A
HOME in INPUT SIGNALS
then slave the A axis the
gantry will move towards
the switches and stop the
motor on the first one to
make contact. The other
axis will continue to run unitl
it contacts it;s swtich . If the
two sides have gotten out of
sync the XY REF will let the
gantry “Auto-square” itself.
Y axis
4 motor setup (dual drive
on the gantry)
X Home
SWITCH
If you make the bracket on
one side or the other
adjustable you and fine
tune the position and
square the gantry with the
table.
CandCNC
X, Y Homes
A Home
SWITCH
Z axis w/ torch holder
Z HOME
Y Home
SWITCH
If you elect NOT to use a
slave axis HOME (in case
you need the input for
something else). You
must still enable A home
in the MACH Profile but
map the A home to the
same Port and PIN as the
Master Home (Y in this
example)
GANTRY
X axis
0, 0
If you stand here to run the machine
then 0, 0 is lower left corner from your
location. X is cross axis (short axis)
Make this
Switch Bracket
Adjustable
Page: 106
SETTING and TESTING INPUTS - HOMES
G
Each HOME Switch in the system has an associated set of parameters to define
how it is used.
To access the Configuration Menu open the CONFIG/Homing&Limits window
shown below. Most of the defaults will be correct. The HOME NEG setting tells
MACH which way to move to find a home switch. After you setup your home
switches you should test each one and setup the seek direction.
1. Make sure the HOME switch shows up in the Diagnostics Window when you
manually activate the switch. On the Z home for a plasma setup using the floating
Torch holder, manually raise the torch by hand and test the switch.
2. Do one axis at a time. In the Program Run and the Diagnostics Tab you will find
a REF button next to each axis DRO. Move (jog) each axis out several inches
away from it’s home switch. Click the REF button on the X axis and if it starts to
move AWAY from the HOME Switch, stop the motion and open the Home & Limits
window and click the Home NEG indicator for that axis. Each time you click it will
change the setting from a Green Check to a RED X and back. Set it to the
opposite value and click OK. Re-Test the REF on the axis you changed and make
sure it moves to it’s Home Switch.
3. Test and set each axis Home that you have
When Homing, the Z axis on a Plasma setup should move down to the material. It
will move until it trips the Z home switch then stop, IT WILL NOT
AUTOMATICALLY PICK UP THE Z above the material.
CandCNC
Page: 107
BladeRunner
Hardware
SETTING HOME SWITCH “SEEK” DIRECTION.
HOME & LIMIT WIRING
Typical connections for Homes and Limits
BladeRunner
Hardware
G
Home and limit switch hook ups
START of
STRING
NO
COM
NC
NO
COM
NC
NO
COM
NC
NO
NC
All of the inputs are opto isolated and
map to a specific pin on the parallel
port(s). In reality you can use any
input for any signal. Inputs are not fast
enough for Encoder feedback faster
than a few pulses per second. The
inputs use a “floating” ground (+12
return). If you need more inputs than
the 8 (9 with EPO) then a PORT 2 card
can be hooked to the UBOB and the
added Aux and BHome inputs will work
with a second parallel port.
COM
Normally closed contacts
For far limits. Wired in series
END of
STRING
NO
COM
NC
NO
X
COM
NC
Y
COM
NC
Z
NO
Individual Homes Wired Normally Open
JUMPER EPO to be able to
bring MACH out of RESET
T19
YHome Xhome
++
+
T11
J1
See FT-01 manual
for installing
Feather Touch
FT-01
PWRIN
D12
D2
K4
6
1
K3
D10
K4
D3
K3
QUAD RELAY
J2
ToUBOB
NO
DANGER!
J14
DANGER!
COM
K4
NO Com2
K3OUT
D11
K3
J17
K4 J4
C&CNC
TABLEI/O
REV10
DANGER!
10
CandCNC
OK
T21
T12
T13
T15
ZHome
C1
1
EPO
CONNECTED TO
TABLE I/O HEADER
ON UBOB III CARD
AHome
DOWN LIMITS
T20
T17
Xhome
T14
J3
T2
Yhome
T16
ARC
UP
ZHome
T18
1
T6
InsideRow
COMMON
T5
AHome
LIMITS
T7
T3
FT-01
DOWN
T9
5
UP
20A240VMAX
Page: 108
BladeRunner
Hardware
G
The X Home should light up when you manually activate X Home switch. It should be off
when the switch is not active. If it is reversed (i.e. goes OFF when you activate the switch
but stays on otherwise) you will need to reverse the polarity of the switch in Ports & Pins/
Input Signals. We recommend using normally open (NO) contacts on Homes and Normally
Closed (NC) contacts on the far limits (if used).
The far limits are wired in series external to the Table I/O card and it is setup so breaking
the string at any point activates a hard limit. The hard limits are safety switches located at
points on the table to prevent the machine from going past the table travel limits. You can
have far limits (opposite the 0,0 location of the table) AND near limits (at points where the
machine would crash on the other side of the Home switches. Limits are optional and on
stepper based systems you could elect to have just hard stops since the motors can be
stalled without damage.
A NOTE ABOUT LIMITS on the BladeRunner:
A stepper motor/driver is a “torque limited system” meaning that the drives limit the amount
of torque a stepper motor can apply to a load. It does that by limiting the current on each
pulse. While most AC and DC motors will quickly exceed their ratings if presented with a
large overload, the stepper just stalls (starts slipping) and “loses steps”. Because if this
they are safe from overload and will simply stop turning. Simple mechanical stops on an
axis will keep motors from running to far and no damage to motor or drive is inflicted. It
sounds bad because the motor vibrates as it attempts to turn but no harm is done. The
motor will not overheat and the electronics will not see it as an overload unless all 4 motors
are stalled at the same time. LIMITS are more for decoration than function on a stepper
system. Some users like to have them. If that describes you then by all means install and
set them up...you will feel much better!
CandCNC
Page: 109
SPECIAL MANUAL JOG INPUT
For Oxy-Fuel Cutting
SPECIAL SECTION: Hooking up a remote control for doing Oxy-Fuel cutting.
Disregard this section if you do not have an oxy-fuel setup on you table.
IF YOU DO WANT TO SETUP AN OXY_FUEL SYSTEM PLEASE NOTE THE
FOLLOWING:
1. Setup and copy your working Plasma Profile using the MACH LOADER covered
inPage 34 of this manual.
2, Make the changes listed on the next pages to THAT NEW PROFILE.
3. You can control the Z UP and DOWN manually during flame cutting using either a
set of switches OR the PC keyboard but not BOTH.
4. There may be some reconfiguration of outputs needed for oxy=fuel if you want
automated control of the Oxygen valve and/or an automatic striker.
5. The THC cannot sense the height of the tip since there is no cutting volts or current
to read. Typically oxy-fuel is done on thicker material and at much slower feedrates
than plasma so manual height operation is possible.
CandCNC
Page: 110
BladeRunner
Hardware
G
SPECIAL MANUAL JOG INPUT
For Oxy-Fuel Cutting
BladeRunner
Hardware
G
If you want to use the manual UP and DoWN inputs on the Table I/O card for controlling the Z while code is running
you can use one of the swtich setups on the previous page into inputs. You must then open the COFIG in MACH
and select PORTS 7 PINS and the MILL OPTIONS TAB as shown. Check the “Allow THC UP/DOWN Control
even if not in THC Mode” Checkbox and then APPLY button. This sets up MACH so it will listen to the UP and
DOWN commands even when the THC Button is OFF in MACH. Also remember that the UP and DOWN inputs on
the Table I/O card are in parallel with the UP and DOWN signals from the DTHC so MACH will LISTEN TO
EITHER. The manual UP and DOWN is not normally used with the DTHC and the THC Button enabled. You CAN
manually control the plasma height if you turn off the THC button and have the above box checked but it is
not recommended. The speed at which plasma normally cuts and the small arc gaps involved makes the
reaction time too slow for manual Z spacing
To do the same thing using the keyboard you must setup the INPUT Pins in MACH so THC UP and THC DOWN
use EMULATED enabled (green check). YOu can then click on the HOT KEY for each and use the Set Hotkey to
select two keyboard keys. Do not use keys assigned to any other function! While you can use both hardware
swtiches and the keyboard hot keys it could get confusing. We present both as options but recommend you use
one of the other
CandCNC
Page: 111
SPECIAL MANUAL JOG INPUT
For Oxy-Fuel Cutting
BladeRunner
Hardware
G
USING TABLE I/O INPUTS FOR REMOTE CONTROL OF UP and DOWN
OR
UP
DOWN
ON-OFF-ON
Center off.
Single toogle
Normally Open Momentary Switches
used for external control of UP and
DOWN (manual) for OXY -FUEL
NO
OK
T12
T13
YHome Xhome
++
+
T11
J1
K4
6
1
FT-01
PWRIN
D12
D2
T21
T14
T15
ZHome
C1
1
EPO
K3
D10
K4
D3
K3
QUAD RELAY
J2
ToUBOB
NO
DANGER!
J14
K3OUT
DANGER!
COM
NO Com2
K3
J17
D11
C&CNC
TABLEI/O
REV10
K4 J4
K4
DANGER!
10
CandCNC
AHome
DOWN LIMITS
T20
T17
Xhome
InsideRow
COMMON
T19
ARC
UP
T16
T18
T2
Yhome
J3
T6
T7
T3
ZHome
1
T9
T5
AHome
LIMITS
FT-01
DOWN
5
UP
NO
COM
20A240VMAX
Page: 112
X HOME
ISO1
R1
RESISTOR
Floating Ground
CANDCNC
5 to 24VDC
100 ma or more
-
+
Table I/O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
RED
CON25
RESISTOR
R3
Page: 113
12 VDC
24 VDC
820
1.5K
5 VDC
10 VDC
330
680
BLK
RED
LED on Table I/O
D4
R3 Values Aux volts
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
T13
T12
GRN
BLU
WHT
XHome Tab
1
Common Tab
OPB917IZ Slot Opto
Qut goes low when light
path is interrupted. Low
signal turns on input
R2
X HOME INPUT
C2
CAP NP
Floating Ground
Table I/O [HCL 301]
C ARD
LED blocks higher voltage to UBOB Opto
BladeRunner
Hardware
Floating Ground
Detail of connection for ONE input (X HOME). All others are the same except on different pins
AUX 5 to 24VDC Supply to match Opto switch. Do
not Ground neg side of power supply to external
ground or chassis. Negative side needs to connect
to input circuit common (Floating Ground on the Table
I/O card ONLY)
Normally a NO switch is connected across T12 and T13
terminals (XHome) and closing the switch turns on D4
through the cable to ISO1 on the UBOB. Since there
are two LED's in series (equal to 4 diodes) current from
the 24V side will not flow backwards through the LED's
and damage anything. Reverse breakdown of LED is >
than 24VDC.
OPTO on UBOB Card
+
4
3
ON UBOB Card
1
CandCNC
2
DC-DC Floating 9V
WARNING Do not attempt this option unless you can read and understand the schematic
and have the wiring skills to make the connections and test equipment to troubleshoot the setup..
We offer this page as an EXAMPLE as to how to wire in other types of sensors. It does not represent components or products we sell or
provide in the BladeRunner. We have been asked in the past on how to do this and this page is the documentation of that request. .Please
do
USING OPTICAL SENSORS FOR INPUTS
G
E-STOP and Safety Shutdown
BladeRunner
Hardware
G
In the BladeRunner system there are two forms of E-STOP:
Software (MACH3 based) E-STOP
Hardware (ESPII / UACM Card) E-STOP
SOFTWARE E-STOP
In MACH there is a manditory input for E-STOP. It is implemented as a normally
closed input (must be held low to come out of RESET). That input is assigned in the
BladeRunner AIO to input pin 10. With nothing attached to that pin it is pulled high by
the parallal port. IF MACH is in RESET, all outputs are disabled and no inputs are
acted on (ignored).
There is a general misunderstanding about software E-stop and if it is safe if the
motors are still under power. The answer lays in the fact that a stepper based system
like the BladeRunner HAS TO HAVE PRECISE TIMED SIGNALS to special drivers to
initiate motion. It cannot simply “run away”. It is virtually impossible to make a stepper
motor turn without the operating software (MACH) and the electronics providing a valid
pulse stream. In any failure scenario of the hardware (drive malfunction, shorted/open
signals, disconnected wires, loss of power, etc) motor rotation is not possible. Since
the software MUST be in control to issue pulses and the Charge Pump will turn off if
the software is frozen, in a loop, or malfunctioning, putting the software into RESET for
any reason will stop motion. It is actually harder to get motion when you SHOULD
have it than to have a stopped system. One of the added benefits to a stepper based
control is IF IT DOES NOT HAVE VALID STEP COMMANDS IT LOCKS THE
MOTORS if power is still on the drives. Any consequence of applying DC or a short to
any motor winding will cease rotation and typically lock the motor. The only argument
is that the input device for E-STOP might fail, but that is no more likely than a failure of
a HARDWARE based e-stop. So a failed drive will not cause a motor to Run Away. A
failed computer or communications interface will not result in random or uncontrolled
motion. Coupled with the Charge Pump (see section on the Charge Pump function)
the probability of any motion more than .050 inches is about the same as a computer
attached to a printer and no keyboard activity (no user) firing up and printing a perfect
copy of the Magna Carta from random noise.
Since it REQUIRES concise control from the software to create motion the software
can effectively control it going into RESET and E-STOP
The user can willfully disable Software E-STOP by setting the E-STOP input to read
the wrong polarity and render the E-STOP disabled but a hardware E-stop can be
disabled as well.
CandCNC
Page: 114
E-STOP and Safety Shutdown
SOFTWARE E-STOP
Implementing a SOFTWARE (ONLY) E-STOP. The BladeRunner AIO when properly
setup will be put into RESET if the E-STOP (EPO) string is broken.
EPO CONTACTS
ON TABLE I/O CARD
Wired Jumper
+
+
Isolated
Power
Supply
Visible LED
J6
ESPII
Supply
Bypass
ESPII Control relay
NC when ON
System is ACTIVE ON. All connections,
voltages and components MUST be
intact and working OR the system will
Software E-STOP. Anytime power is off
MACH cannot come out of reset.
Jumper at EPO can be a string of “N...”
switches (NC in series) that can be
wired at any point on the equipment.
any switch or connection in the string
that open will trigger an E-stop. Once
closed condition is restored the
operator must inititate a RESET to bring
the system back out of Software E-Stop
DANGER ZONE
WHEN AUX AC
CORD IS
PLUGGED IN
CONNECTED TO
TABLE I/O HEADER
ON UBOB III CARD
EPO MUST BE JUMPERED
(Closed). Jumper can be replaced
by one or more Normally Closed
Switches (in series) for Software ESTOP
CandCNC
Page: 115
BladeRunner
Hardware
G
E-STOP and Safety Shutdown
HARDWARE E-STOP
USE Dotted wiring for single
switch. You can wire multiple
switches in series as long as
they all are Normally Closed
when inactive. Pushing any
swtich in the string will OPEN
HARDWARE E-STOP. As an option there are
connections provided for a Normally Closed
Hardware E-stop that removes current flow from the
Control relay. The Control relay is a small electromechanical DPDT relay that DIRECTLY provides
power to the Main Safety Relay (AC INPUT RELAY).
This is a direct shutoff with no semiconductor failure
points. When the HARDWARE E-STOP is tripped
the DC power is removed from the motors, dynamic
braking is applied (Load Dump), a software e-stop is
sent via the second set of realy contacts on the
Control Relay, and the processor that controls all of
the power monitor and functions is signaled. As
long as the Hardware E-STOP is OPEN (tripped)
than the AC is removed from the main power supply.
Barring failure of both the processor and the control
software, there is no possibility of motion from the
system even if the Hardware E-STOP is pulled out of
tripped condition
NO COM NC
BladeRunner
Hardware
G
NO COM NC
Switch must be Normally Closed and
OPEN when pushed (or pulled on
some types). If switch is mounted
more than 6 ft from Front Panel card
use twisted pair wire. 24 to 20 ga
wire is okay.
REMOTE SWITCHES NOT INCLUDED
Serial to UBOB
D19
J3
NC C NO
LS2
J29
J9
BladeRunner
ONLY
1
Interface
+
D5
To External DB9
on MTA Side Plate
2
1
EPO
EPO
Jumper
to RUN
G251-4
DB9 Serial
Q6
2
UACM
16
15
1
4
2
STOP
SW2
J4
3
MODE
Grey = no jumper
MODE
Jumpers
see
Chart
Test
1
1
3
5
2
7
8
CandCNC
1 J52
Power
Fault
J4 MODE JUMPER ON UACM
FRONT PANEL CARD
J4
MODE
1
4
6
TEMP 2
J1
Sensor
TEMP2 KILL
ON for
BladeRunner
Drives
Off
J63
Rear of
Programing
Headers
FRONT PANEL
1
2
SW1
CARD
RUN
4
3
MODE
Jumpers
50hz =Jumpered
1
3
5
2 50/60 HZ
7
8
4
6
BladeRunner
TEMP 2
J1 Jumpered for 650 & 1500
Sensor
TEMP2 KILL
ON for
ALL versions
update: Temp 2 jumper
on all units shipped after 4/2/11
Y1
U7
SW3
MTA
1
TEMP PROBE
C
Test
CandCNC
UACM
FRONTPANEL
REV3
20
19
1
SIP6
1
J45
ESP 650
& 1500
ONLY
2
Temp
Fault
Lamps & Switches
on Backside of card
+5 OK
Drive
Fault
Page: 116
The BladeRunner AIO uses a unique method to get expanded outputs from just one
Parallel Port. Using the CandCNC UBOB III technolgy the outputs are mapped to a
“Virtual Port” (PORT 4). The status of each of those outputs is held in MACH on the
PORT. The ccc_comm plug-in then uses three of the parallel port pins (1. 14 and 16) to
send the data to the UBOB III card. The data has 8 bits and that represents the status
of 8 individual outputs. The data is read and updated many times per second so any
change in the MACH settings get refreshed in the hardware quickly. Unlike most
MACH Breakout Boards (BoB’s) the UBOB III can control up to 8 independant relay
outputs.
DO NOT MAKE CHANGES TO THE Charge Pump SETTINGS
Note: the Output SIGNAL name above is mapped to a PORT/PIN pair and that
defines which physical device is activated by the UBOB output section. While
there are 8 signals two of them (pin 7 and Pin 8 ) are used with the DTHC
internally. Pin 8 goes though the DTHC module and fires the Torch Relay (on a
plasma setup) in the THC SENSOR PWM module.
CandCNC
Page: 117
G
BladeRunner
Hardware
SETUP & TESTING OUTPUTS
Changes to mappings with DTHC II for direct TORCH
ON option
Output mappings for DTHC IV and REV 15 UBOB
units.
CandCNC
Page: 118
BladeRunner
Hardware
G
SETUP & TESTING OUTPUTS
G
10
K4
K3
J2
K4
K3
K3
D3
D10
DANGER! DANGER!
K3
BladeRunner
Hardware
K4
LED
COM J5
K4Panel
J4
K4
K3
COM
NO Com2
NO
C&CNC
TABLEI/O
REV8
K3
NO J18
OUTPUTS
6
D2
+
T7
T6
C9
C5
1
C4
C6
T8
T19
T17
T18
T16
C3
C7
AUX0
DOWN (PORT2]
UP
T9
T2
LIMITS
T3
ZHome AHome
T4
T15
T13
Xhome YHome
T5
C2
TABLE I/O Card
T14
T12
OUTPUT Status (Cont). There are two AUXILLARY OUTPUT Relays on a
BladeRunner AIO unit. They are designed as Output 1 and Output 2 on the Buttons
and they toggle ON/OFF the AC Outlets A and B on the end of the BladeRunner Box.
These AC outlets are wired to the AUX AC line cord on the BladeRunner. That cord
must be plugged in before the outlets can be used. CAUTION there is high voltage
(120VAC ) at the Relays and the Outlets. DO NOT OPERATE THE BLADERUNNER
WITH THE AUX AC CORD PLUGGED IN AND THE TOP COVER REMOVED.
NOTE: The number of output relays can be expanded by adding in a Quad Relay
Expansion card but is seldom used so connections and setup are not covered here
On a BladeRunner Dragon-Cut (with DTHC) OUTPUT 1 is used for turn on the TORCH
Relay located out on the THC SENSOR PWM. Operation is covered in depth in the
DTHCII User Manual but it is easy to simply plug in the THC SENSOR PWM module to
the DTHCII module using the 25ft UTP Cable and test the TORCH ON by toggleing the
TORCH button on the Diagnostics Screen and watching the TORCH LED on the front of
the THC SENSOR PWM module. You can test the other two AUX outputs by plugging
in the AUX AC cable and plugging in an AC load (table lamp, 120VAC FAN . etc) and
toggling the individual outputs on and off.
The AUX outlets can also be turned ON and OFF from G-code using an “M” command.
What M command is used to turn on/off an OUTPUT is a setting in MACh and comes
defaulted so a M03 or M04 turns on OUTPUT1 (Torch on the Plasma Profile, Spindle on
the Router Profile. M05 turns OFF either. In a full Spindle Speed System the M04
turns ON the REVERSE RELAY.
CandCNC
Page: 119
SETUP & TESTING OUTPUTS
BladeRunner
Hardware
G
AUX AC
Line Cord
AC Line Cord
Main Power
10
K4
LED
COM J5
K3
K4
J2
6
UP
K
DOWN
C8
D17
C6
K
C7
C5
C9
LIMITS
D7
AHome
K
C4
D6
K
ZHome
T16
D5
D8
ARC
OK
K3
T18
C3
K
T6
T17
K
K
T7
T19
YHome
D18
T8
T2
T15
T10
C2
1
K3
K4
AUX0
DOWN (PORT2]
UP
T9
T3
LIMITS
T4
ZHome AHome
T5
C15
D4
EPO
+
T20
D10
D3
T11
K
T21
K3
K3Panel
J1
D15
BHOME AUX1
ARC
OK
J13
Xhome
J6
J8
J10
DANGER! DANGER!
K
J12
AUX2
D2
T13
Xhome YHome
T14
T12
CandCNC
J33
K3
AUX4
K4Panel
J4
K4
K3
COM
J7
NO
NO Com2
K3
J11
NO J18
OUTPUTS
AUX3
THIS
SECTION OF
TABLE I/O IS
Dangerous
(High Voltage)
When AUX AC
CORD IS
PLUGGED IN!
Switched B
Outlet
K4 Relay
C&CNC
TABLEI/O
REV8
Switched A
Outlet
K3 Relay
Page: 120
Checking Outputs Using Diagnostics Page
Once you have established that you are getting proper inputs (see previous page) then
you can test the outputs. With the BladeRunner connected and powered up and with
the DC power on (Front panel White Button pushed and GREEN Led is ON) then open
the Diagnostic tab
Bring MACH out of RESET
(Indicator on steady GREEN)
If you cannot come out of
RESET see previous page for
ESTOP input being OFF
Charge Pump LED (Yellow)
As soon as MACH is out of RESET the CP (Charge Pump) LED on
the side of the Bladerunner should come on steady
No CP will inhibit ALL outputs including Motor motion signals.
Nothing will turn on or move. Lack of CP shows the parallel port is
not working or at the wrong port address in MACH. You can also
get no CP if you are not running the correct profile or the ccc_Ubob
and ccc_comm plug-in’s are not active.
Once you have the CP on you can trip an output and it will start
to flash in the OUTPUT STATUS. Plasma systems will have 3
ouputs (Torch is output1). Routers only have two outputs.
If you want to test the physical outputs on a Blade runner plug an AC device (lamp, fan,
etc) into the A or B outlet on the end and toggle Output 2 or 3 to turn it on.
CandCNC
Page: 121
G
BladeRunner
Hardware
SETUP & TESTING OUTPUTS
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