1. Product Introduction
The DDCSV4.1 CNC Offline Controller represents the latest advancement in the DDCS series of motion controllers. It is engineered to operate CNC machines independently, without requiring a connected computer. This controller offers a robust set of upgraded features compared to its predecessor (DDCSV3.1), delivering enhanced accuracy, user-friendly simulation capabilities, and smoother execution of complex G-code programs.
The DDCS V4.1 is the latest generation of Digital Dream’s offline CNC controller series, upgraded from the well-known V3.1 and V2.1 versions. It supports 3 to 4-axis motion control and is designed for use in various CNC machines such as routers, mills, lathes, and plasma cutters. It is commonly employed in industrial CNC applications including milling, engraving, drilling, and tapping.
Designed as an alternative to PC-based systems like Mach3, the DDCSV4.1 ensures precise motion control with up to 500kHz pulse frequency, supporting both stepper and servo motors. Whether you’re building a CNC milling machine, an engraving unit, or a multi-axis gantry system, the DDCSV4.1 provides enhanced offline control, Ethernet communication, and flexible customization options.
The DDCSV4.1 Standalone Motion Controller is a device used to control the movement of a CNC (Computer Numerical Control) machine. It is an offline controller, meaning it can operate independently without the need for a separate computer or other devices to provide input or receive output. The DDCSV4.1 controller is capable of controlling 3 or 4 axes of motion and can execute G-Code programs. It is commonly used in manufacturing, machining, and other industries that utilize CNC equipment, ensuring precise and accurate control of machine movements. The DDCSV4.1 controller is designed to be used as an alternative to the Mach3 motion control system and supports drilling and tapping operations.
2. Setup and Installation
2.1 Unboxing
Carefully unpack your HLTNC DDCS V4.1 CNC Controller and its accessories. Ensure all components listed below are present.
Video 1: Unboxing and overview of the DDCS V4.1 CNC Controller and its components.
2.2 Package Contents
Figure 1: HLTNC DDCS V4.1 Product Package Kit.
- 1 x DDCS V4.1 Controller
- 1 x DDCS V4.1 Breakout Board
- 1 x DB15 interface for handwheel wiring
- 1 x DB37 cable (2 meters) connecting the controller host and the wiring board
- 1 x 50cm USB extension cable
- 1 x U disk
- Some set screws
2.3 Dimensions and Mounting
Refer to the drawing specification for precise dimensions and mounting details of the DDCS V4.1 controller.
Figure 2: Drawing specification for DDCS V4.1 controller dimensions.
The terminal board can be installed in a chassis using a matching C45 guide rail. The recommended guide rail size is TS-35/15/1.5.
Figure 3: Terminal board installation with C45 guide rail.
2.4 Wiring Diagrams
Proper wiring is crucial for the safe and correct operation of your CNC machine. Refer to the following diagrams for power, drive, and input/output connections.
Figure 4: Overview of Interface Buses.
Figure 5: Wiring Port Diagram for DDCS V3.1 & DDCS V4.1.
Figure 6: Power Wiring Diagram and Drive Mode Connection.
Figure 7: Output Port to Relay and Limit Switch/Tool Setter Connection.
3. Operating Instructions
3.1 Controller Interface
The DDCS V4.1 features a 7-inch TFT LCD screen and an intuitive button layout for easy operation.
Figure 8: DDCS V4.1 Controller Front View.
3.2 Key Definitions and Functions
The following table details the function of each key on the DDCS V4.1 control panel:
Figure 9: Definition of Keys.
3.3 G-Code Program Execution
- Loading Programs: G-code programs can be loaded via USB flash drive or Ethernet. The Ethernet file transfer feature allows for larger files without size limitations.
- Starting Operation: Press the START key to begin program execution.
- Pausing/Resuming: Use the PAUSE key to temporarily halt operation and START again to resume.
- Resetting: The RESET key stops the current operation and resets the controller.
- Simulation: The improved simulation function allows for careful observation of the programming path. You can adjust magnification, perform soft limit checks, and pause/resume the simulation at any point.
3.4 Advanced Features
- Mapping Axis Function: Configure dual Y gantry structure machines.
- Servo Spindle Support: The spindle can be configured as a servo spindle.
- Polar Coordinate Programming: Utilize polar coordinate and rotation instructions for complex movements.
- Contour Error Smoothing: New algorithms ensure smoother small line segment paths.
- Detection Functions: Supports corner detection, inner center detection, and outer center detection.
- Quick File Startup: Improved startup functions allow quick loading of files of any size.
- Configurable Input Ports: Input port functions can be arbitrarily configured, with added driver alarm support.
- Cyclic Encoder for A-axis: Particularly useful for processing files where the A-axis value continuously increases.
4. Maintenance
To ensure the longevity and optimal performance of your HLTNC DDCS V4.1 CNC Controller, follow these maintenance guidelines:
- Keep Clean: Regularly wipe the controller's screen and body with a soft, dry cloth. Avoid using harsh chemicals or abrasive materials that could damage the surface.
- Check Connections: Periodically inspect all wiring connections to ensure they are secure and free from corrosion. Loose connections can lead to erratic behavior or system failure.
- Environmental Conditions: Operate the controller within its specified environmental conditions (temperature, humidity) to prevent damage. Avoid exposure to excessive dust, moisture, or extreme temperatures.
- Firmware Updates: Check the manufacturer's website for any available firmware updates. Keeping the firmware up-to-date can improve performance, add new features, and fix bugs. Follow the update instructions carefully.
- Power Supply: Ensure a stable 24VDC power supply. Fluctuations or incorrect voltage can damage the unit.
5. Troubleshooting
If you encounter issues with your DDCS V4.1 controller, consider the following troubleshooting steps:
- No Power: Verify that the 24VDC power supply is correctly connected and providing the specified voltage. Check all power cables and connections.
- Program Not Running:
- Ensure the G-code file is correctly loaded from the USB disk or via Ethernet.
- Check for parsing errors. The DDCS V4.1 provides parsing error prompts, which can help identify issues in your G-code.
- Verify that all axes are homed and limit switches are not triggered.
- Erratic Movement/Axis Issues:
- Inspect motor wiring and connections to the breakout board and controller.
- Check motor driver settings and ensure they match the controller's configuration.
- Review the drive mode direction and pulse connection diagram (Figure 6) for correctness.
- Emergency Stop Triggered: The controller features configurable emergency stop acceleration parameters to prevent sudden, harsh stops during high-speed movement. If an emergency stop occurs, identify and resolve the cause before resetting.
- Communication Issues (Ethernet/USB):
- For Ethernet, ensure the cable is properly connected and the network settings are correct. The Ethernet indicator on the controller should light up.
- For USB, ensure the USB disk is properly inserted and recognized. The USB disk indicator should light up.
- Screen Display Problems: If the screen is blank or flickering, check the power supply and internal connections.
If the problem persists after attempting these steps, contact technical support for further assistance.
6. Specifications
6.1 General Specifications
| Feature | DDCS V3.1 | DDCS V4.1 |
|---|---|---|
| Axis Control | 3 or 4 | 3 or 4, with Slave X/Y/Z |
| Screen Size | 5-inch TFT | 7-inch TFT |
| Communication | USB only | USB + Ethernet file transfer |
| Max Frequency | 500kHz | 500kHz |
| Spindle Control | Analog 0–10V or PWM | Servo spindle via PUL/DIR |
| Gantry Support | No | Yes (dual-motor axis) |
| Simulation Enhancements | Basic | Full simulation with pause/resume |
| Programming Features | Standard G-code | Polar coordinates, rotation, radius comp |
| A Axis Support | Limited | Cycle encoder for unlimited A-axis rotation |
| Language Support | English, Chinese, Russian | Multi-language, user-defined |
| Alarm Inputs & Port Mapping | Fixed | Configurable driver alarm ports |
| Emergency Stop Behavior | Immediate stop | Configurable deceleration stop |
6.2 Internal Hardware & Specs
- Architecture: FPGA + ARM CPU combo for motion + user interface separation
- Operating System: Embedded, Linux-based
- Screen: 7” TFT LCD (high resolution)
- Pulse Output: Max 500kHz per axis
- Input/Output: Configurable Digital Inputs, Custom mapping available for Alarm Inputs
- File Input: USB Flash Drive & Ethernet
- Axis Types: Supports up to 4 axes (X, Y, Z, A), with optional dual motors on any axis
- Voltage: 24VDC input
6.3 Application
The HLTNC DDCS V4.1 is suitable for a wide range of applications, including:
- CNC Milling Machines
- Engraving Machines
- 3D Wood Carvers
- Gantry-Style CNC Machines
- CNC Tapping & Drilling Systems
- Automated Production Lines
Figure 10: Usage Scenarios.
7. User Tips
- Axis Configuration: The DDCS V4.1 controller is versatile and supports both 3-axis and 4-axis configurations. If you have a 4-axis model, it can still be used effectively for 3-axis operations.
- G-Code Compatibility: The controller supports a comprehensive Fanuc G-code set and is compatible with G-code generated by various CAD/CAM software, including ArtCam, MasterCam, ProE, JDSoft SurfMill, Aspire, and Fusion 360.
- Offline Operation: Leverage the offline capability to run your CNC machine without a dedicated computer, enhancing portability and reducing potential interference.
- Ethernet for Large Files: Utilize the Ethernet communication for transferring large G-code files efficiently, as it offers an advantage over USB for file size.
8. Warranty and Support
The HLTNC DDCS V4.1 CNC Controller is manufactured to high-quality standards. For any technical assistance, troubleshooting beyond this manual, or warranty inquiries, please contact the HLTNC Official Store or your authorized reseller. Ensure you have your product model (DDCS V4.1) and any relevant purchase information ready when seeking support.
