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User Manual for AUDIOMS AUTOMATIKA models including: USB-MC-INT-v3 Motion Controller, USB-MC-INT-v3, Motion Controller, Controller
Audioms Automatika doo Kragujevac, Serbia web: www.audiohms.com e-mail: office@audiohms.com Page 4 of 31 USB-MC-INT v.3 Motion controller user’s manual, July 2023
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DocumentDocumentUSB-MC-INT USB Motion Controller User's manual www.audiohms.com USB-MC-INT v.3 Motion Controller User's manual © AUDIOMS AUTOMATIKA DOO CONTENTS 1 Description................................................................................................................................... 4 1.1 Supported Mach3 functions................................................................................................... 5 1.2 Not supported........................................................................................................................ 5 1.3 Other functions...................................................................................................................... 5 2 Technical specifications ............................................................................................................... 6 3 INSTALLATION ........................................................................................................................... 6 3.1 Driver installation................................................................................................................... 6 3.2 Plugin installation .................................................................................................................. 7 3.3 Automatic firmware update.................................................................................................... 8 4 Configuration ............................................................................................................................... 8 4.1 Adjusting ports and pins in the Ports & pins window.............................................................. 9 5 USB-MC-INT configuration dialog ................................................................................................ 9 5.1 General setup tab (Figure 5.1) .............................................................................................. 9 5.1.1 Spindle/laser PWM frequency ........................................................................................ 9 5.1.2 Home retract speed ...................................................................................................... 10 5.1.3 Index pulses per revolution........................................................................................... 10 5.1.4 Dereference all axes on disconnect.............................................................................. 10 5.1.5 Maximum step frequency ............................................................................................. 10 5.1.6 Hardware MPG............................................................................................................. 10 5.1.6.1 Limit MPG federate ................................................................................................................... 11 5.1.7 Laser PWM options ...................................................................................................... 11 5.1.7.1 Ramp power compensation ...................................................................................................... 11 5.1.7.2 Sync output with g-code moves, M10px, M11px ...................................................................... 11 5.1.7.3 Gray level raster engraving....................................................................................................... 11 5.2 Input Filter tab ..................................................................................................................... 12 5.3 Analog input & Encoders tab ............................................................................................... 12 5.3.1 Special function group .................................................................................................. 12 5.3.2 Zero threshold voltage.................................................................................................. 13 5.3.3 Encoder mapping ......................................................................................................... 13 5.3.3.1 Encoder/MPG resolution........................................................................................................... 13 5.3.3.2 Detent (counts/unit) .................................................................................................................. 13 5.3.4 THC options tab ........................................................................................................... 14 6 Shuttle mode.............................................................................................................................. 14 7 Status window............................................................................................................................ 14 8 Connecting USB-MC-INT motion controller into CNC system .................................................... 15 8.1 Connection with computer and power supply for the USB-MC-INT motion controller........... 15 8.2 Connecting stepper motor drives to USB-MC-INT motion controller .................................... 16 8.3 Connecting drives from other manufacturers to USB-MC-INT motion controller .................. 19 8.4 Connecting relays outputs ................................................................................................... 22 8.5 Analog output on USB-MC-INT motion controller ................................................................ 23 USB-MC-INT v.3 Motion Controller User's manual © AUDIOMS AUTOMATIKA DOO 8.6 Analog input USB-MC-INT motion controller ....................................................................... 24 8.7 Opto-isolated digital inputs .................................................................................................. 25 8.7.1 Isolated mode for wiring limit switches to the opto-isolated inputs ................................ 26 8.7.2 Non-isolated mode for wiring limit switches to the opto-isolated inputs ......................... 27 8.7.3 Connecting the cutting tool height measuring system ................................................... 28 8.8 General purpose digital inputs ............................................................................................. 29 8.9 General purpose digital outputs........................................................................................... 30 9 LED indicators ........................................................................................................................... 31 9.1 OP/ER Status LED ........................................................................................................... 31 9.2 Comm LED ......................................................................................................................... 31 10 Safety recommendations ......................................................................................................... 31 USB-MC-INT v.3 Motion Controller User's manual © AUDIOMS AUTOMATIKA DOO 1 Description Con.16 and Con.17 General purpose TTL digital inputs Con.21 and Con.22 Opto isolated digital inputs with 24V level voltage LED indicators Con.1 USB port to computer Con.15 Analog output 0-5V or 0-10V Analog input 0-5V Con.22 Two relay outputs 220VAC/8A or 30VDC/8A Con.2 Power supply 15-25VDC Con.14 TTL digital outputs Con.10, Con.11, Con.12 and Con.13 STEP/DIR digital outputs to control up to 4 axes Figure 1.1 USB-MC-INT v.3 motion controller USB-MC-INT v.3 is 6-axes motion controller (Figure 1.1) designed for use with the popular Mach3 CNC control software in Windows XP, Vista, 7, 8, 8.1 and 10 operating systems with 32-bit (x86) and 64-bit (x64) architectures. In order to provide reliable communication with computer, CMC filter (Common Mode Choke) has been built in on USB line, as well as TVS protection (Transient Voltage Suppressor). The motion controller is supplied with a high-quality 1m long USB cable with two ferrite cores. Many years of experience in designing have enabled us to optimize the USB-MC-INT v.3 motion controller to meet all technical requirements, while being economically affordable. USB-MC-INT motion controller could be also controlled with motion control software mikroCNC. Motion controller USB-MC-INT takes over all real-time tasks that require precision timing. Thus, computer CPU is less loaded, so control software can now work on less powerful desktops, laptops, and even tablet computers. Considering that the controlling task does not need a high performance computer, the price for a complete control system can now be considerably reduced. USB-MC-INT motion controller has: 16 digital outputs, two of them are relays outputs, 14 digital outputs, while 8 of them are opto-isolated outputs for voltage level of 24 V and 6 of them are TTL general purpose digital outputs, One analog output 0-5V or 0-10 V (selectable output level), and One analog input 0-5 V. Maximum output frequency for step signal is 250 kHz, optionally 125 kHz. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 4 of 31 All inputs and outputs are available through terminal block connectors. That way it is easy to connect all peripherals on USB-MC-INT motion controller. Mach3 plugin contains integrated latest compatible version of firmware so in case that firmware has to be updated, this process is automatic and easy for user. Since June 2019, the firmware version of motion controllers (Firmware v01.19 & Plugin v01.16) USB-MC-INT and USB-MC use the same Mach3 plugin. NOTE: USB-MC-INT motion controller can be powered from computer USB port, but in that case some function of the motion controller won't be available. In order to use all available USB-MC-INT motion controller functions it is necessary to use external power supply 15-28 VDC / 500 mA. 1.1 Supported Mach3 functions all jogging modes spindle PWM out, adjustable frequency 10 Hz 200 kHz spindle index input, adjustable divider spindle step/dir axis spindle relays (M3, M4 and M5) coolant relays (M7, M8 and M9) ESTOP input MPG (encoder) inputs, all Mach3 MPG modes + hardware mode freely assignable functions to any of inputs and outputs adjustable active signal state (low/high) for all inputs and outputs homing/referencing (single axis and multiaxis) hardware limit switches softlimits with deceleration for smooth stop limits override, auto/manual/external charge pump outputs, adjustable frequency (12.5 kHz and 5 kHz) slave axes probing function (G31) laser M10p1/M11p1, e5p1/e5p0 fast outputs (#1-6) laser PWM, power compensation (PWM duty cycle can change in relation to velocity of movement), adjustable arbitrary relation curve laser PWM, gate by M10/M11 laser gray scale (8-bit) engraving shuttle mode, adjustable acceleration time detailed adjustment for debouncing of all input signals FRO, SRO or any DRO/Variable control using potentiometer or rotary encoder offline mode threading on lathe using Mach3turn, G32, G76 THC function (integrated and external controller support) THC advanced options (kerf detect, THC lock, low pass filter...) 1.2 Not supported Backlash compensation 1.3 Other functions With softlimits, slow zones are not adjustable, but the width of these zones is automatically determined so that the given criteria for maximum motor velocity and acceleration are obeyed for every axis separately. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 5 of 31 2 Technical specifications Function Description Communication with PC USB port with build-in CMC filter and TVS protection Data buffer of about 1 s for stable communication Number of supported axes 6 Digital outputs - 12 general purpose digital outputs - 1 PNP open collector output (for Enable line) - 1 digital output reserved for analog signal generation Maximum current on general purpose digital outputs 32 mA Relay outputs 2 NO relay outputs with capacity 250 VAC / 8 A max. or 30 VDC / 8A max Digital inputs - 8 opto-isolated inputs for 24V signal levels - 6 Schmitt trigger general purpose digital inputs for TTL levels and with 4.7 k pull-up resistors Maximum STEP signal frequency 250 kHz (optional 125 kHz) STEP pulse width 2 µs (optional 4 µs) PWM output frequency 10 Hz 200 kHz * PWM duty cycle resolution 16-9 bits, depending on frequency; 16 bit for f 2kHz Frequency of signal on Index input 10 kHz Pulse width on Index input 100 ns MPG/enkoder input (x4) frequency 10k steps/sec Number of analog outputs 1 Analog output range 05 V or 010 V Number of analog inputs 1 Analog input range 05 V Number of charge pump outputs 2 Charge pump frequency 12.5 kHz or 5 kHz Power supply 1528 VDC / 250 mA minimum Dimensions 120 mm x 92 mm x 34 mm Weight ~ 125 g NOTE: Shown specifications are subject to change without prior notice * PWM output signal can be assigned to the output pins 1-14 (O1-O14) 3 INSTALLATION 3.1 Driver installation Connect the USB-MC-INT motion controller to a free USB port on personal computer. In most cases, if Windows 7 or newer operating system is used, Windows will automatically find and install required drivers so that manual installation should not be needed. Otherwise, if Windows does not find drivers for motion controller, it will ask for location on local computer to read it from. Drivers can be downloaded from www.audiohms.com site. Note: USB-MC-INT motion controller does not require Mach3 LPT driver to be installed nor does it use this driver. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 6 of 31 3.2 Plugin installation Mach3 plugin contains integrated the latest compatible version of firmware so in case that firmware has to be updated, this process is automatic and easy for user. Plugin can be downloaded from www.audiohms.com. Note: Since June 2019, the firmware version of motion controllers (Firmware v01.19 & Plugin v01.16) USB-MC-INT and USB-MC use the same Mach3 plugin. To install USB-MC-INT Mach3 plugin, copy supplied file usbmc_drv.dll to Mach3 plugins folder (usually "c:\mach3\plugins"). Then, start Mach3 and new plugin should be detected (Figure 3.1). Now choose USBMC-plugin in displayed list of options. Also, optionally turn on option Dont ask me this again so that this choice is remembered and not displayed again on next Mach3 startup. In case that this dialog for plugin selection is not shown, it is possible to initiate it using menu option Function Cfg's\Reset Device Sel... Figure 3.1 Plugin selection Figure 3.2 On power-up, controller is in safe mode, that is, all outputs are in high impedance state (unconnected). Mode indicator LED on controller board is blinking slowly. After clicking RESET button in Mach3, connection with controller is established and status like shown on (Figure 3.2) is reported. Controller then enters normal operation mode, LED indicator on board stops blinking and glows continuously. If USB connection is lost for any reason, controller instantly enters safe mode. Then it is needed to investigate and eliminate cause of error and click RESET button to establish communication again. Also, controller enters safe mode on all configuration changes and also on exiting Mach3 application. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 7 of 31 3.3 Automatic firmware update USB-MC-INT motion controller plugin also contains feqiured firmware for the controller. Thus, upon establishing connection, if it is determined that firmware update is required, message like on Figure 3.3 will be shown. It is necessary to click Yes and wait for the process to be completed (Figure 3.4). Finally, result like on Figure 3.5 should be presented. Current versions of plugin and firmware can be found on About window of USB-MC configuration dialog. Figure 3.3 Figure 3.4 Figure 3.5 4 Configuration Most of configuration is done using existing dialogs for adjustments in Mach3 application, like Ports and pins, General config etc. just like when LPT driver is used. Some additional options, which are offered by USB-MC-INT motion controller, can be adjusted via dialog box that is opened using menu option Plugin Control/USB-MC Config.... The status window that can be opened via Plugin Control/USB-MC Status... Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 8 of 31 4.1 Adjusting ports and pins in the Ports & pins window USB-MC-INT motion controller provides one digital input port with 14 pins and one digital output port with 16 pins. These pins can be remapped as desired, that is, can be assigned different functions that are needed for specific application (Figure 4.1). Figure 4.1 Ports and pins configuration When using configuration dialogs like Motor Outputs, Input Signals, Output Signals etc. number 1 is always used for port number. Available pins on input port are numerated from 1 to 14. Similarly, output port pins are numerated from 1 to 16. USB-MC-INT motion controller will ignore any port number different from 1 and any pin number that is out of available range. 5 USB-MC-INT configuration dialog USB-MC-INT motion controller uses the same configuration dialog as USB-MC motion controller. This dialog can be opened using menu option Plugin Control/USB-MC Config... (Figure 5.1). 5.1 General setup tab (Figure 5.1) 5.1.1 Spindle/laser PWM frequency The frequency of PWM output signal that is used for spindle rpm control or for laser power control, can be adjusted in range 10 Hz 200000 Hz (Figure 5.1). Output pin for this purpose is selected via Spindle axis line in Motor Outputs window (Figure 4.1). Only adjustments for Step signal are used (pin/low act/port), and Dir field is not used for PWM output. IMPORTANT NOTE: Only output pins 1-14 can be used for PWM output (and not pins 15 and 16). Also, in Ports&pins/Spindle setup window, in Motor control group, options Use spindle motor and PWM control should be turned on. PWMBase Freq in the same group, is not used. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 9 of 31 5.1.2 Home retract speed This is the speed of retraction from a home switch given as a percentage of homing speed (Figure 5.1). In first phase of homing (referencing) operation for an axis, movement toward home switch is performed until the switch is activated. Then, movement is performed in the opposite direction (retracting) until the switch deactivates and that position is used as a reference. Home retract speed should be low enough so that good referencing precision is achieved. Figure 5.1 General setup 5.1.3 Index pulses per revolution Index input is used for detection of spindle rotational speed. It is common to use one pulse per revolution, but more than one can also be used (Figure 5.1). 5.1.4 Dereference all axes on disconnect This option should be turned on if it is desired to dereference all axes in case of an error or a break of connection with the controller (Figure 5.1). 5.1.5 Maximum step frequency Enables setting the maximum frequency of the generated step signals (Figure 5.1). Lower speed (125 kHz, 4µs pulse width) is used in case when drivers/controllers that are being controlled are not fast enough for impulse width of 2 µs that is required when using full speed (250 kHz). After changing this parameter it is necessary to restart Mach3 for the new setting to take effect. Also, after the restart, it is needed to check in MotorTuning screen whether the speed for any axis is set to a value greater than the current maximum frequency permits and correct settings if needed. 5.1.6 Hardware MPG If this option is turned on (Figure 5.1) USB-MC-INT motion controller will use hardware MPG mode, that is, reading MPG inputs and generation of STEP/DIR output signals is done completely in hardware without Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 10 of 31 need for communication with PC. This enables very fast response (low latency) and at the same time precise motor control. Configured motor parameters (maximum velocity, acceleration) are obeyed. If this option is turned off, standard Mach3 modes are used for MPG operation. These options can be shown by pressing TAB key in Mach3. In this case USB-MC-INT motion controller reads MPG input, sends current position to Mach3, and Mach3 then, according to the selected MPG mode (Velocity only, Multi-Step...), generates appropriate commands for movements. These commands are then sent to USB-MC-INT motion controller and executed. In hardware mode just like in standard mode, CycleJogStep is used for setting movement step, and also the majority of settings (MPG axis, detent...) are the same. 5.1.6.1 Limit MPG federate If this option is turned on (Figure 5.1), speed limit given with parameter MPG Feedrate is obeyed in hardware MPG mode. This parameter is located on MPG/Jog window (Figure 6.1). 5.1.7 Laser PWM options 5.1.7.1 Ramp power compensation Laser power compensation (Figure 5.1) is used to overcome typical problem during laser engraving, and that is that depth/intensity of engraving depends on movement speed of the laser head. This is particularly visible at the start and at the end of one engraving segment, where laser head slows down and stops, so unwanted black dots appear. To eliminate this phenomenon, laser power can be controlled using PWM so that PWM duty cycle is directly dependent on velocity of the laser head. Thus, for example, if velocity is zero, PWM duty cycle will also be zero. As velocity increases, the duty cycle that controls the laser power is also increased. It is possible to configure an arbitrary relation curve. 5.1.7.2 Sync output with g-code moves, M10px, M11px This option (Figure 5.1) enables that fast commands M10px and M11px, in addition to their primary function of setting state on output x (Output#1-6), at the same time can turn on/off PWM output. Gate port determines which output x controls PWM output in this way. So, for example, if command M11p3 is given and gate port=3, PWM output will be turned on. Laser engraving requires much faster turn on/off of laser then it is possible to achieve using spindle commands (M3, M4, and M5). By using M10/M11 commands, laser turn on/off is also ideally synchronized with g-code execution. This is done in the following way: when, for example, command M11p1 (turn on output 1) is executed in g-code program, initially nothing happens, but this "turn on output x" command is remembered as armed for execution. When next command for positioning (like G01 probably at the very next program line) is executed, then at the same moment when commanded movement begins, the given output is also activated. The same logic applies for M11px (turn of output) command. 5.1.7.3 Gray level raster engraving This option is used for laser engraving of raster images and 8-bit pallet is supported (256 shades of gray) (Figure 5.1). When this option is turned on A axis is used to control laser power i.e. given "movement" of A axis is directly translated to duty cycle of PWM output. G-code should be generated from a bitmap image using one of the programs for that purpose. More details about this option and required settings in Mach3 for raster image engraving can be found in the separate document (USB motion controller laser raster engraving). Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 11 of 31 5.2 Input Filter tab Digital filtering (debouncing) is available for all inputs. Input filter window enables detailed debouncing adjustments (Figure 5.2). Debouncing time is specified in increments of 100 µS. For example, if value 30 is given, that means that 3ms of stable state is needed on input for state to change from active to inactive or vice versa. If debounce time of 0 is given for an input, debouncing is turned off for that input. This is recommended in case we want maximum reading speed and we are sure that signal is clean (e.g. optical encoder). Debounce time can be adjusted for group of pins by function or for every pin separately (Figure 5.2). Figure 5.2 Input filter 5.3 Analog input & Encoders tab USB-MC-INT motion controller offers one analog input, and in addition, enables simultaneous reading of two incremental encoders. Their functionality can be adjusted using this dialog (Figure 5.3). 5.3.1 Special function group In the field on the left, available input signal sources are shown and in parentheses assigned function (if there is one). For the selected signal source, on the right side are shown parameters that can be adjusted. For Special function, available options are: None signal is not used for any special function, FRO 0250% - feedrate override control, SRO 0250% - spindle rate override control, Set user variable read value is put in Mach3 internal variable so that it can be used, for example, from macro script or similar. ID represents identifier (address) of the variable. Type of output can be chosen to be 16-bit value (065535) or percentage (0-100%). Values of these variables can be monitored using Mach3 function Operator/Geode Vary Monitor Set user DROP similar to previous option, only in this case ID represents DROP field indicator. When encoder is used, step increment for a variable is adjusted by setting detent value for the encoder used (see description in further text). Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 12 of 31 5.3.2 Zero threshold voltage Voltage threshold adjustment for analog input, given in mV. Read value that is less than or equal to this is considered to be zero (Figure 5.3). Figure 5.3 Analog input & encoders 5.3.3 Encoder mapping USB-MC-INT motion controller supports simultaneous reading of two incremental encoders, including one from MPG device (Figure 5.3). Since Mach3 offers adjustments for total of seven encoder inputs, it is needed to map these two encoders to desired positions. 5.3.3.1 Encoder/MPG resolution It is used to adjust incremental encoder resolution (Figure 5.3). Available options are x1 and x4. Option x4 gives the best resolution and is appropriate e.g. for optical encoders. Option x1 gives basic encoder resolution, that is, one increment for one full cycle of state change on A and B lines. This option is appropriate for e.g. little mechanical, rotational encoders, for which we want for one detent to correspond to position change of 1 and not 4. Also, with mechanical encoders, there is possible effect of contacts bouncing which induces errors in position reading thus it is needed to set debouncing for encoder to an optimal value. The algorithm that is used for x1 reading option is fairly resistant to these problems so it is possible to set debouncing to zero when this option is used. 5.3.3.2 Detent (counts/unit) Detent is number of pulses (increments) from encoder/MPG for one full movement step in Mach3. For MPG, this step is defined on MPG/Jog screen (Figure 6.1). Detent value is, for better clarity, shown on this dialog, but can be adjusted via Mach3 window Config/Ports&Pins/Encoders/Mpg's together with input ports and pins for encoders. Detent does not have to be a whole number, and also can be negative if it is needed to change direction of rotation. Usually MPG is set to have detent value of 4 if encoder resolution x4 is chosen. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 13 of 31 5.3.4 THC options tab THC (torch height control) function is used with plasma cutters for continuous regulation of plasma head vertical position above the material. In addition to support for external regulators, USB-MC-INT motion controller also contains internal THC regulator that is possible to utilize by connecting appropriate voltage sensor to the analog input of the USB-MC-INT motion controller. More details about THC operation and Mach3 adjustments related to this mode can be found in the separate document (THC operation with Audioms Automatika doo USB motion controllers). 6 Shuttle mode Figure 6.1 It is possible to use MPG also for Mach3 shuttle mode, that is, fine real-time control of execution speed of G-Code program (Figure 6.1). This function is performed completely in hardware and in this mode speed of turning MPG directly affects G-Code program execution speed. Shuttle mode button can also be used as fast FeedHold, even if MPG is not connected or configured in the system. In this case, if shuttle mode is activated during G-code execution, movement on all axes slows down to complete stop. By deactivating shuttle mode, movement on all axes is accelerated to reach the normal speed. This acceleration/deceleration can be adjusted using field Shuttle Accel. which can be found on Mach3 General Config dialog. 7 Status window Status window (Figure 7.1) displays current state of all input and output pins on USB-MC-INT motion controller. Also, on the left side, current position of all 6 axes is shown, and on the right side, various status information for the controller. This window is floating above other windows and does not prevent normal usage of Mach3 controls. Figure 7.1 USB-MC-INT status window Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 14 of 31 8 Connecting USB-MC-INT motion controller into CNC system The following is a description of wiring USB-MC-INT motion controller into CNC control system. 8.1 Connection with computer and power supply for the USB-MC-INT motion controller For powering USB-MC-INT motion controller it is required to provide external power supply 15-28 VDC / 500 mA (Figure 8.1). USB cable (A-B) To computer with control software +15..28 VDC Figure 8.1 Connection with computer and connecting power supply to USB-MC-INT motion controller For connecting USB-MC-INT motion controller to a computer type A-B USB cable is used (Figure 8.1). The motion controller is supplied with a high-quality 1m long USB cable with two ferrite cores. If necessary, it is possible to use other USB cables. In that case, use quality USB cables, preferably no longer than 2 m. It is recommended to use a USB cable with ferrite cores (Figure 8.2). Figure 8.2 Type A-B USB cable with ferrite cores Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 15 of 31 8.2 Connecting stepper motor drives to USB-MC-INT motion controller USB-MC-INT motion controller can accept connection of up to 6 step motor drives. Figure 8.3 shows recommended wiring principle for STEP/DIR/ENABLE command lines to four microstep stepper motor drivers MST-107 or MST-109. Rset STEP DI R A-axis MST-107 or MST-109 ENA Dig G ND Rset 1A 1B 2A 2B +V GND STEP DIR Z-axis MST-107 or MST-109 ENA Dig GND Rs et Rset 1A 1B 2A 2B +V GND STEP DI R Y-axis MST-107 or MST-109 ENA Dig G ND Rset Rset 1A 1B 2A 2B +V GND STEP DIR X-axis MST-107 or MST-109 ENA Dig GND Rse t 1A 1B 2 A 2B +V GND Rset Figure 8.3 Connecting 4 microstep drivers MST-107 or MST-109 to USB-MC-INT motion controller Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 16 of 31 STEP Optionally, USB-MC-INT motion controller can accept two additional axes, that is, two more microstep motor drives MST-107 or MST-109 (Figure 8.4). Rset DIR ENA C- axi s MST-107 or MST-109 D ig GND Rs e t 1A 1B 2A 2B +V GND STEP DIR ENA B-axis MST-107 or MST-109 Di g GND R se t Rset 1A 1B 2A 2B +V GND Figure 8.4 Optional connection of fifth and sixth axis Common Enable output is available on connectors Con.10, Con.11, Con.12 and Con.13 and is labeled ENA O12. Enable output is realized using PNP transistor wired in open collector configuration and is activated by output O12. Maximum current for Enable output is 150 mA. Table 8.1 gives list of recommended outputs for generation of STEP and DIR signals for controlling up to 6 axes. Output O12 is reserved for Enable signal. Table 8.1 List of recommended outputs for controlling 6 axis Axis X Y Z A B C STEP (Output) O1 O3 O5 O7 O9 O15 DIR (Output) O2 O4 O6 O8 O10 O16 ENA (Output) O12 For powering USB-MC-INT motion controller and up to 4 microstep drivers MST-107 or MST-109 it is recommended to use power supply module with integrated motor break PSB-1 (Figure 8.5). More details about power supply module PSB-1 and wiring instructions can be found in the manual for this module. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 17 of 31 AC2 AC1 Prekidac AC MAIN 2x2 N O 220VAC TRANSFORMER 250-400 VA AC1 = 18 ÷ 30 VAC / 10 ÷ 14 A AC2 = 12 ÷ 18 VAC / 750 mA T0. 25-0.5A slow bl ow Power supply board with motor brake PSB-1 STEP DIR A -a xis MST-107 or MST-109 ENA D ig GND Rset F2.5 -3A fa st F2.5 -3A fa st F2.5 -3A fa st F2.5 -3A fa st 1A 1B 2A 2B +V GND STEP DI Z-axis MST-107 or MST-109 RENA Dig GND Rset 1A 1B 2A 2B +V GND STEP DIR Y-axis MST-107 or MST-109 ENA D ig GND Rset 1A 1B 2A 2B +V GND STEP X-axis MST-107 or MST-109 DIR ENA Dig GND Rs et 1A 1B 2A 2B +V GND Figure 8.5 User can also provide his own power supply. In that case Figure 8.6 shows recommended scheme for connecting power supply for USB-MC-INT motion controller and up to 4 drivers MST-107. Power supply must provide two independent sources, one for powering USB-MC-INT controller (1524 VDC / 350 500 mA) and the other for powering drivers MST-107 (20-40 VDC, current for this power source depends on stepper motors used review manual for microstep driver MST-107). On each +V power supply line, for each driver MST-107, it is recommended to use fast melting fuses that protect drivers in case of overload situation. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 18 of 31 STEP DI R A-axis MST-107 or MST-109 ENA Dig G ND Rset D ig GND +V Customized Power Supply Fuse A 1A 1B 2A 2B +V GND STEP Z-axis MST-107 or MST-109 DIR ENA Dig GND Rs et 1A 1B 2A 2B +V GND Fuse Z STEP DI R Y-axis MST-107 or MST-109 ENA Dig G ND Rset 1A 1B 2A 2B +V GND Fuse Y STEP X -a xis MST-107 or MST-109 DIR ENA Dig GND Rse t 1A 1B 2 A 2B +V GND Figure 8.6 Fuse X 8.3 Connecting drives from other manufacturers to USB-MC-INT motion controller Figure 8.7 shows recommended wiring scheme for connecting 4 drives from other manufacturers to USBMC-INT motion controller. Used digital outputs on USB-MC-INT motion controllers are of TTL type. Drives from other manufacturers, regardless whether they are intended for stepper, DC servo or AC servo motors, usually have same or very similar input interface. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 19 of 31 PUL+ PULDIR+ DIRENA+ ENA- A-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- Z-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- Y-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- X-axis Stepper or Servo Drive Figure 8.7 Possible problems when connecting drivers from other manufacturers and suggested solutions. Drivers from other manufacturers often have pretty strong filters on PUL (STEP) and DIR lines. In the case of maximum frequency (250 kHz, while the signal width is 2 µs) of STEP signal on the USBMC-INT motion controller the driver may skip steps or even not detect them at all. When that happens, the maximum frequency should be lowered to 125 kHz (4 µs signal width) in the plugin of USB-MC-INT motion controller (Figure 5.1 General setup). After changing the parameters the control software must be restarted in order for the setting to be activated. Check whether the driver from other manufacturers requires falling or rising edge of the STEP signal. If needed, activate or deactivate the option "Step low active" in the control software. Some drivers from other manufacturers have inverted ENABLE pin logic. USB-MC-INT motion controller can't support this and in that case don't connect ENA+ and ENA- lines (Figure 8.8). That way the driver will always be active. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 20 of 31 PUL+ PULDIR+ DIRENA+ ENA- A-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- Z-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- Y-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- X-axis Stepper or Servo Drive Figure 8.8 Connecting drivers from other manufacturers in the case of inverted logic on ENABLE input Optionally, it is possible to connect additional two axes i.e. additional two drives from other manufacturers to the USB-MC-INT motion controller (Figure 8.9). Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 21 of 31 PUL+ PULDIR+ DIRENA+ ENA- C-axis Stepper or Servo Drive PUL+ PULDIR+ DIRENA+ ENA- B-axis Stepper or Servo Drive Figure 8.9 Table 8.1 gives list of recommended outputs for generation of STEP and DIR signals for controlling up to 6 axes. Output O12 is reserved for Enable signal. 8.4 Connecting relays outputs USB-MC-INT motion controller has integrated two relays with SPDT type contacts. Capacity for each relay is 250 VAC / 8 A max or 30 VDC / 8A max. Figure 8.10 shows possible wiring scheme of relay outputs on USB-MC-INT motion controller. For currents that exceed 3A it is recommended to use external relays with higher nominal current or contactors and in that case these can be activated by relays on USB-MC-INT motion controller. For activation of relay outputs digital outputs O13 and O14 are used and on USB-MC-INT motion controller there are indicators that show state of relay outputs. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 22 of 31 Con.22 O14 NC O ut14 Rel.2 O14 NO O13 NC Ou t13 Rel.1 O13 NO Figure 8.10 Possible connection of relay outputs 8.5 Analog output on USB-MC-INT motion controller Mach3 has the ability to generate a PWM (Pulse-width modulation) signal. PWM or pulse width modulation is a method of control where the frequency of the control signal does not change. What is changing is the signal / pause ratio, i.e. the signal width changes. If an appropriate filter is placed on the TTL output on which the PWM signal is received, then the analog signal will be output at this filter. The voltage level of the analog signal depends on the signal / pause ratio. For example, if the signal width is 10% and the pause width is 90%, the analog output voltage will be 10% of the maximum voltage. This analog signal can be used as a control signal for regulating the spindle speed or for controlling one of the other peripherals on the machine. USB-MC-INT motion controller has one analog output. Analog output Aout is available on connector Con. 15 (Figure 8.11). The control of the analog output Aout is done by generating a PWM signal on digital output O11. Voltage level for analog output is factory preset to range 0-10 V. Optionally it is possible to set voltage level to range 0-5V (on special request). NOTE: Negative output of analog output Aout (O11) is galvanically connected to the power supply ground of USB-MC-INT motion controller. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 23 of 31 Spindle motor revolution speed contoller A na log In GND Figure 8.11 Analog output for controlling spindle motor revolution rate The analog output can be configured to be either in range 0-5V or 0-10V. The range is chosen by the jumper J4 Analog output voltage selector (Figure 8.12). a) b) Figure 8.12 Jumper for analog output range selection, a) position for range 0-5V and b) position for range 0-10V 8.6 Analog input USB-MC-INT motion controller USB-MC-INT motion controller has one analog input (An in) with range 0-5 V and it is available on the connector Con.15 (Figure 8.13). Analog input offers the possibility of connecting potentiometers, THC sensors and other sensors with analog outputs in order to realize some of the special functions (FRO, SRO, THC control, etc.). Figure 8.13.a shows the recommended method for connecting potentiometer to the analog input An In, and Figure 8.13.b shows recommended way for connecting THC Sensor analog output to analog input An In. A detailed description of the Torch Height Control (THC) using USB-MC-INT is given in separate instruction manual. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 24 of 31 a) b) 1-10k 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 19 20 +V GND OP Power Supply 22 23 A0N..5IVN LV LV IN Gnd 12 Ou t G ND Out 0-5V THC Sensor Analog Isolated Voltage Divider Ver. 3 www.audiohms.com 300VDC max THC ARC THC ARC 9 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Figure 8.13 Connecting the source of analog signal to the analog input, a) using potentiometer and b) from THC sensor 8.7 Opto-isolated digital inputs USB-MC-INT motion controller offers connection of signals to up to 8 digital inputs (DIN7-DIN14) of voltage level 24 VDC. These digital inputs are connected to connectors Con.20 and Con.21 (Figure 8.14). For level shifting the voltage levels from 24 VDC to 5 VDC optocouplers on-board are used. NOTE: For the activation of digital inputs, for safety reasons it is recommended to use NC type of switches (Normally Closed). There are two modes for wiring limit switches: non-isolated mode and opto-isolated mode. In addition, Figure 8.14 shows the simplified electric schematic of the input circuit for digital inputs DIN7DIN14, as well as two modes for wiring limit switches (non-isolated mode and opto-isolated mode). Digital inputs DIN7-DIN14 have passive low-pass filter with 3.4 kHz cutoff frequency implemented. Digital inputs DIN7-DIN14 have common negative supply line (DGnd). In the following text there is a detailed explanation of limit switches wiring. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 25 of 31 Optoisolated mode 15..24 VDC Not optoisolated mode J2 J1 +Vex is internally common for all digital inputs from DIN7 to DIN14 +V Con.20 Con.21 J2 8 x +Vex DIN7 DIN8 DIN9 DIN10 DIN11 DIN12 DIN13 DIN14 DGnd J1 GND Internally connected Internally connected Figure 8.14 Location of opto-isolated digital inputs on the USB-MC-INT motion controller 8.7.1 Isolated mode for wiring limit switches to the opto-isolated inputs Isolated mode for wiring limit switches to digital inputs DIN7-DIN14 implies using additional power supply with voltage in range of 15-25 VDC. Figure 8.15 shows connection of electro-mechanical switches, while Figure 8.16 shows a possible way of connecting inductive switches to digital inputs DIN7-DIN14 in isolated wiring mode. Inductive switch with NPN type of output should be used (Figure 8.16). IMPORTANT NOTE: When connecting limit switches in isolated mode (Figure 8.16 and Figure 8.17) it is required to remove jumpers from locations J1 and J2. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 26 of 31 15..24 VDC Figure 8.15 Isolated mode for wiring electro-mechanical type of limit switches 15..24 VDC out out out out out out out out Figure 8.16 Isolated mode for wiring inductive type of limit switches 8.7.2 Non-isolated mode for wiring limit switches to the opto-isolated inputs This mode implies usage of power supply of USB-MC-INT motion controller for activation of digital inputs DIN7-DIN14. In that case it is necessary for supply voltage of USB-MC-INT motion controller to be in the recommended range (15-28 VDC). Figure 8.17 shows wiring of electro-mechanical switches, while Figure 8.18 shows a possible connection of inductive switches to digital inputs DIN7-DIN14 in non-isolated wiring mode. IMPORTANT NOTE: When connecting limit switches in non-isolated mode (Figure 8.17 i Figure 8.18) it is required to set jumpers into positions J1 and J2. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 27 of 31 J2 J1 Figure 8.17 Non-isolated mode for wiring limit switches of electro-mechanical type out out out out out out out out J2 J1 Figure 8.18 Non-isolated mode for wiring limit switches of inductive type 8.7.3 Connecting the cutting tool height measuring system One useful option with modern CNC control systems is to measure cutting tool height across the Z axis (Auto Tool Height). This is done with the G31 function (Probe function). Measuring cutting tool height can be done in different ways. The following are the two most common ways of measuring it. First way: Measuring with a special measuring tool that gets placed between the cutting tool and workpiece (Figure 8.19). When the cutting tool touches the top of the measuring tool, a switch inside measuring tool is activated that tells the control system a contact occurred. This way the switch wires aren't in electrical contact with the metal parts of the machine. This is the recommended way of measuring Z axis height. Second way: Using a metal sheet or block of known width or some simple measuring tool (Figure 8.20). There is an electrical isolator under the sheet or the measuring tool in order for it to be electrically isolated from the machine. In this case the sheet (or the measuring tool) and the cutting tool that is placed in machine clamping tool act as a switch. That way the metal parts of the machine are in direct electrical contact with control electronics. When measuring this way, it is very important to check the wiring of the system so that the control electronics don't get damaged. Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 28 of 31 Figure 8.19 Figure 8.20 USB-MC-INT motion controller offers the possibility of connecting opto isolated digital inputs of 24V. The digital inputs have a common negative supply line (DGnd), so Figure 8.21 shows the recommended way of connecting the cutting tool Z height measuring system. In the given example, the measuring is done over a digital input DIN7. An additional power source of 24VDC is needed in order to ensure opto isolated regime. 15..24 VDC Cutting tool or Probe tool Measurement block or workpiece Insulator Figure 8.21 8.8 General purpose digital inputs USB-MC-INT motion controller offers six general purpose TTL digital inputs which are accessible via connectors Con.16 and Con.17. These are labeled as IN1 to IN6 (Figure 8.22) and have integrated 4.7 k pull-up resistors. Digital input IN5 is used for Error signal from connectors for controlling DC servo drivers (connectors labeled as X-Axis, Y-Axis, Z-Axis and A-Axis). Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 29 of 31 Figure 8.22 Wiring general purpose digital inputs 8.9 General purpose digital outputs USB-MC-INT motion controller also has 4 TTL digital outputs for general purpose. These are marked as O9, O10, O15 and O16 and are available on connector Con.14 (Figure 8.23). General purpose digital outputs can be used for generation of STEP/DIR signals for additional axes (fifth and sixth axis) (Figure 8.4 and Figure 8.9), for activation of external relays etc. NOTE: PWM signal cannot be configured to outputs O15 and O16. TTL outputs Figure 8.23 Location of general purpose digital outputs Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 30 of 31 9 LED indicators 9.1 OP/ER Status LED Does not light up Blinking slow Constantly lights Blinking fast 1 short blink Controller is not powered Controller is in safe mode (outputs are in high impedance state) Established connection with computer, controller is in idle mode (ready for work) A command (jog, G-code) is currently being executed An error is detected (e.g. limit switch activated, ESTOP or similar). For error type look at Mach3 status line 9.2 Comm LED Lights when there is a communication with computer. 10 Safety recommendations It is highly recommended to enforce galvanic isolation between work environment and PC (using opto-isolators and similar). All Audioms Automatika doo drives for stepper and DC servo motors have built-in opto-couplers on STEP and DIR inputs thus for these lines additional isolation is not needed. For other inputs and outputs, and depending on used equipment, it may be needed to use additional opto-isolators. Usage of USB-MC-INT motion controller requires knowledge and understanding of operation of complete work system, also awareness of possible risks of working with machines and tools. It is advisable to place USB-MC-INT motion controller in metal enclosure so that it is protected from external influences in presence of strong electromagnetic field, very high temperature, moisture, and similar. It is necessary to comply with safety standards like installation of EStop button, limit switches and similar. DOCUMENT REVISION: - Ver. 1.0, July 2023, Initial version Audioms Automatika doo web: www.audiohms.com Kragujevac, Serbia e-mail: office@audiohms.com USB-MC-INT v.3 Motion controller user's manual, July 2023 Page 31 of 31