ajax cnc 10 installation manual

1

Ajax CNC

CNC10

Installation Manual

Rev. 050301

© 2005 AjaxCNC Milesburg, PA 16853

3

Table of Contents

1. Introduction

1.1 System Overview

1.2 AJAX Components

1.3 Installer Supplied Components

1.4 Optional Supplied Components

2. Motion Control Card (CPU10)

3. Control Pendant

4. Software

5. System Schematic

6. Electrical Panel Layout

7. Servo Drive (DC3IO)

8. Motor and Encoder Cables

8.1 Motor and Encoder Cable Installation

8.2 Encoder Check

9. E-Stop Circuit

10. Limit Switches

11. Motor Power

11.1 Troubleshooting

12. Lube

13. Coolant Control

14. Spindle Speed

15. Other Outputs

16. Digitizing/Probe

Revisions on 03/01/05 \Manuals\AJAX.pmd

4

54321

COM 1

AJAX

PC

AJAX CONTROL PENDANT

E-STOPCONTACTOR DC

AC

83VAC INCOMINGAC POWER

X Y Z

DC SERVO MOTORSWITH ENCODERS

MOTOR VOLTAGESUPPLY

X 0.0000Y 0.0000Z 0.0000

Z FUSE

H1 4

H5

FIBEROPTICJACK S

H13

5

VCCDF

4321

H 12PLC OK

Y FUSE

X FUSE

DC3IOH 9

REV 040604

Z-EGN D

Y+

Y-

EGN DX+

X-

EGN D

H1

Z+H2

H11

J10

H10

H6H7 H4 H 3

1 IntroductionThis manual describes how to install the Ajax CNC (ComputerNumerical Control) system. It is strongly recommended thatyou follow each step in order without skipping steps. The PCbased Ajax CNC system provides 3 to 4-axis closed loop servointerpolated motion, controlled by industry standard G-codes.The system is intended for CNC control of milling machines,

Figure 1: AJAX System Overview

1.1 System OverviewThe Ajax CNC system is based on two main printed circuitboards and an optional control pendant. Figure 1 shows (1) theCPU10 motion control card and (2) the DC3IO servo driverboard, (3) the jog panel/pendant. Also notice the DC brushservo motors and the DC motor voltage unregulated supply.Servo motors and other CNC components are available fromwww.AjaxCNC.com.

routers, lathes, flame, plasma, laser and water jet cutters andother specialized applications. The Ajax CNC system is intend-ed for use by competent installers, retrofitters and machine toolbuilders who want to do their own installation. This manual isnot intended for casual end users. A separate operators manualis available for end users on CD ROM.

l - CPU10 - Motion Control Cardl DC3IO - Three axis servo amplifier with PLC I/Ol Control Pendant - Provides control keys for the operator


5

Introduction 1

1.3 Installer Supplied Components

Your PC should have the followingminimum specifications:

A. Pentium 400MHZ or betterB. 128MB Hard Drive or better (provided)C. 128MB Memory or betterD. Linux Operating Software (provided)E. 1 open PCI slot

Electrical Enclosure24" x 36" x 12" minimum recommended

1.2 AJAX Components

Qty. Part No. Description1 10464 CPU10 motion control card1 10250 Encoder/Jog Panel Bracket

w/ribbon cables1 10483 DC3IO Servo Drive6 10234 5’ fiber optic cables1 10274 Jog Pendant1 10237 Intermediate Jog Pendant Cable1 -- Ajax CNC CD-containing manuals1 -- Linux Source CD

1.4 Optional Installer or AJAX suppliedcomponents

Axis motorsa) 17in-lb, 29in-lb, and 40in-lb DC brush motors with encoders

are available from AjaxCNC.com.b) Pre-wired motor cables are available from AjaxCNC.com.

DC Power Supply consisting of thefollowing:

a) Primary transformer with secondary 83VAC outputprovides 120VDC after rectification.

b) Capacitor, 12,000uf minimum, 160VDCc) Fuse Holders & 15A fuses

Misc. Electrical components Suggested Source

a) Rotary electrical disconnect AjaxCNC.comb) Fuse Holders AjaxCNC.com

c) Quencharc AjaxCNC.comd) Terminal strips AjaxCNC.come) E-Stop contactor, E stop switch AjaxCNC.comf) Spindle inverter Automationdirect.com

g) E-Stop contactor AjaxCNC.comh Coolant contactors AjaxCNC.comi) Spindle reversing contactors AjaxCNC.comj) Limit Switches, normally closed type Automationdirect.com


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ISA SLOT

PCI SLOT

PCI SLOT

PC MOTHER BOARD

DB9F

DB15F

X Y Z

JOG

DB9F DB9F

JOG PANEL RIBBON CABLE

ENCODER/JOGPANEL BRACKETWITH RIBBON CABLES

HEADER J1PROGRAMING

HEADER J3

21

3N/CN/C45

PLC I/O

PCI BUS

HEADER J4JOG PANEL

HEADER J2EXPANSION

AXIS 6

AXIS 1

AXIS 2

AXIS 3

AXIS 4

AXIS 5

INPUTSENCODER

4 INTERNAL RIBBON

BACK OF PCCABLES TO

FIBER OPTIC JACKSON CPU10 BOARDEXTEND THROUGHTHE PC BACK

ENCODER/JOG PANELBRACKET WTIH RIBBON CABLES

1 2 3 4 5

Z Y X

DB9F

JOG

DB15M

DB9F DB9F

MO

USE

KEY

BO

AR

DRJ45

USB1

USB2

DB

25F

COM

1D

B9M

VG

A

DB

15HD

MID

I

DB15F

AU

DIO

INO

UT

MIC

SERVO PC

N/CN/C

2 CPU10 Motion Control CardThe CPU10 motion control card is an PCI PC interface card. TheCPU10 card accepts encoder inputs from the servo motors anduses a DSP to perform the servo PID control algorithm. TheCPU10 card outputs torque commands serially down onto twofibers (DATA and SYNC) to the DC3IO board. The CPU10 card

Figure 2

also passes PLC I/O information to the DC3IO card through the#1, #2, and #3 fibers.

2.1Plug the CPU10 motion control card into a PCI slot in your PCmotherboard. Notice the AjaxCNC CPU10 requires only one PCIslot.

Figure 2.1: CPU10 Fiber Optic Connections


7

CPU10 2

2.2 Encoder/Pendant Bracket InstallationInstall the backpanel connector bracket into the PC backpanel.Connect the internal encoder ribbon cables to their respectiveaxes on the CPU10 before plugging into the PCI slot.


8

3 Control Pendant InstallationInstall the Control Pendant Intermediate Cable in your electri-

cal cabinet and plug the end WITHOUT the red and blue wiresinto the DB15 pendant connector on the back of your PC.

All key press data and optional MPG data is sent serially to theControl Panel cable, plus an LED indicator status is sent back.

See the E-Stop section and the Schematic for E-Stop circuithookup (Red and Blue wires from the pendant E-Stop button).


Figure 4 - Control Pendant Cable Hookup

Plug In

CNC PC

Encoder/Control PanelBracket with Ribbon Cables

DB15 Control PendantConnector

DB15F

DB15M

CONTROL PENDANT

BRACKET WTIH RIBBON CABLES

EXTEND THROUGHON CPU7P5 BOARDFIBER OPTIC JACKS

ENCODER/JOG PANEL

THE PC BACKDB9FDB9F

Z

1

Y

DB9F

JOG

DB15M

32 4

X

5

KEY

BOA

RD

MO

USE

DB25F

MIC

OU

TIN

VG

A

DB15H

D

DB15F

AU

DIO

MID

I

COM

1

US B2

USB1

DB9M

RJ45

SERVO PC

INTERMEDIATE CONTROL CABLE

DB15F

SWITCHWIRES

E-STOP

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4 SoftwareAjax CNC motion control software (CNC10) is a Linux basedprogram.

4.1 Software/Hard Drive InstallationInstructionsThe AjaxCNC software comes preinstalled on a 128MB solidstate flash drive. With no moving parts, this type of drive is farmore stable in a machining envirinment.1.) Install the IDE Flash drive reader. Install this component inplace of the existing master hard drive. If this is a new PC,simply install the Flash card reader in the first IDE slot on yourmotherboard using the supplied cable.2.) With the Flash drive and the CPU10 motion control cardinstalled, boot up the PC to make sure all of your connectionsare secure.

3.) All of your permanent unlocks have been turned on in yourcontrol. Every system is given a 10 day demo code to allow theenduser to try out all of the AjaxCNC features and options. Toturn on the control demo mode, follow the instructions below.It is suggested that the demo not be entered until the comple-tion of the installation to take full advantage of the 10 dayperiod.

Note that after software installation, it is normal to have errorsdisplayed in the status window, depending upon whether ornot the DC3IO or Control Pendant are connected.

NOTE: If you purchased one of our stocked control systemsand ordered the Control Pendant in addition to the base kit, youwill need to update your PLC program.

The supplimental CD included with you Ajax CNC system con-tains all of our standard PLC programs. The read-me file in thePLC Programs folder clearly explains what each PLC program isfor. Choose the correct PLC program for your application andfollow these steps to update the control:

1.) Unzip and extract the PLC zip file to a blank floppy disk.2.) Insert the floppy into the control computer.3.) From the main screen press <F7> Utlity, <F2> Update.

The files will automatically update the control. You will need toreboot when you are finished. This is the same procedure usedfor all control updates.


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SERVO DRIVE AND PLC BOARDMOUTNT OVERTOP OF THE POWER SUPPLY,EMI FILTER, CAPACITER AND DIODE BOARD

POWER SUPPLY15 PIN TERMINAL STRIP

E-STOP CONTACTOR

FLOODCOOLANTCONTACTOR

24VAC FUSE110VDC FUSE

STEP DOWNTRANSFORMER

RELAY BOARDCAPACITER ANDDIODE BOARD

EMI FILTER

DC3IOREV 040604

H14

FIBER3

H13

OPTIC

DF

PLC OKVCC

1

H12

JACKS2

H9

54

H11

H10

J10 H7 H6

H5

EGNDX-

X+EGND

X FUSE

H2

Z-EGND

Y-

Z+

Y+

H1

Y FUSE

Z FUSE

H4 H3

Electrical Panel 5

5 Electrical Panel System Schematic

A “D” size AJAX system schematic is provided with everykit. The schematic can also be found as an AutoCAD.dwgfile on the Ajax CD that came with your kit along with severalother smaller schematics. They are listed below for yourreference. Also provided on the Ajax CD is a program forviewing CAD files.Included 8 1/2” X 11” Detailed Schematics:

Inverter Power and ControlCoolant ControlLube PumpInputs and Outputs110VDC Power SupplyIndexerE-Stop circuit

BrakeControl PendantProbe/Digitizing Connection Figure 6 - Panel Layout (Suggested)


6 Electrical Panel Layout

The illustration below is how we suggest you lay out yourelectrical panel. This is only a suggestion, however, and youmay need to modify this arrangement to better suit yourneeds.

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ROTARY CLAMP AND MIST

110VDC NOMINAL

Z FUSE

+5VDCLOW LUBE IN18

Z+ LIMIT IN6

Z- LIMIT IN5

Y- LIMIT IN3

X- LIMIT IN1

INPUT COMMONDP4 DETECT IN15

INPUT COMMON

INPUT COMMON

Y+ LIMIT IN4

INPUT COMMON

X+ LIMIT IN2

DP4 IN14

+5VDCH14

E-STOP IN11

TT1 IN13

INPUTCOMMON

INPUT

EXTERNALSWITCH

-10

TO +

10V

-5 T

O +

5V

0 TO

5V

0 TO

10VL IMIT

SWITCHDEFEATER

ANALOG OUTVOLTAGE SELECT

AN

ALO

G C

OM

MO

NA

NA

LOG

OU

T

USV

H5

-12V

+12VG

AIN

OFF

SET

+5V

ROTARY CLAMP NO

ROTARY CLAMP NC

ROTARY CLAMP COM

SPINDLE ENABLE NO

SPINDLE ENABLE NC

SPINDLE ENABLE COM

FIBEROPTICJACKS

5V COMMON

HIGH/LOW RANGE IN9

ROTARY CLAMP ACK IN31

INPUT COMMON

ROTARY HOME IN30

SPINDLE FAULT IN25

INPUT COMMON

TOOL RELEASE IN24

IN19

AU

X IN

PUT

S 2

IN17IN10IN32IN8

+5VDCH13

IN7

5

VCCDF

4321

H12

+5V

PLC OK

IN27

AU

X IN

PUTS

1

IN28IN26IN22IN21IN20

Y FUSE

X FUSE

10A 30VDC

RELAYS RATED FOR10A 250VAC

DC3IO

OUT 30

2A

OUT 14

+5V

H95V COMMON

REV 040604

Z-

EGNDY+

Y-

EGNDX+

X-

EGND

C A

XIS

AN

ALO

GC

AX

IS C

OM

MO

N

VM GND

+VM

H1

Z+H2

AUX OUTPUTS 3

OU

T D

RV

38

FLOOD COM

DC

CO

M

FLOOD COOLANT

LUBE PUMP COM

WAY LUBE PUMP

SPINDLE RESET NO

SPINDLE RESET NC

SPINDLE RESET COM

SPINDLE CCW

SPINDLE CW

SPINDLE DIRECTION COM

MIST COOLANT

RLY1H11

MIST COM

RLY2

J10

+5V

DC

DC

CO

M

H10

4A

1A 30VDC

AND CW/CCWRELAYS RATED FOR0.5A 125VAC

0.3A 60VDC

FLOOD, LUBE,RLY1-2,

SPIN RESET, ENABLEOUT 3

4A

OUT 2

OUT 15

OUT 13

2A

OUT 4

DRIVE FAULT

+5VDC

OUTPUT DRIVER

OU

T D

RV

36

H6

OU

T D

RV

1

+5V

DC

+5V

DC

H7

+12V

DC

+5V

DC

+5V

DC

OU

T D

RV 1

1O

UT

DR

V 1

0O

UT

DRV

9O

UT

DR

V 8

OU

T D

RV 7

OU

T D

RV 6

OU

T D

RV

5

AUX OUTPUTS 1

H4

OU

T D

RV 3

9O

UT

DR

V 5

9O

UT

DR

V 6

0O

UT

DRV

61

OU

T D

RV

62

SPA

RE D

RV

+5V

DC

+5V

DC

AUX OUTPUTS 2O

UT

DRV

31

OU

T D

RV

32

OU

T D

RV

33

OU

T D

RV

34

OU

T D

RV

35

OU

T D

RV

29

OU

T D

RV

12

EXTERNALRELAY

1ST

2ND

3RD

+5V

AXIS BRAKES

OU

T D

RV

37

H3

7 Servo Motor Drive: DC3IOThe DC3IO combines a three axis brushed DC servo motordrive along with sufficient I/O to control lathes, mills or routers.For example, with suitable 29in-lb motors the DC3IO can easilydrive a Bridgeport Boss Series I milling machine.As the name implies, DC3IO stands for 3 axis SERVO drive withintegrated PLC I/O.Specifications of the DC3IO Board:

• 3 DC brush servo motor outputs up to 15Amp at 120VDC• 35 General purpose outputs (recommended for, but not

dedicated to coolant, brake and auxiliary controls)• 4 Dedicated outputs: lube, spindle enable, CW and CCW• 1 Spindle speed control, 12 bit DAC• 1 E-Stop series connection relay contacts• 6 Dedicated limit switch inputs• 24 General purpose inputs• 2 Dedicated inputs, E-Stop + Drivefault

7.1 Installing the DC3IO board on yourelectrical panel

Warning: Do not hookup or apply motor voltageat this stage.

Motor voltage will be applied in Chapter 11. All systems mustbe checked out first. Refer to the Ajax CNC detailed schematic.

Check the connections from the DC3IO to the power supply.The DC3IO is supplied with +12 and +5VDC from the powersupply via the J10. Ensure that J10 is connected to the powersupply. These DC voltages are used to power the logic of theservo drive and the logic of the PLC I/O section.


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8.1 Motors and EncodersAjax CNC motors are DC brush servo motors and have 2000

line/8000 count per revolution encoders. Differential line sig-nalling is used for noise immunity. Encoder cables should useshielded wire with twisted pair signal lines for noise immunityreasons (See Figure 8.1). Reliable operation at distances up to50' are possible. Motors may be “hard wired” without the useof MS connectors for cost reduction reasons. Fully wired ser-vo motors with cables may be ordered from AjaxCNC.

8.2 InstallationWire your motor cables to H2 on the DC3IO board. The DC3IOboard has labels next to each terminal on H2 to aid in the wiring.The earth ground (EGND) terminals are used for shield connec-tions.

Plug the X, Y, and Z axis encoder cables into the X, Y, and Zencoder sockets on the PC’s back panel (Once again pay closeattention to matching up each axis with its corresponding loca-tion). Wildly erratic motor motion will result if encoder andmotor hookups are not correct. Refer to the Ajax CNC schemat-ic.


8.3 Encoder CheckPower up the PC, but do not apply power to the drive (DC3IO).With the PC powered up and without any power to the driveand motors, you can test the encoder feedback. Go to the PIDmenu to verify encoder feedback. From the main CNC10 screen,press <F1> Setup, <F3> Config, <enter password (137)>, <F4>PID . Turn each axis motor shaft slowly and watch the absoluteposition (Abs Pos) column for smooth counting. Turning themotor shaft in the other direction should count down. Ignore“full power w/o motion” or “Position Error” messages in themessage box. Ensure that the correct readout changes for eachaxis motor.

Figure 8.1 - Motor Encoder Diagram

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9 ESTOP CircuitAn effective emergency stop (E-Stop) circuit is essential to anymachine tool and is required by insurance carriers. The E-Stopcircuit allows the operator to push an E-Stop button and stopall axis motion and the spindle motor. The E-Stop circuit shownon the Ajax CNC schematic is based on a 24v AC voltage whichis required to power the E-Stop contactor coil. As long as theE-Stop circuit is not broken, the system will operate. The 24VACcoil voltage is “routed” through the DC3IO relay contacts la-beled “Drive Fault”. From there the E-Stop coil voltage mustpass through the E-Stop button and then through the inverterfault contacts before returning to the 24VAC terminal. E-Stopmay be tripped by pushing the E-Stop button, by a Servo Drivefault, or by an Inverter fault.

9.1 Blue Loop InstallationThe blue loop consists of two blue wires on the IntermediateControl Pendant cable. These two wires must be connected toE-Stop and Common on H14.


9.2 Red Loop InstallationThe Red Loop is the 24v AC circuit that is required to power theE-Stop contactor coil. To complete the circuit connect the firstred wire on the Intermediate Control Pendant cable to the “DriveFault” (RLY2) pin on H11 on the DC3IO. The other “DriveFault” (RLY1) pin on H11 must be connected to terminal 1 onthe 24 VAC supply. The second red wire on the IntermediateControl Pendant cable must be connected in series to A2 on theE-Stop contactor. Connect A1 on the E-Stop contactor toterminal 2 on the 24 VAC supply.

Figure 9.1 - E-Stop Circuit with Pendant

Figure 9.1 - E-Stop Circuit without Pendant

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H14+5VDCTT1 IN13E-STOP IN11INPUT COMMONZ+ LIMIT IN6Z- LIMIT IN5INPUT COMMONY+ LIMIT IN4Y- LIMIT IN3INPUT COMMONX+ LIMIT IN2X- LIMIT IN1

DC3IO SERVO DRIVEAND PLC CONNECTOR H14Z+ LIMIT SWITCH

Z- LIMIT SWITCH

Y+ LIMIT SWITCH

Y- LIMIT SWITCH

X+ LIMIT SWITCH

X- LIMIT SWITCH

10 Limit SwitchesLimit switches are required to be normally closed (NC) switch-es, which are attached to header H14 of the DC3IO board. Eachlimit switch input is actually pulling down on an optoisolatorinput on the DC3IO board (Figure 10.1). When a limit is reachedthe Limit switch will trip the optoisolator circuit. Typical Limitswitches are used for both overtravel protection and HOMINGthe machine at powerup.A typical Limit switch hookup is shown in the diagram below(Figure 10.2). Connect each Limit switch on the X, Y, and Z axisto it’s respective pin on H14 on the DC3IO, as shown in theschematic.

Figure 10.1 - Typical Optoisolated Input

The AJAX system can be operated without limit switches. Todefeat the need for limit switches, flip up (on) all the paddles onthe LIMIT DIP Switches and place a jumper between each limitinput and their respective common. Also, you will need to setthe limit inputs to “0” in the motor setup menu.This is very useful for initial testing, but always remember topush all the dip switches down when you want to install yourlimit switches (See TB061).The AJAX system also supports software travel limits andMachine Home to Mark (See Chapter 3 of the Ajax CNC opera-tor’s manual).


Figure 10.2 - Limits Input

15

Warning: Only a qualified electrical /electronics person should perform these steps.

Install your main power connections. Do Not Turn on thepower yet, just make and check all connections.

Check all Motor Supply (Vm) related connections on the AjaxCNC schematic.

1. Main Disconnect2. Step down transformer for Vm (Motor Supply Voltage)3. Rectifier Bridge (Vm)4. Capacitor (Vm) (double check bridge vs capacitor

polarity)5. Inrush limiter6. Bleed down resistor (6.8k 5W)7. Vm fuse 15A8. Connection to E-Stop Contractor9. PC and DC3IO’s 110VAC power supply

connection10. Ajax Power bridge.

Motor Power 11

With the E-Stop pushed in, apply the AC voltage to the inputof the motor power supply. Check the motor voltage (Vm) fromthe supply at the capacitor terminals. There should be approx-imately 120VDC across the terminals. Notice the DC, this is forservo motor power and is not to be confused with 120VACinput voltage. If you intend to use lower voltage motors suchas Pittman 24VDC motors, then a suitable transformer mustreplace the 83 VAC secondary winding transformer referred toin the Ajax CNC examples. Do not attempt to apply voltagesabove the servo motor’s maximum rating of 140VDC.If you have installed and checked everything up to this pointyou can now check axis motion operation without installing theother optional subsystems such as spindle, coolant, and lubecontrols. Connect the DATA and SYNC fiber cables betweenthe DC3IO and CPU10 cards. See sections 5 and 6 if you havetrouble locating the DATA and SYNC connectors on the cards.Release the E-Stop button and the E-Stop contactor shouldmake a “clunk” sound as it turns on. If you’re using an inverter,you will have to power it up and clear any fault conditions toget the E-Stop contactor to close.Power should now be applied to the drive’s Vm and GND con-nections. Jog each axis in both directions and verify smoothmotion from the motors, see section 11.1 if movement problemsare encountered. If the motors are not mounted on the machineyet, mount them before continuing to section 11.2.

11 Motor Power

Figure 11 - DC Servo Motor Power Circuit


16

11.1 Servo Motor and Encoder Troubleshooting

CNC7 Error Message Motor Symptoms Possible Problems Solutions? Axis position error Makes a quick jump when Motor wires may be Reverse motor lead

jog button is pressed reversed or A and B encoder connection channels have been swapped

? axis full power w/o Moves full speed until error Encoder is not plugged in or Check connections for eachmotion condition is detected encoder is bad, drive is axis -- an encoder is

not powered up plugged into the axis butmay not be from thecorrect motor, replaceencoder and check driveand E-Stop connections.

? axis home to close Will not home correctly Index pulse is missing Check Z and /Z channelto switch wiring, replace encoder if

necessary.? axis runaway: check No Motion Encoder cables for two axes Plug the cables into themotor wiring condition is detected -- are swapped correct locations and restart

runaway is not on axis the control PC (this errorthat was moving latches and requires a cold

restart)? axis runaway: check No Motion Encoder cabling is faulty or Check cables, restart

motor wiring encoder was plugged in with control PC (this error latches power on and requires a cold restart)

? axis encoder connection No Motion Encoder cable is not plugged Check encoder connectionsis bad encoder cable is faulty

Strange sounds or rough PID parameters not correct, Run autotune, swap encodermotion encoder problem, or motor with a known good unit to problem locate problem source.

11 Motor Power

11 Servo Motor PowerThe following steps should be taken to ensure accurate motioncontrol after motors have been mounted on the machine:(1) Check the encoder count settings in the machine setupscreen (Press <F1>, <F3>, <enter password>, <F2> from themain screen). The encoder counts should be 8000 for Ajax CNCsupplied motors.(2) Make sure each jog key moves its axis in the desired direc-tion. See the “Conventions” section in Chapter 1 of the AjaxCNC user’s manual for the recommended axis setup. If an axis ismoving in the opposite direction, change the direction reversalsettings in the machine setup screen.(3) Setup the motor revolutions per inch for each axis. Refer totech bulletin TB036 for assistance.(4) Autotune should be run to set up the motor PID parameters.This can be reached by pressing <F1> Setup, <F3> Config,<enter password>, <F4> PID, <F5> Tune from the main CNC10screen. On-screen instructions will tell you how to start thetuning process. For more information on autotune results referto TB045 and TB004.(5) Run dragplot. This feature will help reveal mechanical prob-lems that may effect performance. TB047 details running drag-plot.Technical bulletins can be found on the supplied CD or on theUser Support section of the AjaxCNC website.

Note: ? will be either X, Y or Z


17

H10FLOOD COMFLOOD COOLANT OUT3LUBE PUMP COMWAY LUBE PUMP OUT2SPINDLE RESET 12NOSPINDLE RESET 15NCSPINDLE RESET COMSPINDLE CCW 13NOSPINDLE CW 13NCSPINDLE DIRECTION COM

H13+5VDCHIGH/LOW RANGE IN9ROTARY CLAMP ACK IN31INPUT COMMONROTARY HOME IN30SPINDLE FAULT IN25INPUT COMMONTOOL RELEASE IN25LOW LUBE ALARM IN18INPUT COMMONDP4 DETECT IN15DP4 IN14

DC3IO SERVO DRIVEAND PLC

AC VOLTAGEFOR THELUBE PUMP

G N H

ACHACNGND

ALARM NOALARM COM

ALARM NC

LUBEPUMP

12 Low Lube Alarm Input

12 Automatic Lubrication PumpThe lube pump should be connected to H10 as shown in thediagram below (Figure 12). The 110 VAC supply for the lubepump should also be connected to H10 as shown in the dia-gram and on the schematic.After the lube pump is installed, you must connect the LowLube warning circuit. Connect the pump alarm common toCommon on H13 on the DC3IO. Then connect the lube pumpalarm (NC) to the “Low Lube” input on H13 on the DC3IO.If you are not using a lube pump, you will need to place ajumper between the Common on H13 and “Low Lube” on H13.

Figure 12 - Lube Connections

13 Coolant ControlThe DC3IO is capable of controlling a coolant pump using acoolant pump contactor.

13.1 Coolant Pump ContactorAjax CNC coolant pump contactors requires a 24 VAC supply topower the contactor coils. You must connect the coolant con-tactor coil to the Flood and Flood Common on H10. Supplypower as shown on the schematic.


18

14 Spindle ControlThe spindle control section of the DC3IO provides an analogoutput that is factory preset for 0-10v DC output to an inverterin 0.004v increments. The internal Digital to Analog Converter(DAC) converts a 12 bit value for high resolution spindle speedcontrol.

14.1 Spindle MotorThe Ajax CNC system is capable of driving a spindle motorusing either an Inverter (recommended), or by using ReversingContactors.

14.2 Spindle Motor with InverterA typical Inverter wiring diagram is shown on the schematic(Figure 14.1). Exact wiring will vary from one Inverter to thenext, so refer to your Inverter manual for specific wiring instruc-tions.In the example shown on the schematic the supply voltage isrouted through the Inverter and E-Stop contactor before goingto the spindle motor. The Spin Forward, Spin Reverse, InverterCommon, 0-10 VDC Input, and the 0-10 VDC Common pins onthe Inverter are all connected to H5 as shown on the schematic(Figure 14.1). Again, the schematic shows only a typical Invert-er Installation, for details on connecting your Inverter pleaserefer to your Inverter Manual.

14.3 Spindle Motor with ReversingContactorsOn the Ajax CNC schematic you see a typical circuit diagramfor wiring the spindle motor with reversing contactors. For theDC3IO to be able to control spindle direction, Pins CW andCCW on H5 must be connected to the Reversing Contactorcoils as shown on the schematic.Terminal 2 on the 24 VAC supply must be connected to the SpinENCOM pin on H5 as in the schematic. Terminal 1 on the 24VAC supply must then be connected to one side of the Revers-ing contactor coils as shown. The other side of the Contactor

coils must be wired as shown to allow the DC3IO to control theReversing Contactors.It is essential that the 220 VAC supply for the reversing Contac-tor and the Spindle Motor be connected to the output side ofthe E-Stop Contactor and NOT the 220 VAC input side of theE-Stop Contactor so that the E-Stop circuit is capable of con-trolling the power to the Spindle Motor and Spindle SpeedControl with inverter.

14.5 Spindle Speed Setup1) Change maximum spindle speed to match your spindle

and inverter.a) From the CNC10 main screen press <F1> Setup, <F3>

Config, <F1> Control.b) Change the value for maximum spindle speed so that

it’s the same as the specs for the inverter and spindle motor.

c) Press <F10> to save this screen and exit.

14.6 Troubleshooting Spindle Output1) Parameters

a) Press <F1> Setup, <F3> Config, <F3> Param to enter the parameters screen.

b) Check parameter 31. This should be set to -1.c) Edit parameter 32. Enter the baud rate of 19200.d) Edit parameter 33. Enter your spindle gear ratio.e) Press <F10> to save and exit.f) Press <ESC> until CNC10 main screen appears.

2) Make sure that the spindle is not inhibited by the PLCprogram.a) The E-Stop must be released to start the spindle.b) The digitizing probe must be unplugged.


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Figure 14.1 - Spindle Inverter Control Diagram

14.7 Spindle Inverter FaultInputRefer to your Ajax CNC schematic.

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14 Spindle Speed Control


14.8 Spindle Hi-Low RangeRefer to your Ajax CNC schematic and Hi-Low schematic

found on the supplimental CD for wiring details if your ma-chine is equipped with a Hi-Low gear range.

Figure 14.3- Spindle Encoder Cable Hookup Diagram

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14.9 Spindle Encoder SettingsThe Ajax CNC supplied encoder is a 2000 line encoder whichyields 8000 counts per revolution of the spindle. Spindle encod-ers have to be connected directly to the spindle itself at a 1:1ratio. Other line encoders may be used. 500, 1000, 1024 etc. andthe control parameter 34 must be adjusted accordingly.The encoder cable used should be a shielded cable. Ajax CNCspindle encoder cable spec: Minimum 22 awg, 4 twisted pair.Attach shield wire to DB9 case, typically soldered, and otherend to encoder case/cover that is grounded to the machine.Listed are some configuration parameters related to thespindle encoder. Parameter # Description:•P34: Spindle Encoder Counts Settings: Must be set to the number of counts for the Spindle Encoder. 1000 line=4000 counts, 2000 line=8000 counts etc..•P35: Spindle Encoder Input, selects which encoder port the spindle encoder is hooked to. Settings: 0 - Encoder port 1 1 - Encoder port 2 2 - Encoder port 3 3 - Encoder port 4 4 - Encoder port 5The 5th axis encoder input is primarily used for spindleencoder input. Set P35=4 when connecting encoder cable tothe 5th axis encoder input as per the Ajax CNC drawing.•P78: Spindle speed display. Settings: 0 - Displays programmed spindle speed 1 - Displays actual spindle speed, from the spindle encoder.•P31: Spindle output port. Settings: -1 for all DC3IO systems•P32: Spindle Output port Baud Rate: Settings: 19200 - Recommended setting•P36: Rigid Tapping. Settings: 0 - Disable Rigid Tapping 1 - Enable Rigid Tapping 3 - Enable Rigid Tapping and Do Not wait for Index pulse 5 - Same as 1, but enable spindle override during tapping 7 - Same as 3, but enable spindle override during tapping•P37 - Spindle deceleration time. Settings: Time in seconds for spindle deceleration during rigid tapping. Typical time = 3 seconds. (Note: Your inverter should be set up with a braking resistor and set up to decel faster than this setting.)•P68 - Minimum Rigid Tapping Spindle speed. Settings: Typical setting is 500 to 600 rpm for Rigid Tapping.•P69 - Duration for minimum spindle speed. Settings: Amount of time to wait when at speed set in P68 Typical setting is 1.5 to 2.•P82 - # of degrees of rotation before bottom of rigid tap hole that the cycle will spin at slow rpm setting #P68


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+5V

DC

+5V

DC

SPA

RE

DR

VO

UT

DR

V 6

2O

UT

DR

V 6

1O

UT

DR

V 6

0O

UT

DR

V 5

9O

UT

DR

V 3

9O

UT

DR

V 3

8O

UT

DR

V 3

7

H4

AUX OUTPUTS #3

OU

T D

RV

12

AUX OUTPUTS #2

+5V

DC

+5V

DC

OU

T D

RV

36

OU

T D

RV

35

OU

T D

RV

34

OU

T D

RV

33

OU

T D

RV

32

OU

T D

RV

31

OU

T D

RV

29

H6

OU

T D

RV

8

AUX OUTPUTS #1

OU

T D

RV

9O

UT

DR

V 1

0O

UT

DR

V 1

1

+5V

DC

+5V

DC

OU

T D

RV

5O

UT

DR

V 6

OU

T D

RV

7

OU

T D

RV

1

H7

DC3IO SERVO DRIVE ANDPLC CONNECTOR H4, H6 AND H7

5VDC RELAY

10 PIN PLUG

5VDC RELAY

10 PIN PLUG

5VDC RELAY

10 PIN PLUG

Figure 15.1 - Relay Output Circuit

Figure 15.2 - Output Driver DC3IO Circuit


User Supplied5 VDC < amps

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Figure 15.3- Ajax Dual Relay Board


Any H10output driver

DC3IO

AnyOutputDriver

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15 Digitizing/Probe ConnectorThe Digitizing/Probe connector allows the use of an optimalDigitizer/Probe with the Ajax CNC system.

15.1 Digitizing/Probe InstallationThe Digitizing/Probe (D/P) connector receives power throughthe attached Molex connector which must be plugged into thePC power supply on the DC3IO board.

Visit our web site for free downloads of other PLC programsfor specific machines. www.ajaxcnc.com.Keep in mind that just because a standard M code is labeledfor a certain function that does not mean you have to use itfor that purpose. For example: M8 is used for Coolant. Youcan use this output to activate a Flood pump OR a mistersolenoid. You can use the M8 output to activate a vacuumpump, a clamp, etc….M8 turns it on and M9 turns it off.


Figure 16.1 - Probe / Digitizing Connection

ajax cnc 10 installation manual

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