GAUGE 1 - CONFIGURATION

GAUGE 1 - CONFIGURATION Document A MACH 3 PWM Configuration 21 May 2010

Table of Contents Revision History 3 INTRODUCTION 4 1.1 CONFIGURATION 1: 4 1.2 CONFIGURATION 2: 4 PRE-REQUISITES 5 CONFIGURATION 1 6 INTRODUCTION 17 HARDWARE DETAILS 17 CONFIGURATION 2 19 Figures Figure 1 - Configuration 1 Physical Topology... 6 Figure 2 - LPT 1 Port Setup... 8 Figure 3 - Spindle Enable... 9 Figure 4 - Spindle Configuration...10 Figure 5 - SmoothStepper PWM Configuration...11 Figure 6 - Motor Tuning...12 Figure 7 - Spindle Pulleys...12 Figure 8 - Huanyang VFD Interface Cables...13 Figure 9 - Huanyang Front Control Panel...15 Figure 10 - MDI Input Window...16 Figure 11 - DigiSpeed DC03 Physical Layout...17 Figure 12 - DigiSpeed Jumper Settings...19 Figure 13 - Configuration 1 Physical Topology...20 Figure 14 - LPT 2 Port Setup...21 Figure 15 - Spindle Enable...22 Figure 16 - Spindle Configuration...23 Figure 17 - SmoothStepper PWM Configuration...24 Figure 18 - Motor Tuning...25 Figure 19 - Spindle Pulleys...25 Figure 20 - Huanyang VFD Interface Cables...26 Figure 21 - Huanyang Front Control Panel...28 Figure 22 - MDI Input Window...29 2

Revision History Version Date Author Reviewer / Approver Version Details Draft 1.0 21/05/2010 Michael Prinzi Initial draft Draft 1.1 28/06/2010 Michael Prinzi Revision with Feedback 3

Chapter 1 MACH 3 PWM Introduction Pulse Width Modulation (PWM) is an efficient means of providing intermediate power levels between zero and full. By varying the duty cycle one can vary the effective power being provided to such elements as motors. This configuration guide will detail how to connect a High Frequency Drive (VFD) to Mach 3. I will provide two configurations which I have used to connect Mach3 to my Huanyang VFD. 1.1 Configuration 1: 1. VFD Huanyang HY02D223B 1.5Kw Spindle Drive Controller 2. Mach 3 Version R3.042.030 3. SmoothStepper - USB 2.06.00 & Beta2_v015ogx2.mp3 4. Geck G540 Stepper Motor Controller 1.2 Configuration 2: 1. VFD Huanyang HY02D223B 1.5Kw Spindle Drive Controller 2. Mach 3 Version R3.042.030 3. SmoothStepper - USB 2.06.00 & Beta2_v015ogx2.mp3 4. DigiSpeed DC-03 GX V3 PWM to Variable DC Output 4

Pre-Requisites Before commencing the configuration guide, ensure you have downloaded and configured Mach 3 with the appropriate WARP 9 SmoothStepper Mach 3 plugin and USB driver. My configuration uses the following SmoothStepper drivers: USB Driver: SmoothStepperUSBDriver2.06.00.zip MACH3 Plugin: SmoothStepper_Beta2_v015ogx2.m3p Light Reading In addition, you need to familiarise yourself with the appropriate hardware manuals supplied by the component vendors. These are available from their respective webpage. 1. Mach3 : http://www.machsupport.com/ 2. SmoothStepper: http://www.warp9td.com/ 3. Gecko G540: http://www.geckodrive.com/ 4. DigiSpeed DC03: http://www.homanndesigns.com/ You must download and read these manuals prior to embarking on the configuration set out within this guide. Be aware of the warnings within these manuals relating to Mains Power Interfaces. You have been warned again!! 5

Chapter 12 Gecko G540 PWM Configuration 1 The following diagram shows the physical connectivity between the elements used in the solution. This solution comprises of the following specific hardware and software. Mach 3 Software R3.042.030 SmoothStepper (USB 2.06.00 & Beta2_v015ogx2.mp3) Gecko G540 (Revision 3) Huanyang HY02D223B (1.5KW HF VFD) F IGURE 1 - C ONFIGURATION 1 PHYSICAL T OPOLOGY 6

SmoothStepper Configuration Setup The SmoothStepper software must be installed prior to progressing to the Mach 3 configuration, as Mach 3 will only display the SmoothStepper settings tabs after the software has been loaded and Mach3 rebooted. The SmoothStepper hardware needs to be connected to your PC via the supplied USB cable. An assumption has been made that you have read the pre-requisite step and Mach 3 is configured on your PC with the appropriate WARP 9 SmoothStepper drivers. From the SmoothSteppers LPT1 port, ensure you have connected the ribbon connector to the Gecko G540. Figure 1 will provide you with a guide on how to hook up the SmoothStepper to the G540. Mach 3 Specific Configuration Settings The following screen captures will show the settings that I have deployed to enable Mach 3 to run solution 1. If you use the same configuration setup as indicated previously, these settings will work. 1. Port Setup & Access Selection: If your system has not been configured to use LPT1, enable the port by following these steps from the main menu: Config Ports & Pins Click on the Port #1 check box. Apply your settings. 7

Troubleshooting Note: F IGURE 2 - LPT 1 PORT S ETUP If the port addresses are swapped (0x378/0x278), don t fret it will work. The port addresses need to be unique and those shown on the screen capture are known to work across all my machines. 2. Motor Outputs: From the same pop up window (Engine Configuration..Ports & Pins), click on to the Motor Outputs tab. Here we will enable the spindle. Use the following table to fill in the appropriate windows as shown in Figure 3 below. 1. Enable Ensure a tick is present on Spindle to enable the device 2. Step Pin# 14 This is the pin that will be used to control the spindle from Mach 3. 3. Dir Pin# 1 This has been set to Pin 1. This is used to control the spindle direction (CW or CCW) either directly to the direction port on the VFD or could be used for a relay to the VFD. 4. Step Port 1 This is the LPT port used for the corresponding Pin, which is Pin 14 in this case on LPT 1. 5. Dir Port 1 This is the LPT port used for the corresponding Pin, which is Pin 1 in this case on LPT 1. T ABLE 1 - MOTOR C ONFIGURATION S UMMARY Troubleshooting Notes: The G540 requires the Step Pin to be Pin 14. For Items 5 & 6, if LPT Port 2 was used instead, you need to set 2 instead of 1 to enable the pin on the second LPT output. 8

F IGURE 3 - SPINDLE E NABLE 3. Spindle Setup From the same pop up window (Engine Configuration Ports & Pins), click on the Spindle Setup tab. Here we need to enable the spindle PWM. Note: The SmoothStepper provides the PWM output to the G540 and not Mach3 via the PC s LPT port. To ensure there is no confusion, I have set the tab settings to those that would be used by Mach3 to output PWM, but in theory we only need to ensure that Use spindle motor output is checked. Figure 4 shows the Motor Control settings to enable the spindle. 9

F IGURE 4 - SPINDLE C ONFIGURATION 4. SmoothStepper PWM Output Setup T O ENABLE PWM TO BE PROPAGATED TO YOUR G ECKO G540, YOU NEED TO CONFIGURE THE S MOOTHS TEPPER TO OUTPUT PWM FROM LPT #1. Figure 5 shows the configuration window output with the modified fields. To get to this configuration window, select from the main menu: PlugnIn Control SmoothStepper Configuration Check the PWM check box and set the PWM frequency to 50Hz 10

F IGURE 5 - SMOOTHS TEPPER PWM CONFIGURATION 5. Motor Tuning The Motor Tuning configuration screen is used to tune the Spindle Motor speed characteristics, just like you would for a stepper motor. The table shows some good starting values, which will require modification once you have your spindle running. Steps Per 1000 You can adjust this later to adjust the acceleration Velocity 60 This only has an effect on some calculations Mach 3 does. It has no effect on the actual output from the SS. Accel 1 The accel is calculated as "Steps Per" * "Accel", so just adjust "Steps Per" to get the accel results that work well) T ABLE 2 - MOTOR T UNING S TART V ALUES To get this configuration window, select from the main menu: Config Motor Tuning Select Spindle tab 11

F IGURE 6 - MOTOR T UNING 6. Spindle Pulleys The Spindle Pulleys menu allows a user to setup several spindles with differing characteristics. Mach3 uses this menu to calculate the displayed spindle speed for a given PWM value. Set a minimum and maximum value as per your spindles characteristics To get this configuration window, select from the main menu: Config Spindle Pulleys F IGURE 7 - SPINDLE P ULLEYS Troubleshooting Note: My spindle operates between 0 and 24,000 RPM and is not geared. The screenshot represents this setting. Smaller mills such as the SYIL X4 typically operate between 0 and 3400 RPM. You would need to reflect this setup here for Mach3 to output the correct speed on the screen. 12

Gecko G540 Configuration Setup The G540 was previously connected to the SmoothStepper via the ribbon cable. For the purpose of this installation, I shall limit any connections from this device to the spindle only. To connect your G540 to the VFD controller, you will need to connect three ports from the G540 to the VFD. These are as follows: Gecko G540 Huanyang VFD Description 1. Output #7 Input ACM Ground from the G540 to the VFD 2. Output #8 Input Vi Variable DC output from the G540 according to the PWM signal derived from MACH3 3. Input #9 Output + 10Vdc This is the +10Vdc of the VFD which is fed back to the G540. This is used to produce the Vi voltage to control the spindle RPM T ABLE 3 - G540 TO VFD CONNECTION S CHEDULE The picture shows the three connections used and described above in the table. F IGURE 8 - H UANYANG VFD INTERFACE C ABLES Technical Notes: This is diagrammatically shown in Figure 1. 13

ACM on the Spindle is available on 2 pins. Either may be used for this solution to work. Vi should vary relative to the PWM signal. The following table shows this simply PWM Dutycycle (%) Vi Voltage (referenced to +10Vdc) Spindle Speed (RPM) 0 0.0 0 25 2.5 6000 50 5.0 12,000 75 7.5 18,000 100 10.0 24,000 T ABLE 4 - PWM V' S V I V' S RPM Input #9 should be close to +10Vdc. When I configured this I noticed the VFD outputting 10.1Vdc. I used a 47 Ohm resistor inline from the +10Vdc VFD terminal to reduce the VFD output voltage to +10.0Vdc exactly. External Spindle Control Setup Control of your spindle will now be via the Mach3 interface. Therefore we need to tell the VFD that control inputs will be via an external interface and not the front control panel. On the Huanyang VFD this is set as follows; refer to Mach3 Control : PD Value Manual Control Mach3 Control PD 001 0 0 PD 002 0 1 T ABLE 5 - PD SPINDLE V ALUES Note: PD001 on some spindles needs to be set to 1. For some reason my unit does not work with this set. 14

F IGURE 9 - H UANYANG F RONT C ONTROL P ANEL To set the values in the VFD via the front panel (Figure 9), use the following sequence: 1. Press Prog Enter Programming Mode 2. Press Up Button Sets a value of 1 3. Press Set Save Value 4. Press Set Enter PD002 as the Software automatically increments numbers 5. Press Up Button Sets a value of 1 6. Press Set Save Value 7. Press Prog Exit Programming Mode Testing Your Spindle Setup Control of your spindle is provided by Mach3 s interface. There are two tabs where the speed may be controlled. I will detail the use through the MDI interface tab. The MDI tab allows for command line entries at the Input window. I have highlighted this window below. 15

F IGURE 10 - MDI INPUT W INDOW To test you spindle functionality, use the following commands: MDI Command to Enter Description Input M3 S6000 M3 - Enables CW rotation S6000 Rotation Speed of 6000 RPM Input M5 M5 - Stop Spindle Rotation T ABLE 6 - MDI COMMANDS Troubleshooting Your Spindle Setup I found that my spindle would start without prompting when switched on. To fix this issue the following parameters were adjusted on the VFD to compensate for anomaly. 1. PD027 = 3.0 2. PD028 = 3.0 I derived these values from reading between Vi and ACM on the VFD and then setting a figure above this reading. 16

Chapter 3 PWM DigiSpeed DC03 Introduction The Digispeed DC03 provided a means to convert the PWM signal derived from the SmoothStepper LPT port to a variable output voltage. In this instance we shall vary the voltage between 0 & 10Vdc as required by the Variable Frequency Drive, which will allow us to control the spindle rotational speed. Hardware Details The Physical board of the DC03 consists of an input (J1) and output (J2) configuration, with three configurable jumpers to set configurable options. F IGURE 11 - DIGIS PEED DC03 PHYSICAL L AYOUT 17

The following table describes each interface on the DC03: Interface Port Description J1 Input Screw Terminal Ana Analog Input +5V Input +5Vdc from external source RL2 Relay 2 pin from LPT port RL1 Relay 1 pin from LPT port Sig PWM signal Input from LPT port Gnd Ground Referenced to PC (Don t use the 5V source ground!!) J2 NO 2 CM 2 NC 2 NO 1 CM 1 NC 1 Output Screw Terminal Normally Open (RL2 output) Common (RL2 output) Normally Closed (RL2 output) Normally Open (RL1 output) Common (RL1 output) Normally Closed (RL1 output) AV+ Vout AGnd Input +10Vdc Output Voltage between 0 10Vdc, depending on PWM duty cycle Ground JP1 Pin 1 & 2 Pin 2 & 3 Source Output Voltage Selection Uses onboard supply voltage Uses VFD supply voltage JP2 Logic Hi Logic Lo Input Signal Polarity Set input to 5V to enable the relay. (^) Board Symbol Set input to 0V to enable the relay. (V) Board Symbol JP3 MS1 MS2 Mode Selection PWM Mode No Jumper Technical Note 1: In this mode the DigiSpeed DC-03 controller accepts an Active Low Pulse Width Modulation signal. The duty cycle of this signal represents 0 to 100% of maximum spindle speed. The PWM signal period can be in the range of 2Hz to 50Hz. The optimum period is 50Hz. This will provide 1023 speed increments from 0 to 100% of maximum spindle speed. Technical Note 2: 18

When +5V is supplied to the DigiSpeed DC-03 module and no PWM signal is present, the LED will produce a slow double green flash. This indicates that the spindle is active but the speed is set to 0 %. When a PWM signal is present, the LED will produce a fast continuous green flash, indicating that the spindle is active and the speed is set to a value greater than 0 RPM. Jumper Options F IGURE 12 - DIGIS PEED J UMPER S ETTINGS Technical Note: JP3 has 3 operational modes. For PWM we have set MS1 mode. The following table summarises the operational modes available and the required jumper settings for each mode. MODE MS1 MS2 Analog No Jumper No Jumper PWM Jumper Installed No Jumper Attenuation Trimpot Jumper Installed Jumper Installed T ABLE 7 - JP3 OPERATIONAL M ODES Configuration 2 The following diagram shows the physical connectivity between the elements used in the solution. This solution comprises of the following specific hardware and software. Mach 3 Software R3.042.030 SmoothStepper (USB 2.06.00 & Beta2_v015ogx2.mp3) Digispeed DC03 (Revision 3) Huanyang HY02D223B (1.5KW HF VFD) 19

F IGURE 13 - CONFIGURATION 1 PHYSICAL T OPOLOGY SmoothStepper Configuration Setup The SmoothStepper software must be installed prior to progressing to the Mach 3 configuration section, as Mach 3 will only display the SmoothStepper settings tabs after the software has been loaded and Mach3 rebooted. The SmoothStepper hardware needs to be connected to your PC via the supplied USB cable. An assumption has been made that you have read the pre-requisite step and Mach 3 is configured on your PC with the appropriate WARP 9 SmoothStepper drivers. Mach 3 Specific Configuration Settings The following screen captures will show the settings that I have deployed to enable Mach 3 to run solution 2. If you use the same configuration setup as indicated previously, these settings will work. The following table provides a summary of the configuration to be used in the written instructions. Signal LPT Port Pin # PC Input/Output DC03 Pins PC LPT Gnd 25 - Gnd PWM 14 Out Sig Relay 1 (Spindle Dir) 1 Out RL1 +5Vdc - - +5Vdc Source T ABLE 8 - C ONNECTION S UMMARY 1. Port Setup & Access Selection: If your system has not been configured to use LPT2, enable the port by following these steps from the main menu: 20

Config Ports & Pins Click on the Port #2 check box. Apply your settings. Troubleshooting Note: F IGURE 14 - LPT 2 PORT S ETUP If the port addresses are swapped (0x378/0x278), don t fret it will work. The port addresses need to be unique and those shown on the screen capture are known to work across all my machines. 2. Motor Outputs: From the same pop up window (Engine Configuration..Ports & Pins), click on to the Motor Outputs tab. Here we will enable the spindle. Use the following table to fill in the appropriate windows as shown in Figure 15 below. 1. Enable Ensure a tick is present on Spindle to enable the device 2. Step Pin# 14 This is the pin that will be used to control the spindle from Mach 3. 3. Dir Pin# 1 This has been set to Pin 1. This is used to control the spindle direction (CW or CCW) either directly to the direction port on the VFD or could be used for a relay to the VFD. 4. Step Port 2 This is the LPT port used for the corresponding Pin, which is Pin 14 in this case on LPT 2. 21

5. Dir Port 2 This is the LPT port used for the corresponding Pin, which is Pin 1 in this case on LPT 2. T ABLE 9 - MOTOR C ONFIGURATION S UMMARY F IGURE 15 - SPINDLE E NABLE 3. Spindle Setup From the same pop up window (Engine Configuration Ports & Pins), click on the Spindle Setup tab. Here we need to enable the spindle PWM. Note: The SmoothStepper provides the PWM output to the DC03 and not Mach3 via the PC s LPT port. To ensure there is no confusion, I have set the tab settings to those that would be used by Mach3 to output PWM, but in theory we only need to ensure that Use spindle motor output is checked. Figure 16 shows the Motor Control settings to enable the spindle. 22

F IGURE 16 - SPINDLE C ONFIGURATION 4. SmoothStepper PWM Output Setup To enable PWM to be propagated to your DC03, you need to configure the SmoothStepper to output PWM from LPT #2. Figure 17 shows the configuration window output with the modified fields. To get to this configuration window, select from the main menu: PlugnIn Control SmoothStepper Configuration Check the PWM check box and set the PWM frequency to 50Hz 23

F IGURE 17 - SMOOTHS TEPPER PWM CONFIGURATION 5. Motor Tuning The Motor Tuning configuration screen is used to tune the Spindle Motor speed characteristics, just like you would for a stepper motor. The table shows some good starting values, which will require modification once you have your spindle running. Steps Per 1000 You can adjust this later to adjust the acceleration Velocity 60 This only has an effect on some calculations Mach 3 does. It has no effect on the actual output from the SS. Accel 1 The accel is calculated as "Steps Per" * "Accel", so just adjust "Steps Per" to get the accel results that work well) T ABLE 10 - MOTOR T UNING S TART V ALUES To get this configuration window, select from the main menu: Config Motor Tuning Select Spindle tab 24

F IGURE 18 - MOTOR T UNING 6. Spindle Pulleys The Spindle Pulleys menu allows a user to setup several spindles with differing characteristics. Mach3 uses this menu to calculate the displayed spindle speed for a given PWM value. Set a minimum and maximum value as per your spindles characteristics To get this configuration window, select from the main menu: Config Spindle Pulleys F IGURE 19 - SPINDLE P ULLEYS Troubleshooting Note: My spindle operates between 0 and 24,000 RPM and is not geared. The screenshot represents this setting. Smaller mills such as the SYIL X4 typically operate between 0 and 3400 RPM. You would need to reflect this setup here for Mach3 to output the correct speed on the screen. 25

DigiSpeed DC03 Configuration Setup For the purpose of this installation, I shall limit any connections from this device to the spindle only. To connect your DC03 to the VFD controller, you will need to connect three ports from the DC03 to the VFD. These are as follows: # DC03 JP2 Huanyang VFD Description 1. AV+ Input ACM Ground from the DC03 to the VFD 2. Vout Input Vi Variable DC output from the DC03 according to the PWM signal derived from MACH3 3. AGnd Output + 10Vdc This is the +10Vdc of the VFD which is fed back to the DC03. This is used to produce the Vi voltage to control the spindle RPM T ABLE 11 DIGIS PEED DC03 TO VFD CONNECTION S CHEDULE The picture shows the three connections used and described above in the table. F IGURE 20 - HUANYANG VFD INTERFACE C ABLES Technical Notes: This is diagrammatically shown in Figure 13. 26

ACM on the Spindle is available on 2 pins. Either may be used for this solution to work. Vi should vary relative to the PWM signal. The following table shows this simply PWM Dutycycle (%) Vi Voltage (referenced to +10Vdc) Spindle Speed (RPM) 0 0.0 0 25 2.5 6000 50 5.0 12,000 75 7.5 18,000 100 10.0 24,000 T ABLE 12 - PWM V' S V I V' S RPM AV+ should be close to +10Vdc. When I configured this I noticed the VFD outputting 10.1Vdc. I used a 47 Ohm resistor inline from the +10Vdc VFD terminal to reduce the VFD output voltage to +10.0Vdc exactly. External Spindle Control Setup Control of your spindle will now be via the Mach3 interface. Therefore we need to tell the VFD that control inputs will be via an external interface and not the front control panel. On the Huanyang VFD this is set as follows; refer to Mach3 Control : PD Value Manual Control Mach3 Control PD 001 0 0 PD 002 0 1 T ABLE 13 - PD SPINDLE V ALUES Note: PD001 on some spindles needs to be set to 1. For some reason my unit does not work with this set. 27

F IGURE 21 - HUANYANG F RONT C ONTROL P ANEL To set the values in the VFD via the front panel (Figure 21), use the following sequence: 8. Press Prog Enter Programming Mode 9. Press Up Button Sets a value of 1 10. Press Set Save Value 11. Press Set Enter PD002 as the Software automatically increments numbers 12. Press Up Button Sets a value of 1 13. Press Set Save Value 14. Press Prog Exit Programming Mode Testing Your Spindle Setup Control of your spindle is provided by Mach3 s interface. There are two tabs where the speed may be controlled. I will detail the use through the MDI interface tab. The MDI tab allows for command line entries at the Input window. I have highlighted this window below. 28

F IGURE 22 - MDI INPUT W INDOW To test you spindle functionality, use the following commands: MDI Command to Enter Description Input M3 S6000 M3 - Enables CW rotation S6000 Rotation Speed of 6000 RPM Input M5 M5 - Stop Spindle Rotation T ABLE 14 - MDI C OMMANDS Troubleshooting Your Spindle Setup I found that my spindle would start without prompting when switched on. To fix this issue the following parameters were adjusted on the VFD to compensate for anomaly. 3. PD027 = 3.0 4. PD028 = 3.0 I derived these values from reading between Vi and ACM on the VFD and then setting a figure above this reading. 29

Chapter 4 Acronyms Acronym ACM PROG PWM Vi VFD Meaning Common Terminal of Analog & Control Signals Programming Mode Pulse Width Modulation Analog Voltage Frequency Reference Input Variable Frequency Drive +10V Power Supply for Speed Setting 30

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