compact 1000 circuit description
TRANSCRIPT
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Compact 1000 Circuit Description
General Test Procedure
1. Measure the power supply at the site. The voltage should be between 220and 250Vac
2. Check the machine serial number label to see the voltage matches the supply
3. Power on the machine. Check the neon illuminates in the switch and the
machine light comes on in the cabinet.
4. Check LED 1 and 2 are lit on the distribution board
5. Check the 7 segment display is lit. The link below shows the meaning of the
display. http://www.denfordata.com/bb/files/NextStepLEDSWEB.htm
6. Press the E-Stop button and release it. Ensure Relay 1 the E-Stop relay
energises and de energises.
7. Measure both power supplies on TB 11 of the next move. 24V DC and 38V
DC
8. Check the guard has unlocked and can be opened.
9. Connect the computer to the machine and ensure it communicates.
10. Home all 3 axes in turn.
11. jog each axis and ensure that they travel smoothly
12. Check the spindle starts.
13. Check the guard locks when the spindle is running, or the E-Stop is pressed.
14. Jog the axes and check the feederate override functions correctly
15. Open the guard and check there is a warning message on the control panel
16. E-Stop the machine and check there is a warning message on the control
panel.
http://www.denfordata.com/bb/files/NextStepLEDSWEB.htmhttp://www.denfordata.com/bb/files/NextStepLEDSWEB.htm -
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Power Supply
The compact 1000 is designed to run from 115V or 230V ac at 50 or 60Hz. The voltage
selection is made at the factory by wiring links to Conn5 on the distribution PCB,
The mains supply is connected to the machine through a switched and fused inlet unit.The fuse is located in a draw located below the socket for the mains lead. (a spare fuse is
also located in the draw)
The power passes through a mains filter then into the distribution PCB on Conn1.
The mains then supplies a transformer (protected by FS1) which then creates a 24V dc
Control output and a 38V axis motor supply.
24V dc Supply
The 18Vac secondary winding from the transformer is protected by FS3. The 18V is
rectified and smoothed to give 24V dc. When the 24V is present LED1 on the
distribution PCB is illuminated.
This supply is used to control all the machine logic and control relays. This supply is
present when ever the machine is connected to the power.
When the 24V is present the 7 segment display on the NextMove controller will be
illuminated.
38V DC Supply
The 38V supply is created by rectifying the 28V secondary of the transformer.
When the 38V is present and the machine is not in E-Stop LED 2 is lit. When the E-Stop
is pressed the LED goes out.
The 38V is connected directly to the Nextmove controller onTB-10.
Power Supply Checks
Power on the machine
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Check LED 1 is lit
Check the 7 segment display on the next move is lit
Release the E-Stop and check LED 2 is lit
Measure the voltages on TB11 of the NextMove
Measure the 5V, +12V and 12V on the NextMove TB10
Simple checks if you do not have a meter
If the 7 segment display is lit on the Nextmove the 24V supply is probably OK
Try to turn any of the leadscrews with the E-Stop pressed and they should turn, release
the E-stop and the motor power should hold the screw so it cannot be turned. If this is the
case the 38V supply should be OK.
The Emergency Stop Circuit
The emergency stop circuit is a failsafe system that ensures the machine cannot run in a
dangerous state.
The emergency stop push button has two contacts either of which will make the machine
go into a safe mode. The first contact signals to the microprocessor that the machine
should stop. The microprocessor will instantly stop the spindle and axes and prevent the
machine restarting until the button is released.
The second contact is used to drive the Emergency stop relay. This also prevents spindle
operation and axis motion as well as applying the brake to the Z axis motor.
The first contact of the E-Stop button is wired directly to TB1 on the NextMove. This
signal is used to create all the software interlocks but also to display the E-Stop message
in the control panel.
The second contact is wired directly to Conn 8 on the distribution PCB. This switches
24V to the coil of RL1. If the button is pressed the 24V is removed and the relay de-
energises (as it would in the case of power failure). Only when RL 1 is energised can the
spindle or axes motors receive power. RL 1 also supplies power to release the Z axisbrake. So if the E-Stop is Pressed or the power fails the Z brake will lock and prevent
motion.
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E-Stop Checks
With the machine powered up and the software connected to the machine press the E-
Stop Button. A red message will appear in the control panel.
Look at the 7 segment display of the NextMove control card and when the E-STOP is
pressed the letters: E . S t O P scroll round on the display
Press and release the E-Stop button and check the E-Stop relay (RL 1) energises and de-
energises.
If the 24V supply is failed the above tests will not function.
The Guard Circuit
The guard switch electrically and mechanically interlocks the machine door. There are
two sets of normally closed contacts on the switch.
One contact is used to let the NextMove know the guard status by connecting Input 6 to0V when the switch is closed (this allows the software logic to limit the speed of axis
travel, disable the spindle and display a warning message in the control panel).
The second contact is in series with the spindle enable relay coild and prevents the
spindle starting even if there is a logic failure.
There is also an electro magnetic solenoid which locks the guard when the E-stop is
pressed, the power is removed or the spindle is running. The solenoid is energised to
unlock the guard. There is a software time delay on the guard release to allow the spindle
motor time to stop before allowing the door to be opened.
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Guard Checks
If the Guard cannot be opened check the following
The 24V logic supply
The E-Stop button is released
The spindle is not running
The machine is powered on and connected to the software
Spindle Circuit
The spindle circuit on the Compact 1000 is very simple as the motor is either on or off
and is connected directly to the mains supply switched through the E-stop Relay and theSpindle enable Relay.
Relay 2 is the Spindle enable Relay. The coil of this relay is energised when Output 0
turns on provided that the guard interlock contact is closed.
Then provided the E-Stop relay is energised (which it would have to be otherwise the
logic would not let output 0 turn on) the 240V is connected to the motor.
The Mint logic checks that the machine is not in E-Stop, the Guard is closed and that
there is a demand for the spindle to start before letting Output 0 turn on.
Pressing E-stop would cause the E-Stop and Enable relays to de-energise and disconnect
the spindle motor.
Relay 3 will de-energise when either the spindle is running or the E-stop is pressed or the
power is removed from the machine. This locks the guard to ensure the machine is safe.
The relay re-energises (unlocking the guard) after a time delay once the spindle has
stopped or the power has been applied.
Note: There is a switch on the spindle motor. This should be left in the on position!
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Axes Motors
The axes motors are powered from the 38V DC supply that is connected to TB 11 of the
NextMove.
The axes are energised whenever the machine is powered on and the E-Stop is not
pressed.
The Z axis motor is fitted with a brake to prevent the axis moving downward if the power
fails or E-stop is pressed.
The motors are controlled by stepper motor drive chips mounted on the Nextmove base
board.
There is a fuse fitted on the NextMove board to protect the stepper drives.
Fault Finding
Check LED 2 is lit when the machine is not in E-Stop
Check the 38V supply on TB11 of the NextMove
Check the fuse on the NextMove
Check the Feed override is not at Zero
Open the guard and check the motors are energised by trying to turn a screw, then
Press E-stop and see the resistance disappears.
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If only one drive fails to move, press E-Stop or power off the machine and switch
stepper motor outputs on the NextMove card.
Home Sequence and Switches
The homing switches on the machine are mechanical. The switch sense is normally
closed (opening when the machine is home).
When an axis home request is sensed the axis first looks at the switch, and then if the
switch is not open (the axis is not at home) the axis drives at a medium feederate towards
the home switch. Once the switch is opened by the axis it slows to a stop then reverses
back slowly until the contact of the switch is made again. This is the home position.
If when the homing request is made the axis is on the home switch (the contacts are
open), then the axis just drives slowly away and stops as soon as the switch closes.
Fault Finding
There are two things that could happen when homing fails.
If the axes do not move at all check the motor power and that the drives are energised
(the ball screws have resistance when e-stop is released)
The NextMove control card should display h when homing has been requested.
The machine could travel towards the switch then stall. The machine will make a noise
but never home. Eventually a time out warning message will appear.
This could be because of several things:
There could be a debris or a component blocking the axis travel so the axis never
reaches the switch
The switch could be faulty and permanently short circuit
The switch could be miss positioned so that it never actuates
There could be a mechanical problem stalling the axis
You can check the home switch function by pressing the switch manually. From VR
Milling 5.23 onwards a green indicator shows in the control panel window when the
switch is activated.
You can use the secret home button to allow the axis to be jogged in the opposite
direction so you can clear any obstruction from the travel
Check the switch is being activated by the axis
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The second homing failure will result in the axis jogging slowly away from the home
switch eventually stalling at the opposite end of axis travel.
Again pressing ESC will abort homing.
This would be caused by the home switch being permanently open circuit
Check the switch by manually pressing and watching the icon on the control
panel.
Vacuum the switch while manually clicking it to release any debris trapped
between the contacts
The switch could be broken
The wiring of the switch could be open circuit
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I/O and Relay designation
Inputs
The inputs are activated by connecting them to ground. They have an internal pull up onthe NextMove card that connects them to 5Vdc when not operating.
The readings on the input can be measured with a meter and will read either 5V or 0V.
TB1
STOP Emergency stop Input
X DATUM X Datum switch
Y Datum Y Datum switch
Z Datum Z Datum switch
TB9
I/P 6 Guard Status
I/P 1 Vacuum Pump push button
Digital Outputs
TB3
Out 0 Spindle Enable
Out 6 Vacuum Pump Enable
Out 7 Guard Un-Lock
TB2
Out 15 Z axis brake release
Relays
RL1 Emergency stop relay
RL2 Spindle Enable
RL3 Guard Lock Relay
RL4 Vacuum Pump Relay
RL5 Z Brake Relay
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Tips and passwords
Double clicking on the banner of the flash screen at start up loads the software
without having to wait for the timer
Password for VR Milling functions is denny
Easy upgrader has several hidden features:
o Double clicking in the banner launches an option to force firmware
o Right clicking on the banner gives two options: Advanced and Card Test.
The passwords are dave and tristar
Secret home button activated by double clicking between home all and home X.
http://www.denfordata.com/bb/viewtopic.php?t=53&highlight=secret
Technical forum http://www.denfordata.com/bb/index.php
My e-mail address: [email protected]
http://www.denfordata.com/bb/viewtopic.php?t=53&highlight=secrethttp://www.denfordata.com/bb/index.phpmailto:[email protected]://www.denfordata.com/bb/viewtopic.php?t=53&highlight=secrethttp://www.denfordata.com/bb/index.phpmailto:[email protected] -
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Whilst NextStep is powering up:
This indicates FPGA has booted successfully.
Indicates FPGA 'walking ones' test on FPGA scratchpad has failed. HALT.
Indicates pseudo random number test on all of RAM has failed. HALT.
Indicates CAN controller reset has failed. HALT.
Indicates 'walking ones test' on the CAN controller has failed. HALT.
Indicates that power up test did not find any valid Firmware in Flash device
Indicates that new firmware is being loaded into the NextStep control
When NextStep has powered up:
Normal indication that card is powered up - the 2 is the cards NODE number (default)
Axes disabled, normally after downloading Mint (MEX file) for first time, before starting Denford S/W
Flashing E whilst Flash memory is being erased and mint (MEX) file is being downloaded
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When Mint is running and Denford S/W is connected:
Note that these figures relate to axis 0 specifically (ie, the X axis)
Axis is enabled
A general error has occured (Mint failure maybe)
A SPLINE move is being executed
A circular move is being executed
A Flying shear (used in lathe threading moves) is being executed
Axis is in homing sequence
Axis is performing a positional linear move
Emergency Stop has been pressed - None Denford S/W-this is a solid S symbol
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CNC Machine Language
G-Code List
G-Code Description
G00 Rapid Linear Interpolation
G01 Linear Interpolation
G02 Clockwise Circular Interpolation
G03 Counter Clockwise Circular Interpolation
G04 Dwell
G05 High Speed Machining Mode
G10 Offset Input By Program
G12 Clockwise Circle With Entrance And Exit Arcs
G13 Counter Clockwise Circle With Entrance And Exit Arcs
G17 X-Y Plane Selection
G18 Z-X Plane Selection
G19 Y-Z Plane Selection
G28 Return To Reference Point
G34 Special Fixed Cycle (Bolt Hole Circle)
G35 Special Fixed Cycle (Line At Angle)
G36 Special Fixed Cycle (Arc)
G37 Special Fixed Cycle (Grid)
G40 Tool Radius Compensation Cancel
G41 Tool Radius Compensation Left
G42 Tool Radius Compensation Right
G43 Tool Length Compensation
G44 Tool Length Compensation Cancel
G45 Tool Offset Increase
G46 Tool Offset Decrease
G50.1 Programmed Mirror Image Cancel
G51.1 Programmed Mirror Image On
G52 Local Coordinate Setting
G54 - G59 Work Coordinate Registers 1 Thru 6
G60 Unidirectional PositioningG61 Exact Stop Check Mode
G65 Macro Call (Non Modal)
G66 Macro Call (Modal)
G68 Programmed Coordinate Rotation
G69 Coordinate Rotation Cancel
G73 Fixed Cycle (Step)
G74 Fixed Cycle (Reverse Tapping)
G76 Fixed Cycle (Fine Boring)
G80 Fixed Cycle Cancel
G81 Fixed Cycle (Drilling / Spot Drilling)G82 Fixed Cycle (Drilling / Counter Boring)
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G83 Fixed Cycle (Deep Hole Drilling)
G84 Fixed Cycle (Tapping)
G85 Fixed Cycle (Boring)
G86 Fixed Cycle (Boring)
G87 Fixed Cycle (Back Boring)
G88 Fixed Cycle (Boring)
G89 Fixed Cycle (Boring)
G90 Absolute Value Command
G91 Incremental Value Command
G92 Work Offset Set
G101 User macro 1 (substitution) =
G102 User macro 1 (addition) +
G103 User macro 1 (subtraction) -
G104 User macro 1 (multiplication) *
G105 User macro 1 (division) /
G106 User macro 1 (square root)
G107 User macro 1 (sine) sin
G108 User macro 1 (cosine) cos
G109 User macro 1 (arc tangent) tan
G110 User macro (square root)
G200 User macro 1 (unconditional branch)
G201 User macro 1 (zero condition branch)
G202 User macro (negative condition branch)
M codes chart
M00 Program Stop
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M01 Optional (Planned) Stop
M02 End of program
M03 Spindle CW
M04 Spindle CCW
M05 Spindle OFF
M06 Tool change
M07 Coolant #2 ON
M08 Coolant #1 ON
M09 Coolant OFF
M10 Clamp
M11 Unclamp
M12 Unassigned
M13 Spindle CW & Coolant ON
M14 Spindle CCW & Coolant ON
M15 Motion +
M16 Motion -
M17 Unassigned
M18 Unassigned
M19 Oriented spindle stop
M20-M29 Permanently unassigned
M30 End of tape
M31 Interlock bypass
M32-M35 Unassigned
M36-M39 Permanently unassigned
M40-M45 Gear changes if used, otherwise unassigned
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M46-M47 Unassigned
M48 Cancel M49
M49 Bypass override
M50-M89 Unassigned
M90-M99 Reserved for user
*if the connection error, try click task manager and go to proses and than endtask to Milser
Easy upgrade solfware
Double click1. select - nextmove ST RS232 and usb
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- usb
2. click force firmware
Right click
1. Right click and choose advance
2. password ( dave )
Right click
1. Right click and choose test card2. password ( tristar )
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3. just click connection
4. digital output
TB3
Out 0 Spindle enable
Out 7 Vacuum pump enable
Out 6 Guard lock
TB2
Out 15 Z axis brake return
Work banch
Installation
1. browse cd
2. click utility3. click workbench
To open
1. click menu
2. workbench v5
3. star new project
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4. click com1
5. search up to Node2
6. scan
7. select usb
8. click configuration Node2
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9. click Update firmware
10. Controller Type: nextmove ST11. select baldorCAN
12. Download to Controller
Z checking offsets
g00z0 g00z0 g00z0
g4 x1 z-15 z-15
z-15 z10 z10
g4x1 z-30 z-30
z10 z10 z10
z-30 m99 m99
s4x1
z10s4x1
m99
VR MILLING
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a. 2D 3D for change the material
click simulation,
click billet material
vr billet setup
b. 2D 3D simulation