Compact 1000 Circuit Description

8/14/2019 Compact 1000 Circuit Description

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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)


G87 Fixed Cycle (Back 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

Documents

Compact 1000 Circuit Description