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 220 and 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.

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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 deenergises (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 axis brake. 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 EStop 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 deenergises. 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 to 0V 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 the Spindle 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

Awe 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 on the 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 X DATUM Y Datum Z Datum

Emergency stop Input X Datum switch Y Datum switch Z Datum switch

TB9 I/P 6 I/P 1

Guard Status Vacuum Pump push button

Digital Outputs TB3 Out 0 Out 6 Out 7

Spindle Enable Vacuum Pump Enable Guard Un-Lock

TB2 Out 15

Z axis brake release

Relays RL1 RL2 RL3 RL4 RL5

Emergency stop relay Spindle Enable Guard Lock Relay Vacuum Pump Relay 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

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Password for VR Milling functions is denny

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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”

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Secret home button activated by double clicking between home all and home X. http://www.denfordata.com/bb/viewtopic.php?t=53&highlight=secret

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Technical forum http://www.denfordata.com/bb/index.php

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My e-mail address: [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 G00 G01 G02 G03 G04 G05 G10 G12 G13 G17 G18 G19 G28 G34 G35 G36 G37 G40 G41 G42 G43 G44 G45 G46 G50.1 G51.1 G52 G54 - G59 G60 G61 G65 G66 G68 G69 G73 G74 G76 G80 G81 G82

Description Rapid Linear Interpolation Linear Interpolation Clockwise Circular Interpolation Counter Clockwise Circular Interpolation Dwell High Speed Machining Mode Offset Input By Program Clockwise Circle With Entrance And Exit Arcs Counter Clockwise Circle With Entrance And Exit Arcs X-Y Plane Selection Z-X Plane Selection Y-Z Plane Selection Return To Reference Point Special Fixed Cycle (Bolt Hole Circle) Special Fixed Cycle (Line At Angle) Special Fixed Cycle (Arc) Special Fixed Cycle (Grid) Tool Radius Compensation Cancel Tool Radius Compensation Left Tool Radius Compensation Right Tool Length Compensation Tool Length Compensation Cancel Tool Offset Increase Tool Offset Decrease Programmed Mirror Image Cancel Programmed Mirror Image On Local Coordinate Setting Work Coordinate Registers 1 Thru 6 Unidirectional Positioning Exact Stop Check Mode Macro Call (Non Modal) Macro Call (Modal) Programmed Coordinate Rotation Coordinate Rotation Cancel Fixed Cycle (Step) Fixed Cycle (Reverse Tapping) Fixed Cycle (Fine Boring) Fixed Cycle Cancel Fixed Cycle (Drilling / Spot Drilling) Fixed Cycle (Drilling / Counter Boring)

Awe G83 G84 G85 G86 G87 G88 G89 G90 G91 G92 G101 G102 G103 G104 G105 G106 G107 G108 G109 G110 G200 G201 G202

Fixed Cycle (Deep Hole Drilling) Fixed Cycle (Tapping) Fixed Cycle (Boring) Fixed Cycle (Boring) Fixed Cycle (Back Boring) Fixed Cycle (Boring) Fixed Cycle (Boring) Absolute Value Command Incremental Value Command Work Offset Set User macro 1 (substitution) = User macro 1 (addition) + User macro 1 (subtraction) User macro 1 (multiplication) * User macro 1 (division) / User macro 1 (square root) User macro 1 (sine) sin User macro 1 (cosine) cos User macro 1 (arc tangent) tan User macro (square root) User macro 1 (unconditional branch) User macro 1 (zero condition branch) User macro (negative condition branch)

M codes chart M00

Program Stop

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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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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 end task to Milser

Easy upgrade solfware Double click 1. select - nextmove ST RS232 and usb

Awe - usb 2. click force firmware

Right click 1. Right click and choose advance 2. password ( dave )

Right click 1. Right click and choose test card 2. password ( tristar )

Awe 3. just click connection 4. digital output TB3 Out 0 Out 7 Out 6

Spindle enable Vacuum pump enable Guard lock

TB2 Out 15

Z axis brake return

Work banch Installation 1. browse cd 2. click utility 3. 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 ST 11. select baldorCAN 12. Download to Controller

Z checking offsets g00z0 g4 x1 z-15 g4x1 z10 z-30 s4x1 z10s4x1 m99 VR MILLING

g00z0 z-15 z10 z-30 z10 m99

g00z0 z-15 z10 z-30 z10 m99

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2D 3D for change the material click simulation, click billet material

vr billet setup

2D 3D simulation