KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com sales@kdntool.

com [email protected]

Proxxon MF 70 CNC Package

Tabletop Milling Machine with Three Axis CNC Retro-fit

FEATURES & SPECIFICATIONS:

100W 5-20K RPM Spindle with 6 collets (1, 1.5, 2, 2.35, 3, 3.2mm) 7 7/8 X 2 Table Size (200 X 70 mm) 5 17/64 X 1 13/16 X & Y Travels (134 X 46 mm) 2 Z Travel (70 mm) 110-120 VAC 15 LBS Weight 5 7/64 X 8 55/64 Footprint (130 X 225 mm) 13 25/64 Height (340 mm) Includes standard workholding package Multiple accessories available 83 OZ /IN NEMA 17 Step motors Xylotex based step driver box Internal 24 VDC power supply Standard DB-25 parallel port interface Precision machined aluminum step motor mounts .000025 Step resolution 20 IPM rapid traverse speeds MCR style Emergency-Stop circuit Works with Mach I-II-III, TurboCNC, EMC*, and DeskCNC* control software
*EMC and DeskCNC require further interface processing available separately.

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

CONTENTS:
Page 1&2 Welcome and Overview Page 3 CNC Safety Page 4 Software Set-up Page 5 Electronics Application Notes Page 6&7 Electronics Installation Page 8 Lubrication Schedule Page 9 Step Chart matrix Page 10-17 Xylotex manual

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

Hello and thank you for purchasing one of our cnc retrofit Proxxon MF70 milling machines. The German based Proxxon mill is of fine quality and design. With our CNC components added to it, you will enjoy a machine capable of automating many tasks involved with precision miniature machining. A good bulk of the work still lies in the drawing and programming of the part to be machined. At this point we will leave those aspects in your hands as this package is only designed to provide the machine motion from a programmed part file via the interpreter software of your choice. Whether you are a seasoned CNC operator, or are new to the field of CNC machining, we have put together this set of notes, instructions, and diagrams to assist in the set-up, basic operation, and maintenance of the machine. Due to the vast array of machine control softwares currently on the market, we are not able to detail every aspect of each softwares set-up characteristics, however we will propose to give a greater overview of the entire set-up process and provide the necessary information you will need. This will enable you to get the machine moving without a plethora of head scratching or nail biting. A personal computer (PC) based CNC machine control package is comprised of various subsections we will refer to as blocks. Following is a diagram that defines the 5 basic blocks:

cont KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

BLOCK 1- PC running control / interpreter software.

This is typically a dedicated host PC running your selection of control software. TurboCNC, Mach 3, Quickstep, and DeskCNC are a few common softwares currently on the market. Software set-up is to be performed off-line prior to the motor driver box being powered up. Software set-up should be your first priority before making any machine connections!!

BLOCK 2 Communication Distribution.

For this package you can think of this as the DB-25 cable that connects your computer to the motor driver box. Your interest in this block regards which pins of the DB-25 cable are assigned to communicate with the proper motor drivers. A pin-out listing is included on a later page. Some softwares do not allow pin choices and may require a pin converter interface in addition to the DB-25 cable. If you find this is the case, we can provide a converter based upon your specifications. (Some versions of software utilize a DB-9 serial connection and require an interface, containing a slave processor board, between the host PC and the motor drivers.) (DeskCNC is one example)

BLOCK 3 Input / output devices.

This refers to a machine that has been wired with overtravel limit switches and / or homing switches. It also includes provisions for output relays to control the spindle and / or coolant-vacuum functions. This package, being entry-level in price, does not include any of these aforementioned options so you may disregard them during software set-up.

BLOCK 4 Axis motor drives.

This block refers to the electronics instrument case included with your package. This case contains the actual motor driver electronics and the power supply for the motors. It is IMPERATIVE that NO CONNECTIONS ARE MADE OR BROKEN WHILE THE REAR POWER SWITCH IS ON!! This includes connecting the motors to the box as well as connecting the power cord to the rear inlet or removing the fuse holder. Doing so will DESTROY the driver electronics and render them useless. Instructions for setting the box up are located on a future page within this package.

BLOCK 5 EMERGENCY STOP Provisions.

An Emergency Stop is a safety device designed to stop the machine axes motion in the event of a dangerous situation arising. It is typically a device that interrupts the motor drivers power supply line to halt motion once pressed. The Emergency Stop button must always be located within the machine operators reach while he or she is within the danger zone of the machine. Further explanation of this packages Emergency Stop functionality is detailed on a future page.

Well, thats enough hooting, lets get to work!!

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

CNC Safety
All machinery has a certain level of danger about it. CNC machinery has a heightened level in that it has the potential to move, turn the spindle on, to run off course, etc without any input from you. The wisdom to not reachin or place your hand too close while a machine is operating is common place for some, learned the hard way knowledge for others, and still some may never comprehend it at all. Body parts are not replaceable!! End mills, drills, reamers, scales, and clamps, even machine tables are. Respect, good judgment, and common sense are a must for operating CNC machine tools and all the guarding and/or bright colored stickers in the world will not protect you better than they can!!!!! Safety Glasses are also a no-brainer when you are in the trajectory range of an operating machine. Try to fathom the thought of a smoking chip of steel penetrating your eye and it will become quite obvious why you need them. I recently ordered an industrial sized package of straight edge razor blades and sure enough, printed on the sticker, it said CAUTION: Blades are sharp. I stopped and thought to myself, sharp razor blades, what a novel idea. By assuming the role of a CNC machine tool operator you place yourself at risk of bodily harm / dismemberment or even worse unmentionable dangers. Take this responsibility, apply your own respect, good judgment, and common sense; and you will benefit from an enjoyable CNC machining experience. Ken Cardolino KDN Tool & Automation Engineering Co. LLC

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit with one of our kits.

8/26/05

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

Software Set-up
As previously stated, this is a generic overview into setting up PC based CNC control software. It is intended to provide you with the necessary information you will need to set-up most of the commonly available CNC control software packages. Refer to the documentation provided with your chosen software package for specific set-up related characteristics and requirements.

Configuring CNC control software is a matter of inputting machine specific data into the software, to be used by it, for calculating the motor drive signals needed to move the machine per the part program. These values are normally named and stored by the software in a .ini type file somewhere in its registry. Typically you input the information from within the running software program using a set-up / configuration screen, save the configuration file with a unique name for the given machine, and shut down and restart the program to load the newly saved data.

We will now bullet the most common set-up parameters you are likely to encounter, as well as our recommended settings* for the Proxxon MF70 CNC mill. At this point you will need to make the decision between using the Imperial or Metric measurement system. Both are provided for your reference. (NOTE that the MF70 uses 1mm pitch lead-screws so that the following Imperial
settings have been converted to six decimal place precision.)

Motion Parameters:
Motor steps per 1 revolution = 1600 (with micro-stepping applied) Inches traveled per 1 step = .000025 Millimeters traveled per 1 step = .000625mm # steps per 1 inch travel = 40640 # steps per 1 mm travel = 1600 Backlash = 0 to start Starting step frequency = 500 hz or .75 per minute or 19mm per minute Maximum step frequency = 13500 hz or 20 per minute or 500mm per minute Acceleration Ramp Rate = 30000 hz per second or .75 per second or 19mm per second Slow jog speed = 3400 hz or 5 per minute or 125mm per minute Fast jog speed = 13500 hz or 20 per minute or 500mm per minute Motion profile = linear Driver type = step and direction Port number = ? computer dependent Step pulse width = 10 microseconds minimum Per axis step pin # = see set-up instructions Per axis direction pin # = see set-up instructions

Velocities:

Communication:

*Our recommended settings are intended as a baseline starting point and make no guarantee as to actual machine performance. Individual results may vary.

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

Basic CNC Electronics Application Notes:

The electronics arrive in your hands as basically a plug and play type system. Your job is to set-up your software to match what is taking place with the electronics and lead screws. The driver box is based around a Xylotex four-axis driver board. Jeff at Xylotex stresss the importance of NOT connecting or disconnecting anything with the power applied to the unit. Doing so will destroy the onboard drive chips and the board will require repair or replacement. Any board failure will be the customers responsibility as we bench test each system before packing for shipment. There are two fuses in the unit. One fuse controls the AC line voltage and is located inside the unit on the power supply. The other is a collective safeguard for the three axes DC power. These are the first place to start if the unit does not function properly. Disconnect power cords before attempting to replace either fuse. There is raw line voltage potential inside the unit when opened so caution should be observed by anyone attempting to perform work inside. KDN Tool will not be held responsible for any injuries incurred from anyone opening the unit for any reason. You may return the unit to us for repair if needed. It is normal for the step motors to run hot to the touch. Use caution when positioning hands etc. in the vicinity of the motors. If the unit is powered up and you will not be running for a while, you can dis-able the axes and cut down on some heat generation and power consumption. The trick is remembering to re-enable them before you hit the start button! The Emergency Stop is the large RED pushbutton located on the top left of the motor driver box. Behind it lies a small black RESET pushbutton. The E-STOP button is connected to a Master Control Relay (MCR) located inside the box. This is a latching relay that removes power from the motor drivers when the E-STOP button is depressed. To latch the relay and enable the motor drivers, you depress the RESET button. The relay will stay in the latched position until either the E-STOP button is de-pressed or the main power is removed. This in turn causes all axes motion to come to an immediate halt. This will not stop the spindle, and it will need to be stopped by its own means. The reset button is used to restore DC power to the motors when ready as well as at initial start-up of the day. This safety feature has been included and is intended for just that, THE ESTOP IS INTENDED TO BE USED IN AN EMERGENCY SITUATION ONLY, it is not intended to be used as a means of stopping mid motion when the softwares stop button could otherwise be utilized.
KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

Basic CNC Electronics Set-up Instructions: (non-DeskCNC)

Assuming you have your mechanics installed and your motors mounted, you are now ready to set-up the electronics and start throwing chips. Due to the vast array of control softwares on the market we are not able to provide a detailed set-up for each one. Instead we have attempted to provide to you enough knowledge to allow a relatively trouble free integration with whatever software you have chosen.

Hardware Set-up:
1. Position driver box so that it will be accessible to all motor cables and to yourself for switch manipulation. Use caution to avoid the line of fire of metal chips from the machining process. The unit IS NOT a sealed enclosure and such is susceptible to metal chips getting inside and shorting out the circuitry. 2. Connect motor cables to their respective receptacles on face of driver box. Make sure they are plugged in completely to assure continuity of connectors. 3. Connect power cord to power inlet on back of unit and to accessible dwelling 120 volt power receptacle. 4. Turn power on using the switch located at the power inlet on rear of box. 5. Once software has been set-up, you are ready to reset the motor power circuit (using the small black reset button located next to the Emergency Stop button) and begin motion.

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

Software Set-up Help:

Please refer to your softwares literature for details about setting parallel port pin designations. The Xylotex board inside the unit accepts the following pin/signal arrangement: LPT pin 2 = X axis step/clock signal LPT pin 3 = X axis direction signal LPT pin 4 = Y axis step/clock signal LPT pin 5 = Y direction signal LPT pin 6 = Z axis step/clock signal LPT pin 7 = Z axis direction signal LPT pin 8 = A axis step/clock signal LPT pin 9 = A axis direction signal LPT 18-25 = Ground Please feel free to bring any other questions / concerns /or suggestions to our attention so we may include them in future revisions. Enjoy your CNC machine and please exercise caution if you are new to CNC machining, as it is possible to be injured by computercontrolled machines. We advise those completely new to CNC to take a course at their local high school or community college to become familiar with the overall function of such a machine.

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

KDN Tool & Automation Engineering Co. LLC 34 Church Street West Warwick, RI 02893 401-615-0267 www.kdntool.com [email protected] [email protected]

KDN Tool & Automation Engineering Co. LLC will not be held responsible for injuries sustained while operating CNC machinery retrofit by us or with one of our kits.

6/27/06

25.4 (1mm) T.P.I. LEAD SCREW

MOTOR STEP ANGLE 1.8 1.8 1.8 1.8 1.8 0.9 0.9 0.9 0.9 0.9 DRIVER STEPPING LEVEL FULL HALF 1/4 1/8 1/10 FULL HALF 1/4 1/8 1/10 STEPS PER 1 REVOLUTION 200 400 800 1600 2000 400 800 1600 3200 4000 STEPS PER INCH 5080 10160 20320 40640 50800 10160 20320 40640 81280 101600 INCHES PER STEP 0.0001968504 0.0000984252 0.0000492126 0.0000246063 0.0000196850 0.0000984252 0.0000492126 0.0000246063 0.0000123031 0.0000098425 I.P.M. PER 1000 HZ 11.81102 5.905512 2.952756 1.476378 1.181102 5.905512 2.952756 1.476378 0.738189 0.590551 MOTOR RPM PER 1000 HZ 300 150 75 37.5 30 150 75 37.5 18.75 15

Using the above matrix as a guide, you can compare a step motor's torque curve to see if it is compatable for your desired application. The following example uses a commonly available imported NEMA 23 double stack step motor with a 1.8 degree step angle, 2.8 amp/phase current rating, and 276 ounce/in's of holding torque, direct coupled to the lead screw. The torque curve is based upon an operating voltage of 32 volts DC provided by a linear un-regulated power supply. This is a good choice of motor for the Sieg X2 mini mill. The motor is driven by 1/10 microstepping driver. You will also be able to determine if your chosen control software is capable of delivering a step pulse train fast enough to achieve your desired speed requirements.
EXAMPLE: Proposed rapid travel speed = 60 I.P.M 60 IPM = 1 inch per second 1 inch of movement requires 40,000 steps 40,000 steps in 1 second would require a 40,000 HZ (40KHZ) pulse train from the control software. If the motor spins 30 RPM for every 1000 HZ than 40,000 HZ would equal 30 X 40 = 1200 RPM. At 1200 RPM the step motor would have @ 35 ounce/inches of torque available.(per the above mentioned torque curve data) 6/27/06 KDN TOOL AND AUTOMATION ENGINEERING CO. LLC ALL RIGHTS RESERVED

XS-3525/8S-4
Preliminary DataSheet Version 4.00

The XS-3525/8S-4 microstepping stepper motor driver is the perfect choice for CNC retrofitting of desktop and small benchtop milling machines. Connect bipolar wired stepper motors, power, and a parallel port signal source

Small Size 4.275 X 2.8? inches. Drives up to 35Volts @ 2.5 A/phase 4 different microstepping step levels from Full-Step(FS) to 1/8 step Filtered & Buffered Step & Dir lines Built in DC-DC converter for +5V Break-out screw terminals for I/O Microstepping Truth Table axS1 0 0 1 1 axS0 0 1 0 1 Output Full Step Half Step Quarter Step Eighth Step

The XS-3525/8S-4 Stepper Driver is a 4 axis pulse-widthmodulated (PWM) current controlled bipolar micro-stepping controller. Each axis drive has a 2.5 Amp/phase @ 35Volt maximum continuous Output Rating. The drive circuitry has thermal shutdown protection and crossover-current protection. Synchronous rectification circuitry eliminates the need for external clamp diodes in most applications. Each axis accepts Step & Direction signals, along with 2 jumper inputs to define microsteps per full step. The board is of 4-Layer construction with Isolated Power and Logic supply planes. The drive circuitry has a heat sink attached to allow cooler operation.

1 means jumper NOT installed

2004 Xylotex www.xylotex.com 1

Power
Each axis can be separately setup to deliver different maximum current levels by adjusting an on-board potentiometer (VRX, VRY, VRZ & VRA). The potentiometer creates a voltage which is input to the drivers Vref (Voltage Reference) pin. The Vref voltage is referenced to ground (GND) and can be monitored at the test points TPX,TPY,TPZ and TPA. The reference voltage at the test points is related to the motor drive current by the following formula: Vref = Motor Current * 1.44
2.5 Amp = Vref 3.60V 2.0 Amp = Vref 2.88V 1.5 Amp = Vref 2.16V 1.0 Amp = Vref 1.44V 0.5 Amp = Vref 0.72V

The Vref circuitry is based on the +5V generated with the on-board DC-DC converter. The Vrefs allow for a wide selection range, which can be set to exceed the maximum (3.60V) Exceeding the 3.60V will cause the drive circuitry to attempt to deliver more current than it is rated for, which can cause overheating of the device. Overheating the device lowers life expectancy of the circuitry as well as introducing the possibility of a thermal shutdown cycle (which can lead to motor/system position losses). You should never drive the motor at a current higher than specified by the motor manufacturer. Generally, very little extra torque will be achieved, and the motor will probably overheat. The Vref voltage is compared to on-board Sense Resistors which have a 5% accuracy rating. Full current can be achieved with voltages as low as 3.42V on Vref. When attempting to deliver 2.5A/phase, start with a Vref voltage of 3.42V. The system motor drive circuitry can handle up to 35 volts which includes Back EMF (BEMF). The recommended maximum running voltage is 30VDC. The absolute maximum voltage is 35VDC. Exceeding the maximum voltage (35V) will destroy the circuitry! Because stepper motors are current driven, rather than voltage driven devices, it is generally acceptable, and most often necessary, to drive the motor at a voltage higher than the motors rated (nameplate) voltage. The on-board drive circuitry limits the source/sink current to the motor without the need for external power resistors. 12 Volt and 24 volt power supplies are the most common power sources with voltage outputs under the maximum 35V. Of the two, 24V will provide much better performance. 24V will charge the motor coils to the proper level twice as fast as 12V. This means reaching the proper torque quicker, and means getting a more torque at a higher step rate. Because 24V will allow the motor coils to charge quicker, the internal switches will remain ON for a shorter amount of time. This allows the board to run cooler. 12VDC may be used for initial setup and testing however it does not provide any level of protection over using a higher voltage like 24VDC. The minimum motor supply voltage is 8.0 volts. Connector J15 is tied to the system ground (GND) and motor power supply planes (VBB). In systems using 12 or 24 volts, this connector can be used to supply power to a cooling fan rated for the appropriate voltage. Use of a cooling fan is recommended for systems operating at or near the maximum current rating (see below). Lower voltage system (12V) may also require fan cooling since the internal drivers will be ON for longer periods during coil charging.

ABSOLUTE MAXIMUM RATINGS

TA=+25C

which should not be exceeded Load Supply Voltage(VBB) (including Back EMF) Output Current(IOUT) Operating Temperature Range(TA) Junction Temperature(TJ)

35V 2.5A 20C to +85C +150C

Logic Input Voltage Logic HIGH min. voltage 2.9V (MAX. +5.0 VDC) Logic LOW max. voltage 1.5V

Restrictions
Do NOT adjust the Vref voltages with motors attached Do NOT adjust the Vref voltages to more than 3.60V Do NOT connect or disconnect motors, fans, etc when the drive is powered. Do NOT place a fuse between the motors and the drive. Do NOT allow VBB to exceed +35VDC, STEP & DIR lines to exceed +5.0 VDC Do NOT connect scopes or any other test devices to the motor leads (A, A#, B, B#)

Step C A B D MS0, MS1, DIR, RESET

A) Minimum Command Active Time Before Step Pulse B) Minimum Command Active Time After Step Pulse C) Minimum STEP Pulse Width D) Minimum STEP Low Time

200nS 200nS 1.0uS 1.0uS

Step Sequencing
Table 1. FULL HALF 1 QUARTER 1 2 1 2 3 4 3 5 6 2 4 7 8 5 9 10 3 6 11 12 7 13 14 4 8 15 16 9 or 1 17 or 1 360 is 4 FULL Steps EIGHTH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 or 1 ANGLE 0 11.25 22.50 33.75 45 56.25 67.50 78.75 90 101.25 112.50 123.75 135 146.25 157.50 168.75 180 191.25 202.50 213.75 225 236.25 247.50 258.75 270 281.25 292.50 303.75 315 326.25 337.50 348.75 360 or 0 NOTE:

HOME#

restart cycle

Connectors
J? The 5-pin header on the Right of the board has ENA# for all four axes as well as GND J9 2-connection screw terminal on the left is used for Motor Power Supply (VBB) (Min 8.0 Volts, Max 35.0 Volts) J15 2-pin header on the left of the board is connected to system VBB and GND. Systems using 24V (or 12V) for motor power supply can use this connector to power a 24V (or 12V) DC fan used for improving air flow across the heat sinks (recommended for enclosed systems running higher voltage/full amperage). J7 is used as a source for the axes STEP and DIRECTION signals. The following is a pin-to-pin correspondence a typical usage. IDC Pin ---------3 5 7 9 11 13 15 17 10,12,14,16 18,20,22,24 Typical Usage -----------------STEP X DIR X STEP Y DIR Y STEP Z DIR Z STEP A DIR A GND (Pin18) GND Parallel Port --------------PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 GND GND DB25 Pin Number ------------------------2 3 4 5 6 7 8 9 18,19,20,21 22,23,24,25

Pin 26 on J7 is connected to system VCC. In most configurations, the pin will not be connected since typical IDC DB25 adapters do not use this pin. Special designs may use this pin as a voltage source for signal power (i.e. 10K resistor pullup for I/O lines). It is not intended to power external devices.

Screw Terminals
The break-out screw terminals provide the user with access to all unused Parallel Port I/O. The I/O may be used for software driven functions such as limit switches, home switches, E-STOP switches, spindle motor enable, coolant pump enable, etc. The stepper driver board play NO role in the processing of these signals other than to provide a place to access them. Refer to your software package to properly setup and use function similar to the ones listed above.

Setup & Operation

Almost all board failures occur during initial setup, while moving the board to a new location or adding connectors because of miswiring and shorts. It is imperative that the wiring to the board be double checked, that the motor phase information is correct. You should be familiar with, and ready to use your signal generator (i.e. software such as TurboCNC or Mach2, or a step generator like a microprocessor)
Take static discharge precautions (ground yourself before handling the board).

With Power Supply (PS) off, Attach Vbb & Gnd to screw terminals. Note Polarity when connecting! Power ON PS (see red LED light up on stepper driver board) Check/adjust your Vrefs (Black Lead to GND, Red lead to Vref Make sure Black not on +5VDC, Vcc) Power OFF PS Hook up 24VDC fan if you are going to be using one (and Vbb is 24VDC) Hook up a stepper motor. Make sure that the Phases are correct. Double check connections (no disconnected wires, bare ware or shorted wires) Power ON PS The motor should "lock up" (not turn with simple finger pressure). If NOT then STOP here Power OFF PS Connect the IDC26-DB25 cable. It is generally then connected to a PC parallel port extension cable Power ON PS Try to jog the motor with software (i.e. TurboCNC or Mach2) If motor moves properly -> continue, otherwise STOP here. Turn OFF PS Hook up your other motors Double check connections (again!) Turn ON PS Test jogging for newly attached axes

If the motors run backwards, swap either the A-A#, or B-B# wire pairs (but not both). Generally though, this can be achieved through software.

ENA# Inputs
The drive ships with all four axes enable by use of the ENA# jumper. This is the jumper, in the set of three each axis has, that is closest to the IDC header. By removing these jumpers, enable control can be passed to the ENA# connector (J?). This connector can allow the remote enabling/disabling of any or all of the axes. For a single switch enable of all four axes, simply make a connector that wires all four axes enables together, and place this on one side of a SPST switch. Wire the GND from the header to the other side of the switch. When the switch is in the closed position, the GND will be connected to the ENA# inputs and the drives will be enabled. When the switch is open, the drives will become disabled. Similarly, four separate switches each with an individual ENA# and GND can be wired up to allow separate enabling/disabling of the drives. As an alternative, the ENA# can be controlled by software through an output port (i.e. one of the parallel port outputs). In this case, when the ENA#(s) are connected to an output, and the output state is LOW, the drive(s) will be enabled. When the output goes HIGH, the drive(s) will be disabled. The Heat Sinks are attached with thermally conductive adhesive pad. The driver board is meant to operate in a Horizontal position. The adhesive pad has not been tested for holding strength when the driver board is operated in a vertical position. In practical application however, the boards may be mounted vertically once the adhesive has cured. This will generally have taken place by the time you receive it. The heatsink conduct heat away from the driver chips. A cooling fan can help this process considerably, and given the cost of small fans, they are well worth the expense. If the board is mounted within an enclosure, place the fan so that it will bring in cool outside air and blow it over the heatsinks. Make sure there is adequate ventilation holes so that

the warm air in the enclosure can exhaust. Be sure that the fan is situated so that no flying debris, such as coolant, chips or dust can get sucked in by the fan. Dust and dirt blown in and deposited on the heatsink will degrade the heat transfer and the board can fail due to overheating. You may want to periodically blow out any dust accumulated on the heatsinks. . Unipolar Motor Note: When Setting Vref for a UNIPOLAR rated motor, use a current of 50.0% of the rated unipolar current, when wired for series mode. EX: Unipolar rated at 2.0A, when wired in series mode would be setup for 1.00A, or Vref of 1.44 Volts. Half winding mode would use the full 2.0A rating, Vref = 2.44V. The drive will work with three type of stepper motors, 4-wire, 6-wire or 8-wire motors. 4-wire motors are truly bipolar, and can only be run as such. 6-wire motors can be wired two ways to work with the bipolar drive. The first is half-winding. In this method, one end wire, and the center-tap wire of the phase is used. The other end is insulated and left unused. This method uses unipolar nameplate current specifications, and will produce nameplate torque. The second is series winding. In this configuration, the center-tap is insulated, and unused. This method uses all of the wiring per phase, but has double the number of wire turns as halfwinding or unipolar mode. Because of this, the amperage requirement becomes half the nameplate rating. Because the wire in the coil can handle more current than half, motor manufacturers will often boost the torque rating by specifying currents up to 71% of unipolar rated current while running in series mode. This is fine for FULL step motor drives, but bad for microstepping drives. Using this much current will fully magnetize the motor, and destroys any microstepping smoothness and accuracy. Any extra torque achieved by this method will generally be lost to machine vibrations due to loss of microstepping smoothness. The advantage of using series winding is that lower power drives may be used. For example a unipolar motor rated for 4.0A/phase is over the 2.5A/phase maximum of the XS3525/8S-4. Running in series requires only 2.0A/phase to achieve the same torque. The disadvantage of this method is that it raises motor inductance, which in turn, slows motor coil charging time. Since proper torque is reached only when the coil has charged to the required level, the longer it takes to charge, the longer until full torque is achieved. This leads to slower full torque stepping rates. Conversely, a half-winding configuration requires full nameplate rated current, but if the drive is capable of this, the advantage is that rated torque can be achieved twice as fast as series winding (using the same voltage, when comparing half-winding and series). The GND & Vcc (+5VDC) available on the right hand side of the board can be used to pull limit inputs high through a 10K resistor. It is not intended to drive other devices.

 2004 Xylotex www.xylotex.com