USN 3D8A CNC universal numerical controller

The USN-3D8A controller is a ready-made product and does not require any preparatory work on the part of the user. Just connect it via the LPT port to a computer and power it with 230V mains voltage. The system allows you to control three, two-phase, bipolar stepper motors with a maximum current of up to 7.8 A per phase. 4, 6 and 8 wire motors are micro-step controlled, which allows for increased precision of the machine's operation. The device can work with any program that controls via the computer's LPT port. When the motors are stopped, the current is automatically reduced, which causes the motors to heat up less (it is possible to select 50% or 100% of the set current value).

The USN-3D8A controller has a number of protections implemented by varistors and fuses. This ensures response to a short circuit of the motor coil to the system ground, too high current consumption of individual axes, or overvoltage from the power supply network. Additionally, the system is equipped with a fan that prevents the system from overheating.

The USN-3D8A device uses SSK-B04 controllers as power output stages. SSK-B04 is an economical, high-performance microstepping controller based on the latest technical achievements. It is adapted to control 2-phase and 4-phase hybrid stepper motors. Using advanced bipolar constant-current technology, it allows for greater speed and power from the same motor compared to traditional techniques used, for example, by L/R controllers. Its 3-state control technique allows for correct control of the coil current while maintaining low ripples, which in turn results in reduced motor heating. The SSK-B04 controller can control hybrid stepper motors with 4, 6 or 8 pins. The diagram below shows connections to motors in various configurations.

4-wire motors are the least flexible, but the easiest to connect. The speed and torque will depend on the inductance of the turns. When setting the controller output current, multiply the phase current by 1.4 to determine the peak output current.

6-wire motors can be connected in two configurations: high speed-lower torque or high torque-lower speed.
The higher speed or half coil configuration is so named because it uses half the turns of the motor. This reduces the inductance, which reduces the motor torque. It will be more stable at higher speeds. When setting the controller output current, multiply the phase (or unipolar) current by 1.4 to determine the peak output current. A higher torque or full coil configuration uses the entire inductance of the phase turns. This application should be used where higher torque is required at low speeds. When setting the output current, multiply the phase (or unipolar) current by 0.7 and set this peak value on the controller.

8-wire motors offer high flexibility to the system designer because they can be connected in series or parallel, allowing for use in many applications.
Series connection is typically used where high torque and low speed are required. Since inductance is highest with this configuration, efficiency drops at higher speeds. To determine the peak output current, multiply the phase (or unipolar) current by 0.7.
The parallel connection of the motor windings offers more stable torque at higher speeds. To determine the peak output current, multiply the phase (or unipolar) current by 1.96 or the bipolar current by 1.4.

After selecting the configuration with which the engine is to operate, unnecessary (unconnected) wires should be thoroughly isolated from the rest. We can now start connecting the cables to the power stages of the USN-3D8A universal numerical controller. Particular care must be taken during this operation. Bad contacts can result in incorrect operation of the motors, interference or, in worse cases, a short circuit. In order to reduce interference, the motors should be connected to the cabinet with shielded cables and properly grounded using stainless steel clamps prepared for this purpose.

After connecting the motor and before starting the entire system, the final stages must be configured correctly. The selection of the current fed to the motors and the step division is made using 8 microswitches located on the module housing. The first three bits (Sw1, 2 and 3) of the DIP switch are used to set the motor operating current (dynamic current). Select the settings closest to the current required by the motor according to the table below:

Switch SW4 is used to set the holding current. OFF means the holding current will be limited by half of the selected dynamic current value. ON means that the holding current will be the same as the selected dynamic current value. The controller, 1 second after the last step signal, automatically reduces the selected dynamic current value to 60%. This reduces engine heating by up to 36%.

The step division is set using SW switches 5, 6, 7 and 8 according to the table below:

By default, the microstep division is set to 1/8. If the controller was purchased together with the motors, then the controller current was set to the appropriate one for the given motor. Otherwise, the current was set to 7.8 A. You should then set the appropriate value for your motors.

The operation of the power stages is indicated by two LEDs located at the control signal connector (green - correct operation, red - error). After applying the supply voltage and the Enable signal, the green LED lights up continuously. After the EAW status changes to the opposite, the diode goes off.

The operation of the engines is controlled by the SSK-MB2 motherboard, which distributes signals from the LPT port to individual axes. It also allows you to connect base and limit switches or an emergency stop button. There are two relays on the module, each with two separate sections, each of which can switch currents up to 8A and voltages up to 250V. Using the relays mentioned above, we can perform the functions of turning on/off the electrospindle and supplying coolant. The use can be any.

For applications with spindle speed regulation, we can expand the system with the Spindle Control module produced by our company. It converts the frequency sent from the control program into analog voltage 0...10V. We can regulate some inverters with this potential.

In the ready-made USN-3D8A kit, the board connections that remain to be made by the user are limited to a minimum (possible connection of relays). The installation of limit switch cables was moved to the junction box by using which we eliminate the number of cables led to the cabinet. The system enables efficient group connections while maintaining electromagnetic compatibility. The module is produced in two versions: standard and extended. In both cases, the use of a tight housing and good quality channels provides excellent protection against both dust and moisture. Connectors mounted on a DIN rail were used to install cables inside the box. The use of a box reduces the costs of wiring the machine, facilitates connections, and most importantly increases the aesthetics of the entire system.

Version I
Number of entries ................................................. ......................................... 8 pcs
Number of outputs ................................................. ........................................... 1 piece
Cable length for connection to the control cabinet .................................... 2.5 mb (*)
Cable connections .................................................... ......................... connectors on a DIN rail
Number of connectors ................................................. ............................................ 8 pcs
Grounding attachment ................................................................. ............................. stainless steel clamps
Box dimensions (without glands) ........................................ .................... 160 X 120 X 76 [mm]
* the length of the cable for connection to the control cabinet may be different, indicated by the customer.

Version II
Number of entries ................................................. ......................................... 8-16 pcs (depending on arrangements with the client)
Number of outputs ................................................. ........................................... 1 piece
Cable length for connection to the control cabinet .................................... 2.5 mb (*)
Cable connections .................................................... ......................... connectors on a DIN rail
Number of connectors ................................................. ............................................ 8- 22 pcs (one DIN rail),(**)
Grounding attachment ................................................................. ............................. stainless steel clamps
Box dimensions (without glands) ........................................ .................... 225 X 175 X 80 [mm]
* the length of the cable for connection to the control cabinet may be different, indicated by the customer.
** it is possible to install an additional DIN rail, which will enable the installation of additional ZJU connectors or additional modules, e.g. a relay.

When purchasing a universal numerical controller, the customer receives a ready-made device ready to connect external elements (limit switches, sensor, etc.). It is best to start the assembly by installing the module in question into the machine body. The next step is to route the cables through the glands, arrange them appropriately and connect them (it is best to end them with tubular ends, which will facilitate installation and subsequent service). The photo below shows an example of connections inside the box. You can also observe the correct installation of cable screens, which allows for compliance with electromagnetic compatibility standards (example when installing motors).

Description of pinouts and connections made by the manufacturer.

Version I

The diagram below shows the most popular way of connecting peripheral components. Please note that all limit switches are in the normally open NO state. In this configuration, they are all connected in parallel. If we use NC type switches, remember to change the settings in the Mach, Activ Low program to the opposite one. In this arrangement, the limit switches are connected in series. If inductive proximity sensors are used, the GND ground connected to connectors 4 and 8 will also be used.

The entire set, both the logical part and the power stages, is powered by the MZ-03 module. It is based on the basic application of an unstabilized power supply (external transformer in the control cabinet housing, bridge and filter implemented using electrolytic capacitors). The second block is a separate power supply with an additional transformer, bridge, filter and integrated 12V stabilizer. LED diodes indicate the correct operation of each block. The motherboard is powered by 12 V.

The FM-01 fuse module was used to divide the current at the MZ-03 output. The system has four independent outputs. Each of them has a fuse and voltage indication. Damage to the fuse is indicated by the appropriate LED going off.

Soft start of the high-current part transformer is provided by a soft starter module with an additional fuse. In the first milliseconds, the current flows through the power resistors and then it is switched on to 100% using the relay. This prevents the transformer from temporarily drawing high power and thus "blowing the fuses".

The 230V voltage from which the system is powered is distributed using the FM-02 fuse module. It eliminates additional connectors and tangled wires, ensuring the aesthetic appearance of the device. Both channels are protected by two protections - current and overvoltage. The device is equipped with: main switch, softstart module, fan, and signaling diode. It has an additional OUT2 output to which we can connect an additional receiver and turn it on via relays on the motherboard. The maximum power of such a device cannot exceed 1.05 kW (4.5A, 230V).

Attention!!!

When installing an additional load, a current balance must be prepared. Please note that the maximum current of the main switch is 10A.

Before starting the USN-3D8A controller for the first time, check the connections of motors, limit switches and relays. Careless preparation of the cabling may result in system damage or unstable operation. We once again check the current settings on individual power stages. We connect the computer, run the program and turn on the controller.

ATTENTION!!!

When starting the machine, turn on the following: computer, program, controller. The program takes control of the LPT port pins. When shutting down the system, we use the reverse order. This will protect against unexpected and dangerous machine movements.

USN 3D-8A controller configuration file

The Mach 3 program is one of the most popular CNC machine control programs in our country, both for commercial and hobby solutions. It controls the operation of stepper motors or servo drives by sending step and direction signals (Step/Dir). This program works perfectly with all controllers available in our offer. Using the Mach3 program, we can transform the computer into a CNC machine controller. It enables, among others, the control of the following machines: plotters, milling machines, engraving machines, lathes, plasma burners, Styrofoam cutters. Thanks to the ability to simulate a PLC controller and ModBus communication using the Mach3 program, we can transform a PC into a controller for virtually any machine. Our clients have successfully controlled a pipe bender, an automatic welding machine or a powder coating device. Mach3 can control any device that has a maximum of 6 axes. The Mach3 program controls their work based on the so-called G-codes that we can prepare from vector files, for example using the LazyCam program. The program can control any set of controller and stepper motor. Any mechanical drive transmission solution (screws, strips or toothed belts) can also be used? the program has the ability to define the operating parameters of each axis separately. In the program window, we can preview the tool path and can constantly control machining parameters, such as feed speed or spindle speed. The program is available in a demo version. It is fully functional. It was only limited to 500 lines of G-code.

After purchasing the license, the program limit is 10,000,000 lines of G-code.

Files that will facilitate configuration are available at https://www.akcesoria.cnc.info.pl/mach3.htm .

The motherboard used in the USN-3D8A universal numerical controller enables control of four axes with base and limit switches, operation of the E-STOP emergency stop button and control of two relays (located on the board). Additionally, the board is prepared to support the Kanthal module (wire temperature control) and Spindle Control (spindle speed control).

The LPT printer port was used to connect the system to a computer. All devices (controllers, limit switches, spindle) are connected independently to the appropriate pins. The parallel port has 25 pins. Pins 1-9, 14, 16, 17 can be used as outputs, 10-13, 15 as inputs. Pins 18-25 are not used (ground). The program works with any combination of connections, i.e. specific output or input pins can be selected.

By default, the following configuration is assigned to the controllers manufactured by our company:

Start the program configuration by assigning tasks to the appropriate pins of the LPT port. In the Settings menu (Config), select the Ports and Pins tab. In the first Port Setup And Axis Selection window, we set:

In this tab we configure the program to work with the drivers. Here we can set, among other things, which computer port will be used to control the machine and the speed of the program. The Port #1 and Port #2 boxes are used to indicate the addresses of the LPT ports on the computer. We can mark here which ports we want to use. If there is one port in the computer, it most likely has the address 0x378, the other one is usually 0x278, although in the case of ports on PCI cards it may be a different value. You can check this in the Windows Device Manager by selecting the port there and checking the first address in the "resources" tab. (Start/Control Panel/System/Hardware/Device Manager/Ports (COM and LPT)/Printer port/Properties/Resources/Resource type = I/O range. The number defining the lower I/O range will be the address of our port. The Mach3 program allows work with 2 LPT ports, which gives us more inputs and outputs. Determining the program's operating speed depends on the speed of our computer's processor. If your computer has a 1GHz or faster processor, we recommend setting it to 45000Hz. The configuration should be confirmed with the "Apply" button.

ATTENTION !!!

Please remember to click the apply button before leaving the configuration window. Otherwise, we will lose the changes made.

Then we go to the Motor Outputs tab. The settings in this tab allow you to define how many axes the program should control and which pins the stepper motor drivers are connected to. Following the list in the LPT port description, we enter the settings. Below are the settings for controlling the four axes X, Y, Z, A and output to the Spindle Control module.

Meaning of the option:
Enabled - a given axis is to be used if the checkbox is green
Step Pin# - pin number on which step pulses for a given axis will be sent
Dir Pin# - pin number on which the direction of movement for a given axis will be determined
Dir Low Active - determines whether the direction control line should be high or low by default - changing the selection allows you to reverse the direction of axis movement
Step Low Active - determines whether the step control line should be high or low by default, usually the drivers operate correctly regardless of the setting of this parameter

Please remember that changes must be confirmed by clicking the "Apply" button.

The next step will be to configure the settings in the Input Signals tab. The settings concern, among others, homing limit switches, safety and the E-STOP button. The Active Low option is used to select the type of limit switch that has been connected to the main board, i.e. normally closed or normally open. Next, in the same tab it is possible to set options for the E-STOP emergency stop button. Here we can similarly choose what type of switch was used. It is recommended to use normally closed NC switches as emergency limit switches. This will eliminate the possibility of a break in the circuit. When, for example, the limit switch wire is interrupted, E-STOP will turn off the machine. Following the list in the LPT port description, we enter the settings.

Please remember that changes must be confirmed by clicking the "Apply" button.

The next step will be to change the settings in the Output Signals tab, where you can set the Enable output and general-purpose outputs (Output#n). The Enable output will be used to turn on the axis controllers. Output#1 and Output#2 will be used to control the PK1 and PK2 relays. The Mach 3 program allows you to define more general-purpose outputs to which we can connect, for example, further relays. However, this requires the use of additional pins on the motherboard.

The last tab left to configure is the Spindle Setup tab. Here we can make settings regarding the spindle, coolant and fog.

The Relay Control group allows you to control on/off. the spindle and its working direction using the relays available on the board. Check Disable spindle relay support. (Diable Spindle Relays) will make the service INACTIVE. In the Output signals tab, we have already assigned the appropriate pin numbers to the appropriate outputs. Now you need to enter the numbers of the outputs that will control the spindle using relays. These relays are activated by the M3 and M4 commands in our G-code. The Flood Mist Control group allows us, similarly to the above, to define outputs that control appropriate relays. After configuring the pins, we suggest testing the input devices? for this purpose, on the main screen, press the "Alt-7 Diagnostics" key, which causes a list of devices connected to the computer to appear. When switching on the limit switches manually, the yellow lights next to the appropriate labels should light up. If this does not happen, check the configuration of the input pins and the correctness of the electrical connections.

To fully enjoy the working machine, all you need to do is tune the engines. To do this, in the Configuration menu, select the Motor Tuning option. The following window will appear:

The X, Y, Z Axis buttons (X, Y, Z Axis) will allow you to select the axis for which you want to make settings. Only axes that have been activated in Motor Outputs are available. Using the up and down arrows, we can control the motor of a given axis in both directions (before entering the "motor tuning" tab, the program cannot be in RESET mode, because the motors will not rotate). The engine speed (Velocity) and its acceleration (Accel) are set using the appropriate sliders or entered manually in the appropriate box. The current characteristics of the engine speed are presented on an ongoing basis (the so-called ramp). A very important parameter is the number of steps per unit of measurement (Steps per). The unit is millimeters or inches, depending on the settings in Configuration/Units of Measure. This value should be determined based on the controller settings and the screw pitch, as well as any gears used. We enter this number in the box in the lower left corner of the screen (Steps per). For example, we have a 200 steps/revolution motor, an SSK-B04 controller with step division set to 1/2, and a 10x2 trapezoidal drive screw. Splitting the step will allow you to obtain 400 steps per motor revolution. The screw pitch is 2mm per revolution. In this configuration, the number of steps needed to move the axis by 1 mm is 200. This value should be entered in the Steps per field. An incorrect value entered will result in the machine not maintaining the set dimensions during operation. Examples of Steps per values (the number of steps needed to move the axis by 1 mm) for the most popular trapezoidal screws are included in the table below (motor 200 steps/revolution):

After entering the number of steps, we recommend that you start tuning the engines with low speeds and accelerations, gradually increasing their value. Both sizes should be selected to obtain the required feeds with stable machine operation (no loss of steps or engine failure). The limit switches also work in motor tuning mode. If the engine does not rotate, check whether the safety switch is not activated (the "Reset" button is flashing on the main screen, if it is flashing, press it). However, if the safety switch is not active and the motor still does not rotate, check the configuration of the output pins as well as the connections and configuration of the controller. The setting of each axis should be confirmed with the "Save axis settings" button before changing the axis or closing the window. ?Step impulse? allows you to determine the pulse width for a single step. The shorter it is, the higher the movement speed that can be achieved, but some controllers may not be able to cope with lower values. The direction pulse is the minimum time required for a change in the state of the direction control output. We recommend leaving these two values unchanged. As already mentioned, the motherboard allows you to connect the Spindle Control module, which allows you to control the spindle speed via an inverter. The method of configuring the Mach3 program with the mentioned device will be presented below.

The program allows you to adjust the spindle speed by controlling the direction and step signal, while in most cases, the spindle speed is controlled by an inverter that can be controlled with a voltage in the range from 0 to 10V. The Spindle Control module is an F/U (frequency to voltage) converter whose maximum output voltage is 10V. It converts impulses from the Mach 3 program proportionally into voltage, which allows for smooth speed control directly from the program. The module has been tested with inverters that have an analog input for speed regulation. In order for the module to work properly with the inverter, the Mach3 program must be properly configured. The first step is to select the Ports and pins option in the Config menu. Then, in the Spindle Setup tab, we define how the spindle is controlled. We set:

The next step will be to change the settings in the Motor Outputs tab. We enable the spindle option and enter the port and pin number from which we will control our module. According to the description of the LPT Spindle Control port, we connect it to the output (pin) number 14. This was illustrated in the configuration of the motors' output pins. The spindle is often driven by a motor via a gear. The spindle speed, depending on the degree of gear used, will differ from the rotational speed of the driving motor. Mach 3 program control refers to the speed of the motor driving the spindle. With this in mind, now click on the Config menu and select the Motor Tuning option. Click on the Spindle option. The value entered in the Velocity window determines the maximum speed of our spindle motor in revolutions per minute.

For example, let's assume that the maximum speed of our spindle is 18,000 rpm. A 1:2 gear ratio is used, so the speed of the driving motor is 9,000 rpm. The Step per value determines how many pulses the program generates for one engine revolution. To calculate this value, first convert the spindle speed to a value expressed in [rpm], i.e. 9000[rpm]/60=150[rpm]. The next step is to calculate the Step per value. You should use the relationship here:


which gives us a value of 66.66 [1/rev] pulses per engine revolution. It requires explanation where the value of 10,000Hz (Hz=1/s) in the above formula comes from. As already mentioned, the Spindle Control module is an F/U converter whose maximum output voltage is 10V. The conversion constant is: 1000Hz/1V, so 1000Hz*10=10000Hz. However, if one of the electric spindles available from our offer was used, e.g. TMPE4 10/2 3.3kW by Elte, which has 18,000 rpm, then we would enter 18000 in the Speed field and the Step per value would be 33.33. It is worth noting that the above assumptions are only true when the inverter is configured so that for a voltage of 0V the motor speed corresponds to 0 rpm, while at 10V the motor reaches 18,000 rpm. Then we set the Acceleration using the slider. Please remember that any changes must be confirmed by clicking the Save Axis Settings button. For assumptions, the geared spindle setup will look something like this:

As already mentioned, program control refers to the speed of the motor driving the spindle. However, we care about regulating the spindle speed. The Mach 3 program has the ability to define the so-called gear ratios, which enable the motor speed to be related to the spindle speed. To do this, select the Config menu and then Spindle Pulleys.

A new window should open. In the Current Pulley field, select one of the available positions, e.g. number 4. Then you can define the maximum and minimum spindle speed. The Max Speed field specifies the maximum spindle speed, which corresponds to the defined maximum speed of the drive motor set in the Motor Tuning window. For both of our examples, i.e. the example with a gearbox (the engine speed is 9000 rpm and a 1:2 gear ratio was used) and the TMPE 18000 rpm electrospindle, we set the maximum speed to 18,000 rpm. When we enter the S18000 command in G-code, it will mean for the program that the spindle should run at maximum speed. It comes down to the fact that the program is supposed to generate the maximum number of pulses per revolution, in our case it was 66.66 and 33.33 pulses per revolution, respectively. Selecting lower speeds will result in a corresponding reduction in the speed of the motor and spindle. However, if we want to work at a speed higher than the defined one in g-code, e.g. 20,000 rpm, the program will report an error and set the possible maximum speed, i.e. 18,000 rpm. This error will be visible in the Status pane (at the bottom of the page). The text of the message will be: 'To fast for Pulley. Using Max?. The Min Speed field specifies the speed below which the program will not allow the spindle to slow down. The minimum speed option is useful for spindles that are cooled by a fan placed on the rotor.

When the spinning speed is reduced, the cooling efficiency decreases. Below a certain speed it may be insufficient, which may lead to spindle damage. It is recommended to set the minimum speed of a given spindle recommended by the manufacturer. The last step is to test the operation of the module. The spindle is controlled using buttons located in the lower right corner of the main program window. The S-ov parameter determines the current spindle rotation speed (e.g. changed by the S parameter in the G-code), Spindle Speed determines the maximum speed at which we want the spindle to operate. It cannot be higher than the speed defined in the gear window. The Spindle CWF5 button enables spindle control.

To test the Spindle Control module "dry" A voltmeter will be useful and should be connected to the transmitter output. The order of checking the work can be as follows: enter the maximum spindle speed, i.e. 18,000 rpm, then turn on the spindle using the Spindle F5 button. If the S-ov parameter field is 0, then the module output should be 0V (With the defined minimum speed, we will not be able to set the speed to 0). Then press the Reset button (the one under the Spindle F5 button). This should set the current spindle speed (Parameter S-ov in the photo) to 18000. Then the voltage at the converter output should be approximately 10V. If the voltage is slightly different from 10V, please adjust it using the potentiometer located on the module board. By setting the set speed (S-ov) to 9000, 5V should appear at the module output. By clicking the ?-? and ?+? buttons we are able to adjust the speed within the entire range, i.e. from minimum to maximum speed, defined in the gear ratio window.

Of course, you can skip the stage of checking the operation of the module with a meter and go straight to checking the operation of the inverter, but in this case we recommend setting a protection on the inverter in the form of limiting the motor speed, just in case it turns out that something has been configured incorrectly. Then, in accordance with the instructions of the given inverter, we connect the output of our Spindle Control module to it. If everything has been connected and configured correctly, a change in spindle speed should be visible when adjusting the spindle speed in the program. Relays located on the main board can be used to turn on/off and change the direction of spindle rotation.

If the SSK-3D8A controller does not work properly, the first step should be to check whether the problem is electrical or mechanical. The next step is to isolate the component that is generating the error. It may turn out that you will need to disconnect all system components and check each one individually whether it works properly. It is important to document every step in solving the problem. You may need to use this documentation at a later time, and the details contained therein will greatly help our Technical Support employees solve the problem. Many errors in a motion control system can be related to electrical noise, control device software errors, or wiring errors. Below is a table with the most popular problems that customers report to our Technical Support.

Installation personnel must have basic knowledge of how to handle electrical equipment. The device should be installed in closed rooms in accordance with environmental class I, with normal air humidity (RH = 75% max. without condensation) and temperature in the range of +5°C to +40°C.

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