SKIP THIS SECTION IF YOU ARE NOT UPGRADING
The following 12 pages are an addendum to the DTHCIV Setup and Config Manual. This addendum is to be used ...
The following 12 pages are an addendum to the DTHCIV Setup and Config Manual. This addendum is to be used in conjunction with that manual to do a field upgrade of the Bladerunner AIO Controller
OVERVIEW: DTHCII to DTHC IV UPGRADE In the following pages you will: ? Open the Bladerunner Enclosure and unplug some cables and remove the
DTHC/DTHCII (UBOB ) Sub-Assembly ? Put in the new DTHC IV or DTHC IV Ether-Cut sub assembly ? Reconnect one ribbon cable (AXIS I/O) and the wires to the Table I/O ? Mount the new Sub-Assembly module to the enclosure ? Make the physical connections (cables) to the devices ? Proceed to the connection of the software install/update using the Master Installer . ? Add the 4 port hub and the in the case of the Ether-Cut setup the Ethernet port on the PC and test communications ? Open your old MACH Profile and retrieve the Motor Tuning (Steps per Unit, Velocity and Acceleration for each axis. Write them down. ? Open the new DTHCIV or Ether-Cut profile (ICON) and put in the motor tuning using the MACH Config menu ? Use the DTHCIV Manual to setup and tune the DTHC IV response and Motor Tuning.
CandCNC
Page:A1
ADDENDUM
DTHC/DTHCII to DTHCIV UPGRADE
FOR USERS THAT HAVE PURCHASED THE DTHCII TO DTHC IV UPGRADE 1. The upgrade to the DTHCIV consists of a sub-chassis swap rather than a module or card level swap. This is done because the UBOB card has to be modified and setup differently. The Table I/O card is positioned differently to allow clearance for other cards above it and to allow the AC lines to the relays to reach. 2. The swap is straight forward with most cables being in the same place. The front panel serial cable (RS232) 4 wide cable from the UBOB to the front panel is no longer used. Power Supply information is no longer displayed on the screen. 3. DB9 RS232 serial port is no longer used. All backside communication is via the C3BUS RS485. The new DTHC IV sub-assembly comes with an RS485 input connector on the front plate 4. Once the hardware is swapped make sure MACH3 is updated to version 3.043.067 or later. Never go DOWN in revision numbers. The proper revision number is in our installer CD and our Manuals Page on the CandCNC website. 5 The Master Installer # .exe on the CD or from the website has choices for installing either the DTHC IV (parallel port) and the Ether-Cut (Ethernet port) installer. Select the Install menu item for what you have: Either the DTHC IV or the ETHER-CUT but NOT BOTH! 6. The DTHC IV WILL NOT WORK without the C3BUS RS485 4 Port Hub installed and working. If you already have the C3BUS 4 port Hub (aka USB to RS485 4 port hub) installed from a previous setup go ahead and run the USB485 4 Port Hub installer. It will update drivers you need and you will have updated firmware available in the USB_HUB4 folder on your C drive.
DTHC/ DTHCII to DTHCIV and Ether-Cut UPGRADE CHECKLIST With the BladeRunner disconnected from power, Open the Front cover and being careful not to unplug front panel cables set it out of the way so you can access the UBOB sub-assembly module. ¨
On your older module make note of the connections to the Table I/O module. You will find wiring locations for the older and the new REV 10/12 Table I/O card. The existing inputs for homes, limits and the AUX relay OUTPUTS will be moved to the new sub assembly. If your wires are not color coded label each pair with masking tape (i.e. XHome, Yhome, etc) Because the DTHC IV no longer uses the THC UP and THC DOWN and the THC ON inputs to MACH the MACH Profile is different . DO not try to run the DTHC IV or the ETHER-CUT products from an older MP3000 or Bladerunner profile...It will not work correctly
0
Unplug the 25 pin Axis I/O cable from the UBOB card. It is the cable that runs back to the G251-4 motor interface card (connects to the MTA150 in larger Plazpaks and Bladerunner Servo systems). Do not pull on the ribbon cable directly. Work the connector back and forth in the header while pulling up to free the cable from the PC Board header. Label the ribbon cable with a marker as “Axis I/O”
0
CandCNC
Page:A2
ADDENDUM
QUICK START NOTES for DTHCII to DTHC IV UPGRADES
DTHC/ DTHCII to DTHCIV and Ether-Cut UPGRADE CHECKLIST
0 Carefully disconnect the DC power to the UBOB card. Note the wire colors . Most newer UBOB cards only have one DC INPUT (12VDC). If you have an older BladeRunner that has both 12 and 5V cables running to the inputs you will not reconnect the 5 V side. Clip the exposed wire on the 5V side and insulate them from touching each other or anything in the inside of the enclosure. On most UBOB cards the 12v input are removable screw terminals that plug onto to vertical posts. If you have that type on your old UBOB simply pull up on the screw terminals and it will unplug
0 Remove the 6 front panel screws that hold the Sub-Assembly module in place and remove the module from the enclosure and set it aside.
0 Mount the new module into the enclosure using the 6 self-tapping screws. Do not over tighten.
0 You may need to unmount the ESS module from the sub assembly to access the terminals on the Table I/O. To do so, remove the two front panel screws on the ESS module and pull the ESS out of the way (IF YOU DISCONNECT THE CABLES TO THE ESS USE THE CABLE CONNECTION DIAGRAM IN THIS SECTION TO PROPERLY RECONNECT You can possibly damage the ESS if you connect the cables incorrectly)
0 Make the cable connections from the control PC and any external modules to your new DTHC IV or Ether-Cut system and run the Master Installer application. Use the DTHC IV Setup and Config manual to install and test the C3 Bus 4 port Hub, the computer Ethernet communications port and to do the setup and calibration of the DTHC IV.
CandCNC
Page:A3
ADDENDUM
DTHC/DTHCII to DTHCIV UPGRADE
The Following overlays are for connecting up the Aux relays on different revision levels of the Table I/O. You should identify the connections BY LOCATION since the wire colors may vary and the direction they travel will be different. Label the wires prior to removal. MAKE SURE YOU HAVE THE AUX POWER CORD THAT SUPPLIES AC TO THE AUX RELAYS (AUX line INPUT ) UNPLUGGED (DISCONNECTED)
OLDER TABLE I/O FOUND IN SOME BLADERUNNERS
LIMITS T2
T19
T17
AUX0
DOWN T3
UP
T4
EPO
T11
ARCOK
J1
C14
K5 D15
AUX1 BHOME
D3
J13 C10
Xhome
K3
R1
J8
AUX2 AUX4
K3
J12
K4
R2
J5
Com1
AUX3 C11
NO Com2
NO J18
J4
13
25
To AUX line INPUT Hot side
REV 8 and older
DANGER! DANGER!
J7
J11
T13
K4
J33
C&CNC TABLEI/O REV6
T15
C1
J6
T12
K4
C13C12
10
QUADRELAY
J10
K3
D2
D9
6
1
J9
C2
YHome
ZHome
AHome
LIMITS
AUX0
UP
14
1
T20 T21
T14
T10
AHome
C9
T16
C4
ARCOK
T18
C3
T5
T6
Xhome YHome ZHome
T7
C5
T8
C8
PLUG
C7
C6
J2
T9
Hot Feed To “A” Socket HOT terminal
To “B” Socket HOT terminal
CandCNC
Page:A4
ADDENDUM
DTHC/DTHCII to DTHCIV UPGRADE
T7
T6
AUX0 DOWN (PORT2]
LIMITS
T3
T2
T17
T14
Xhome
K
ARC OK
+ C1
K
ARC OK
D15
D2
D3 K
K3
K3
D11
K
NO J18
COM J5
K4
NO Com2
K4Panel
K3
J4
AUX3 J11
D4
D5
YHome
K
K3
K4
C12
K4
UP
J7
C&CNC TABLEI/O REV8
REV 9
DANGER! DANGER!
J12
J33
T10
T11
J6
AUX2
AUX4
T13
K3Panel
J13
J8
T12
T15
ZHome
D6
AHome
K
C4
J2
K4
BHOME AUX1 J10
K
D8
T21 J1
D7
D18
DOWN
D17
UP
D16
1
6 QUAD RELAY
EPO J9
T19
LIMITS
K
K
K
K
1
T20
T16
C3
T4
C9
T5
T18
AHome
T8
Xhome YHome ZHome
T9
ADDENDUM
DTHC/DTHCII to DTHCIV UPGRADE
To AUX line INPUT Hot side
Hot Feed To “A” Socket HOT terminal
To “B” Socket HOT terminal
T19 AHome
T17
T15 YHome
T13 Xhome
ZHome
ARC
DOWN
OK
T11
1
++
T20 EPO T21
Xhome
J3
T2
T12
Yhome
T16
T10
T3
T14
ZHome
1
T5
T18 AHome
FT-01
T6
LIMITS
5
T7
UP
J1 D2
6
1
R1
NO
DANGER!
J14
K3OUT
Hot Feed
COM
DANGER!
K3 J17
K4
NO Com2
C&CNC TABLEI/O REV10
MH2
DANGER!
10
D11
D3
K3
ToUBOB
CandCNC
K3
D10
K4
QUAD RELAY
J2
To AUX line INPUT Hot side
K3 R2
REV 10 and later
FT-01 PWRIN D12
K4
K4 J4
InsideRow COMMON
T9
HOLD
20A240VMAX
To “A” Socket HOT terminal
To “B” Socket HOT terminal Page:A5
Push
Active
TEST
ARC OK
DTHC ON
Steps Z
CandCNC C3BUS
DTHC IV Digital Torch Height
SENSOR INPUT
To PWM Module
FRONT VIEW
Electronic Controls for CNC
CandCNC
ADDENDUM
CP PWR UBOB III™ Technology
ETHER-CUT
Ethernet
To PC
DTHC/DTHCII to DTHCIV UPGRADE
Status
Status
To HUB
RS485
HOLD
Page:A6
Push
Active
TEST
ARC OK
DTHC ON
Steps Z
CandCNC C3BUS
DTHC IV Digital Torch Height
SENSOR INPUT
To PWM Module
FRONT VIEW
To PC
Port1 INPUT
Electronic Controls for CNC
CandCNC
ADDENDUM
CP PWR UBOB III™ Technology
DTHC/DTHCII to DTHCIV UPGRADE
To HUB
RS485
HOLD
Page:A7
ADDENDUM
DTHC/DTHCII to DTHCIV UPGRADE
CandCNC
Page:A8
DTHC IV CARD
J8
1
BPort
Y X B
4
3
Page:A9
1
PPORT1
U7
1
5
J11
J13
3 2 1 ZAXIS OPTIONS
6 4
1
1
1 SIP1 SIP2
J66
J4
+
+
DTHCII Default
D2
26
D17
+5
R7 D16
3
1 2
CP
J12
SELECT
SKT J29
1
2
3
REV
DIROPTION NORM
J68 DTHC
IV 3 DTHC II 1
J67
C59
2 3 4 J53
1
+10FLT
C
+
REG1
J7
J9
+
R8
27
ADDENDUM
CandCNC 4/14
UBOBIII REV15B
K
+12 POWER
REV15B UBOB III
1
SerialtoFP
PCSERIAL
DTHC
L1
RV1
EXPANSION
T1 DTHC IV
J5
2
4
6
DTHC
Q53
+ DTHC5
ESS CARD
PORT2I/O
TABLEI/O
MUXSELECT
26
14
SIP4
1
3X
5Y
SIP3
AXIS I/O
J65
12 AXIS I/O Q9
2
J63
DIR
OPTIONS
5thAXIS
Q3
STEP
TABLEI/O
PORT2
24
EPOB-PASS J6
C60
1
J3
DTHCIV C4
J15
AUXOUT ++12 AXIS I/O
UBOBIII
1
28
1
J56
GND +5 GND+12
D20
5V 12V OUT IN
REV15B
II
16 15
J1
2
26
CandCNC 1
1
UBOB III + DTHC IV + ESS TOP VIEW
DTHC/DTHCII to DTHCIV UPGRADE MODULE/CARD LOCATION
J8
1
4
3
26
1
3X
5Y
AXIS I/O
J65
STEP
1
1
PPORT1
1
14
SIP4
5
J13
4 3 2 1 ZAXIS OPTIONS
6
J11
+
DTHCII Default
D2
PORT2I/O
26
1
SELECT
REV
DIROPTION NORM
J68 DTHC
IV 3 DTHC II 1
C59
RV1
2 3 4 J53
D17
+5
SKT J29
1
2
3
1
+10FLT C
J7
J9
+
REG1
+
CandCNC 4/14
UBOBIII REV15B
R8
K
+12 POWER
27
REV15B
1
SerialtoFP
EXPANSION
L1
PCSERIAL
DTHC
DTHC IV
J5
2
4
6
DTHC
Q53
J67
2 Cable
D16
3
1 2
CP
R7
J12
PO RT
J4
+
+ DTHC5
J66
D20
SIP2
Page:A10
SEE NEXT PAGE FOR CABLE CONNECTIONS FOR PORT1, TABLE I/O ADDENDUM
ESS CARD
CABLE CONNECTION DETAILS NOTE The ESS card is normally mounted directly above the UBOB card. It is shown here removed and moved to the side so cable runs can be shown. Use the Color codes of the connectors on each end and the cable names to properly connect the cards in the EtherCut sub assembly, The Ether-Cut sub assembly is shipped with all cards connected as a unit and tested.
PORT 1
U7
AXIS I/O
BPort
Y X B
12 AXIS I/O Q9
2
J63
DIR
OPTIONS
5thAXIS
SIP1
UBOB III CARD PORT2
Q3
SIP3
TABLE I/O
1
MUXSELECT
RS485 Jack to DTHC IV
DTHC IV CARD EPOB-PASS J6
AUXOUT ++12 AXIS I/O
T1
TABLEI/O
J15
24
DTHCIV C4
C60
1
J3 TABLEI/O
1
28
II
16 15
J56
GND +5 GND+12
1 2
26
REV15B
1
1
CandCNC J1
UBOBIII
IF YOU DO NOT HAVE THE ETHER-CUT MODEL you will not have the ESS Cqard and ther DB25 connector on the front is connected to the PORT 1 header. Therw is no PORT2 cable. All other connections are the same
DTHC/DTHCII to DTHCIV UPGRADE RIBBON CABLE CONNECTIONS (1)
J8
EPOB-PASS J6
1
BPort
Y X B
STEP
4
3
1
PPORT1
U7
1
5
J11
J13
3 2 1 ZAXIS OPTIONS
6 4
1
+
DTHCII Default
D2
PORT2I/O
26
1
1 SIP1
J12
1 2
J4
+
SELECT
REV
DIROPTION NORM
J68 DTHC
3 DTHC II 1
IV
J67
C59
RV1
2 3 4 J53
1
+10FLT C
J7
J9
+
REG1
D17
+5
R7 D16
CP
3
SKT J29
1
2
3
+
CandCNC 4/14
UBOBIII REV15B
K
27
-
Page:A11
ADDENDUM
IF YOU DO NOT HAVE THE ETHER-CUT MODEL you will not have the ESS Cqard and ther DB25 connector on the front is connected to the PORT 1 header. Therw is no PORT2 cable. All other connections are the same
ESS CARD 5V DC
SIP2
IMPORTANT The AXIS I/O cable is NOT shown. It is connected in the BladeRunner to the G251-4 Driver sub-assembly. In the Plazpak systems the AXIS I/O is connected to the MTA150 card.
R8
+12 POWER
REV15B
1
SerialtoFP
PCSERIAL
DTHC
L1
EXPANSION
T1 DTHC IV
J5
2
4
6
DTHC
Q53
+ DTHC5
J66
D20
UBOB III CARD MUXSELECT
26
14
SIP4
1
3X
5Y
SIP3
AXIS I/O
J65
12 AXIS I/O Q9
2
J63
DIR
OPTIONS
5thAXIS
Q3
TABLEI/O
+
SEE PREVIOUS PAGE FOR CABLE CONNECTIONS FOR PORT 2, RS485, and DTHC IIV to UBOB
IF YOU DO NOT HAVE THE ETHER-CUT MODEL you will not have the ESS Cqard and ther DB25 connector on the front is connected to the PORT 1 header. Therw is no PORT2 cable. All other connections are the same
Assembly.
SIP2
IMPORTANT The AXIS I/O cable is NOT shown. It is connected in the BladeRunner to the G251-4 Driver sub-assembly. In the Plazpak systems the AXIS I/O is connected to the MTA150 card.
R8
+12 POWER
REV15B
1
SerialtoFP
PCSERIAL
DTHC
L1
EXPANSION
T1 DTHC IV
J5
2
4
6
DTHC
Q53
+ DTHC5
J66
D20
UBOB III CARD MUXSELECT
26
14
SIP4
1
3X
5Y
SIP3
AXIS I/O
J65
12 AXIS I/O Q9
2
J63
DIR
OPTIONS
5thAXIS
Q3
TABLEI/O
Parallel Port version. The DB25 Male Connector is connected to the PORT 1 header and is secured in the front panel of the UBOB Sub-
SEE PREVIOUS PAGE FOR CABLE CONNECTIONS FOR PORT 2, RS485, and DTHC IIV to UBOB
