Sound Logic

Encoder Interface

4-axis parallel port encoder interface

For Mach2/3 CNC control software

Closed loop operation for Servo and Stepper systems

General User’s Guide

Sound Logic
James Cullins
3454 Sprindletree Dr.
Grapevine, Tx. 76051
[email protected]
IMPORTANT INFORMATION

Copyright and Trademarks

Copyright 2005 by Sound Logic

Disclaimers of liability

Sound Logic or James T. Cullins assumes no responsibility or liability for

any damage done to persons, PC, Geckodrives, encoders, or any other electronic
component used in conjunction with this Sound Logic Encoder Interface including
material in process. Also, loss of time or loss of work incurred. Use at your own risk.
 4-axis Mach2/3 Encoder Interface

Purpose:

To interface a second PCI parallel port card from a PC running Mach software with up
to 4 individual encoder/Gecko drive inputs. Which will display the data in a “DRO” on a
Mach screen. Giving the user, real time data count feedback from each encoder
thereby displaying the actual position of each axis. And used with provided Macropump
for this particular purpose, alerts the user with an LED next to the offending axis and
prompts a sonalert device if used in the event of a step/count discrepancy. The
machine will be halted in “feedhold” status. A screen.set is also supplied that is
designed for this purpose as well and both are sent via Email with purchase.

May also be used as a stand-alone device to accept encoder data and relay it to PC for
use solely as DRO for all types of encoder data input with Mach software.
Which would require, only one PCI parallel port card, Namely, Port1. Or simply used as
8 general use inputs instead of encoder inputs. Inputs such as MPG’s, Probes, OEM
triggers etc. Plus 4 software controlled onboard relays rated 125 VAC and 15 amps.
Designed to be used in conjunction with Sound Logic PC-2-route breakout board.

Operates on 115/220 volts at 60 Hz. Note: 115 volts- JP1 and JP2 are installed. 220
volts must have a jumper installed between JP1-1 to JP2-2. And existing jumpers must
be removed.

Features:

! PCB
! Fr4 Material
! Solder mask on both sides
! Silkscreen legend on topside
! Plated through holes
! Isolated 5 volts and grounds for the encoder interface parallel port IO
! All outputs are buffered
! Operational when Mach is in “reset” to provide the user encoder DRO position
for manual machining operations.
! 4 onboard relays rated 125 volts AC at 15 amps
to control spindle, coolant, vacuum pump etc. via M-codes in Mach software. Coupled
with Sound Logic PC to route Breakout board relay control jumpers will equal 8
controllable outputs in total.
Connectors:

J1 (X axis)
+5v Encoder +5v Note 1: Any axis J1 connector not
XA Encoder A Used with a Gecko may be used
XB Encoder B For general purpose inputs on
GND Encoder Gnd A & B terminal. The optical
Isolator associated with an input
J2 (X Gecko encoder inputs) used for general purpose may
Gnd Gecko Gnd NOT be used if anyone of the
XA Gecko encoder A input encoder inputs are wired to
XB Gecko encoder B input A Gecko drive’s encoder inputs.

J1 (Y axis) All the inputs except J18-1 has

+5v Encoder +5v comparators on them set for
YA Encoder A ½ VCC to provide good noise
YB Encoder B immunity.
GND Encoder Gnd

J2 (Y Gecko encoder inputs) J16 General use input

Gnd Gecko Gnd
YA Gecko encoder A input
YB Gecko encoder B input

J1 (Z axis) J17 General use input

+5v Encoder +5v
ZA Encoder A
ZB Encoder B
GND Encoder Gnd
J18 General use input
J2 (Z Gecko encoder inputs) Note: J18-1 does not have a comparator
Gnd Gecko Gnd associated with its input.
ZA Gecko encoder A input
ZB Gecko encoder B input

J1 (A axis)
+5v Encoder +5v
AA Encoder A
AB Encoder B
GND Encoder Gnd

J2 (A Gecko encoder inputs)

Gnd Gecko Gnd
AA Gecko encoder A input
AB Gecko encoder B input
Connectors:
J11 Connected to second parallel port

Pin 1 K1 relay out J12

Pin 2 Encoder/general purpose input see Note1
Pin 3 Encoder/general purpose input see Note1
Pin 4 Encoder/general purpose input see Note1
Pin 5 Encoder/general purpose input see Note1
Pin 6 Encoder/general purpose input see Note1
Pin 7 Encoder/general purpose input see Note1
Pin 8 Encoder/general purpose input see Note1
Pin 9 Encoder/general purpose input see Note1
Pin 10 Input 1/MPG1 A to J16-2
Pin 11 Input 2/MPG1 B to J16-1
Pin 12 Input 3/MPG2 A to J17-1
Pin 13 Input 4/MPG2 B to J17-2
Pin 14 K2 relay J13
Pin 15 Probe/Switch (pulled up to +5v) J18-1 & J18-2 = GND
Pin 16 K3 relay J15
Pin 17 Charge pump / K4 relay J15
Pin 18-28 GND

J9 (mode)

CP uses charge pump

NCP no charge pump
A special cable can be connected (see note 2) from the MODE jumper on the encoder
interface to the MODE jumper on the Sound Logic breakout board and use the charge
pump from the breakout board for both boards.
This provides one more relay out (K4) for other uses.

J10

115 vac / 220 vac

For 115vac JP1 and JP2 are installed, use as is

For 220vac A jumper from JP1-1 to JP2-1 must be installed and the two existing
jumpers for 115 vac operation must be removed.

Note 2:
J9-1
J9-2 Red jumper between J9-1 and J9-2 is for charge pump on output 4.
J9-3 Red jumper between J9-2 and J9-3 is for no charge pump and output 4 may be
used in the same manner as output 1,2 and 3.
Typical wiring for use with a Gecko servo-drive, To use with other types
of drives such as stepper-type that require no feedback, connection to the
encoder is all that is required. And is the same basic configuration for any
type of 5VDC input device i.e. MPG’s, OEM triggers, Probes etc.
Guide for installing second PCI parallel port in Windows XP

Step 1. Remove power from PC and open enclosure. Install PCI parallel
port card in any available PCI slot. Replace screw and secure PC
enclosure.

Step 2. Boot PC, Windows will automatically find the new hardware and
install a driver for it. If not, the card should come with it’s own software
driver on included disc. Install from the OEM disc instead.

Step 3. Mach will need to know the address of this port to communicate
with it. It will need be entered into the “Config/ports and pins/ port setup
and axis selection” menu in Mach software. To find the address of the
newly installed second parallel port, simply navigate to the hardware
profiles in Windows XP as follows:

Click: Start/Control Panel/System/Hardware/Device Manager/Ports (Com &

LPT)/ Printer Port LPT/ Resources.

A window like the one below should be displayed. The first line will be the
primary parallel port and the second line should correspond to the second
parallel port. The four digits in the box are what is needed to be entered
into Mach “config” “Ports and pins” menu. Mach will automatically change it
to “0x778" when the address is saved/Applied. Also on the same menu in
Mach, place a check in the “Enable port
2" and “Pins 2-9 as inputs” boxes.

Will be one of these.

Typical screen configuration:

On the following pages are displayed screenshots with suggested configurations for
Mach software using the Sound Logic Encoder interface. Each tab of the of
“Config”/”ports and pins” screen will be covered

Note that Port#2 is enabled. Address has been entered and “Pins 2-9 as inputs” has
also been enabled. Kernel speed is based on each users particular demands.

Motor Outputs: 2nd port address entered here.

The following screen is a configuration for use with the Sound Logic Breakout Board. If
another breakout/distribution device is used your configuration may differ. Note that
“active low” may be opposite also depending your particular configuration. All axis’s
used must be enabled.
Input Signals:

Below are two depictions of the same tab and screen. The upper screen depicts the
port and pin selection for limits and may also be used as general purpose inputs. And
pertains to the Sound Logic Breakout Board. Note that port two is entered in the lower
screenshot. This pertains to the Encoder interface. Port 1 deals with the Breakout board
and Port 2 is associated with the Encoder interface.
Output Signals:

Output signals are depicted below. Note which are enabled and which pins are selected
and their respective ports. These will control auxiliary devices such as spindle, coolant,
pumps, etc. The encoder interface has 4 relays on board rated at 125 vac and 15 amps.
The Sound Logic Breakout board requires a solid state relay to be used with each of its
outputs. Note on Charge pump J-9 mode, See page 5 to free up one of the outputs for
other uses.

Encoder MPG’s:

In the screen below, Port 2, proper pin number and steps per unit must be entered. The
steps per unit will be the same as in “motor tuning” menu. Or simply the CPR in
quadrature of the encoder device times the pitch lead of the ballscrew. Again,
depending on your particular configuration. If the DRO reads in opposite, simply swap
encoder A&B pins. If encoder data is displayed on an incorrect DRO simply swap with
the correct encoder entry. Example: If Encoder 3 is displayed on Encoder 2, and 2 on 3,
swap with one another.
Spindle Setup:

Below is the spindle setup menu. Note that the “Disable spindle relays” and “Disable
flood/Mist relays” are unchecked and the proper output numbers are selected. And are
the only entries relevant to the encoder interface on this menu.

Mill options: (not shown)

The last tab in the “Ports and Pins” configuration covers digitizing and THC selections.
And there are no relevant entries to the Encoder Interface.
Encoder screenset for Mach3:

Below is a screenshot of the encoder screenset for Mach3. The software DRO’s
(shown) and the encoder DRO’s (on settings page) are monitored and in the event that
the two are out of synchronization with one another, The machine is halted in
“feedhold”, an LED next to that axis flashes and a sonalert if used sounds an audible
alarm. The “Sync” key to the left of the offending axis may be pressed and this will
update the software DRO in relation to the encoder DRO, and ultimately machine
position, clearing the fault. Jogging is not affected by a discrepancy/fault and allows the
user to reposition machine if necessary before clearing fault. The max allowable error
is entered on the settings page as well.

Accompanying this screenset is one special screen for manual operation which
basically consists of three large DRO’s that read encoder data while Mach software is in
reset or for those who wish to use the Encoder Interface in conjunction with Mach as a
simple DRO for all types of measuring applications and data collection.

Essentially, A PC running Mach, the Encoder Interface and up to 4 encoders will

produce a 4 axis DRO for all types of machines. Plus, 4 software controlled relay
outputs.

The possibilities and uses of the Encoder Interface are virtually unlimited. Any input
device that operates on 5vdc and has a return signal of at least 2.5 vdc may be used.