CNC USB Controller Mk3

User manual

2014-06-12

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 Disclaimer

CONTROLLER AND CONTROLLER SOFTWARE ARE PROVIDED TO YOU "AS IS," WITHOUT
WARRANTY. THERE IS NO WARRANTY FOR THE CONTROLLER AND CONTROLLER
SOFTWARE, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. THE ENTIRE RISK AS TO THE QUALITY
AND PERFORMANCE OF THE CONTROLLER OR CONTROLLER SOFTWARE IS WITH YOU.
SHOULD THE CONTROLLER OR CONTROLLER SOFTWARE PROVE DEFECTIVE, YOU ASSUME
THE COST OF ALL NECESSARY SERVICING, REPAIR OR CORRECTION.
IN NO EVENT SHALL THE AUTHOR BE LIABLE TO YOU FOR DAMAGES, INCLUDING ANY
GENERAL, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUTOF THE USE
OR INABILITY TO USE THE CONTROLLER OR CONTROLLER SOFTWARE.

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1 Introduction

1.1 Overview

The PlanetCNC series of USB CNC motion controllers is link between a personal computer and motor
drivers supporting step/direction control. PlanetCNC series of motion controllers are compatible with
most motor drivers. The controllers use the USB port, available on all modern computers and laptops.
They can serve as direct replacement or upgrade for many parallel port break-out boards. There are
different models available.

PlanetCNC controllers provide a complete, fully integrated software/hardware solution. Additional

machine control software is NOT required. The USB CNC Controller software is a dedicated
application, designed to fully exploit the features of the purpose-built hardware. It has many advanced
features to assist day-to-day CNC machine operation.

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1.2 Features and specifications:
• USB (V2.x) from PC/Laptop running Windows XP, Vista, Windows 7, 8 or 8.1 (32 bit or 64bit)
• motor driver connector pin-out is compatible with 10 pin open source interface
• controller works with most step/dir stepper and servo motor drivers available on the market
• buffered IO for maximum performance
• advanced interpolation algorithms
• start, stop, pause and resume execution of program on your machine
• standard RS274/NGC G-code (EMC2 and LinuxCNC compatible)
• advanced G-codes - G40, G41, G42 (Cutter Radius Compensation) supported
• advanced G-codes - G43, G49 (Tool Length Offsets) supported
• advanced G-codes - G54, G59.3 (Coordinate System Origins) supported
• tested with SolidCAM, MasterCAM, ArtCAM, Vectric, CamBam, MeshCAM ... generated G-code
• Profili 4-axes and 3-axes G-code supported
• import toolpath from DXF files
• import toolpath from PLT/HPGL files
• import toolpath from image files
• import toolpath from NC-Drill (Excellon) files
• import toolpath from Gerber (RS-274X) files
• toolpath simulation
• automatic homing procedure
• advanced toolchange procedures
• automatic tool length measuring
• export toolpath to G-code
• export toolpath to DXF
• SDK (software developers kit) is available
• works on MacOS with virtual machine emulating Windows

Mk3 - 9 axes USB CNC controller

• 9 axes controller for stepper and servo motors
• USB and Ethernet connection
• 110 kHz maximum step frequency
• 25 us pulse width, 50% duty cycle at higher frequencies
• 8 digital outputs on board
• 3 PWM capable outputs with selectable frequency (10Hz to 500kHz)
• 3 outputs with support for RC servo motors
• additional outputs with add on boards (currently up to 32)
• jogging keyboard support with speed potentiometer, shift, step and spindle sync feature
• 8 limit switches with shift feature
• 8 digital inputs on board, filtered and protected
• additional inputs with add on boards (currently up to 32)
• 4 analog inputs
• MPG pendant support

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 • spindle encoder and index signal support for spindle synchronization
• SD card support for running g-code without computer
• control external devices with I2C and UART protocol
• homing procedure
• tool change procedure
• tool length sensor support
• sensor for capturing and measuring
• digitizing probe support
• H-bot kinematics support
• transformation matrix
• soft limits
• slave axes
• backlash compensation
• integrated web server for monitoring state and sending commands
• API

1.3 System Requirements

Minimum system requirements:
• 1 GHz or faster processor
• 512MB RAM
• 500 MB available hard disk space
• Graphics with OpenGL support
• USB 2.0 port
• .NET Framework 3.5 SP1

Recommended system requirements:

• 2 GHz or faster processor
• 2GB RAM
• 500 MB available hard disk space
• Graphics with OpenGL support
• USB 2.0 port
• .NET Framework 3.5 SP1

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2 Hardware

2.1 Installation

Installation of PlanetCNC CNC USB Controller requires a USB equipped PC or laptop along with motor
drivers appropriate to the motors in use. The USB CNC controller is compatible with the vast majority of
motor drivers that use step/direction signals.

Optional support hardware can be employed to customize installation to suit user requirement. Use of a
screw terminal adapter makes connection to the type of drive in the image much easier. A DB25
adapter is available, for motor drivers requiring this form of input, with male or female DB25 connector.

For maximum flexibility in controller layout, a ribbon cable and plug kit is available. This aids the
construction of longer cables and ensures plug-in connections correspond to the USB CNC Controller
pin outs.

IMPORTANT:
The controller should be powered with an external power supply.
Mk3 - 9 Axis controller hardware requires 8 - 24V DC supply
Power supply should be at least 200mA.

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2.2 Mk3 - 9 axis CNC USB controller description

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2.2.1 Mk3 AXIS connector

Each connector controls one motor driver. Controller has 9 connectors for axes 1-9. This means 9 axes
which can all be moved at same time.

Axes are usually named like this: Axis 1=X, Axis 2=Y, Axis 3=Z...
On some machines this can be different. For example Foam cutter uses axis names such as Axis 1=A,
Axis 2=Y, Axis 3=U, Axis 4=V. Lathes use Axis 1=Z, Axis 2=X. Configuration of axes, as well as their
naming can be set in File/Settings/Axes.

CONNECTOR PIN DESCRIPTION:

+5V: +5V power. Motor drivers can take power for logic circuit or common anode connection
from the USB controller.

ERR: Error signal from driver to controller.

STEP: Provides a STEP signal of minimum 25 us pulse width or 50% duty cycle at higher
frequencies to the motor driver.

DIR: Provides DIR or DIRECTION signal to the motor driver.

ENABLE: Provides an ENABLE signal for motor drivers. When the ENABLE signal is lost, due to
output command, E-Stop or limit switch activation, motor drivers will deactivate.

A dedicated E-Stop switch connected to the CTRL or INPUT connector can control the
signal. It can also be operated by limit switch activation, software command or on
shutdown of the control software.
This arrangement provides a useful safety feature that can be user-configured to operate
under manual and/or computer control.

GND: Ground connections.

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2.2.2 Mk3 JOG connector

Switched operation of JOG 1-8 controls manual jogging.

Jogging keyboards can use a ‘SHIFT’ key, allowing Mk3 controller users to jog additional axes or toggle
the option of jog ‘step’ mode. ‘SHIFT’ key function is defined in settings, as is the ‘step’ value for each
key press.
Jogging keyboards can use two ‘ALT’ keys. Function is defined in 'settings'.
Jogging directions and axis assignment can be defined in 'settings'.

CONNECTOR PIN DESCRIPTION:

A typical use might be as below.

JOG 1: Jog Axis 1 in negative direction.

JOG 2: Jog Axis 1 in positive direction.
JOG 3: Jog Axis 2 in negative direction.
JOG 4: Jog Axis 2 in positive direction.
JOG 5: Jog Axis 3 in negative direction.
JOG 6: Jog Axis 3 in positive direction.
JOG 7: Jog Axis 4 in negative direction.
JOG 8: Jog Axis 4 in positive direction.
SHIFT: Jogging for additional axes or selects 'step' jog mode.
ALT1: Selects different jog mode
ALT2: Selects different jog mode
+3.3V: Power for jogging speed POT
POT: Jogging speed POT
GND: Ground connections

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2.2.3 Mk3 LIMIT connector

LIMIT 1-8 connects limit switches. It’s recommended that a 100nF capacitor is connected
directly across switch terminals.

The 'SHIFT' key toggles limit options using one of two possible configurations. The chosen
configuration determines hardware connections.

Limit switches can be connected in 'Normal' method or 'Single input' method. In software, you can set
this in File/Settings/Limit. If you are using 'Normal' method, 'Single Input' feature must be disabled.

To pause all axes, if certain axes limit switch has been activated, you enable 'Lock Other Axes'.

NORMAL: Each switch is connected to its own pin.

LIMIT 1: Axis 1 negative limit

LIMIT 2: Axis 1 positive limit
LIMIT 3: Axis 2 negative limit
LIMIT 4: Axis 2 positive limit
LIMIT 5: Axis 3 negative limit
LIMIT 6: Axis 3 positive limit
LIMIT 7: Axis 4 negative limit
LIMIT 8: Axis 4 positive limit
SHIFT: Toggle Limit switch options
GND: Ground connections

SHIFT OFF: Axes 1 to 4 limits are selected

SHIFT ON: Axes 5 to 8 limits are selected

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SINGLE INPUT: Both axis limit switches are connected to one pin.

Direction of travel determines if positive or negative switch is triggered.

LIMIT 1: Axis 1 negative and positive limit

LIMIT 2: Axis 2 negative and positive limit
LIMIT 3: Axis 3 negative and positive limit
LIMIT 4: Axis 4 negative and positive limit
LIMIT 5: Axis 5 negative and positive limit
LIMIT 6: Axis 6 negative and positive limit
LIMIT 7: Axis 7 negative and positive limit
LIMIT 8: Axis 8 negative and positive limit
SHIFT: Axis 9 negative and positive limit
GND: Ground connections

NOTE: If 'normally open' (NO) type switches are used, wiring must be done in parallel method, if
'normally closed' (NC) type switches are used, wiring must be done in serial method.

Software 'Invert' options allow use of ‘normally closed’ or ‘normally open’ switch hardware. This feature
can be set in File/Settings/Limit/Invert

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2.2.4 Mk3 CTRL connector

This connector provides inputs for use of MPG pendant devices and E-Stop.
Spindle speed encoder for spindle synchronization can also be connected.
GND pin provides ‘Ground’ or common connections.

An E-Stop switch attached to this connector can be configured in software to activate/deactivate E-

Stop.
E-Stop switch hardware for use with this connector can be NC (Normally Closed) or NO (Normally
Open). If NC is used, 'Invert' feature must be enabled in 'settings'. Locking switch is recommended.

CONNECTOR PIN DESCRIPTION:

E-STOP: E-Stop
MD1: Mode switch
MD2: Mode switch
AX1: Axis switch
AX2: Axis switch
EN1A: Encoder for MPG
EN1B: Encoder for MPG
IDX: Index signal for spindle synchronization
+5V: Power supply for encoder
EN2B: Additional encoder
EN2A: Additional encoder
EN3B/AX3: Axis switch for additional axes or encoder
EN3A/AX3: Axis switch for additional axes or encoder
EN4B: Encoder for spindle synchronization
EN4A: Encoder for spindle synchronization
GND: Ground

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2.2.5 Mk3 INPUT connector

This connector provides input for user-assigned functions.

CONNECTOR PIN DESCRIPTION:

INPUT1: Input 1
INPUT2: Input 2
INPUT3: Input 3
INPUT4: Input 4
INPUT5: Input 5
INPUT5: Input 6
INPUT5: Input 7
INPUT5: Input 8
+5V: Power supply
GND: Ground

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2.2.6 Mk3 OUTPUT connector

This connector provides 7 digital outputs for control of external devices.

The optional ‘Output board’ links to the Mk3 controller using this connector.
Output assignment is controlled in software.

CONNECTOR PIN DESCRIPTION:

OUT 1 - 8: Digital Output

GND: Ground
+5V: +5V supply.

OUT 1, 2 and 6 can generate PWM signal, RC servo signal or frequency modulation.

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2.2.7 Mk3 IO EXT connector

Connector for additional IO extension boards.

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2.2.8 Mk3 SD&I2C connector

This connector allows use of SD Card with PlanetCNC SD card adapter, I2C and UART protocol
devices.

DAT0: SD card signal

CMD: SD card signal
CLK: SD card signal
TX: UART signal
I2C CL: I2C signal
I2C DA: I2C signal
GND: Ground
+3.3V: +3.3V supply
GND: Ground
+5V: +5.0V supply

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2.2.9 Mk3 AUX connector

Reserved for future use.

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2.2.10 Mk3 POT connector

A potentiometer attached to this connector provides a manual jog speed control when using jogging
keyboard connected to JOG connector. Mk3 controller also has this pins on jogging connector.

+3.3V: +3.3V power supply for use with potentiometers.

POT: 5k or 10k ohm, logarithmic taper potentiometer can be connected to provide a jog
speed control.
GND: Ground

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2.2.11 Mk3 USB connector

The Mk3 USB CNC controller connects to computer via the USB port. The port uses the USB 2.x
standard.

2.2.12 Mk3 Ethernet connector

The Mk3 USB CNC controller connects to computers via the Ethernet port.

2.2.13 Mk3 Power terminal

The controller should be powered with an external power supply.

Mk3 - 9 Axis controller hardware requires 8 - 24V DC supply
Power supply should be at least 200mA.

2.2.14 Mk3 LED indicators

The user is provided with helpful feedback and live ‘status’ information via on-board LED indicators.
There are four indicators.

Power: Lights when the controller is powered.

Data: Indicates controller functions.
Link: Indicates controller communication.
Status: Blinks to indicate controller function is ‘good’.

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Table of Contents

1 Introduction........................................................................................................................................ 3

1.1 Overview..................................................................................................................................... 3
1.2 Features and specifications:........................................................................................................4
1.3 System Requirements................................................................................................................. 5

2 Hardware........................................................................................................................................... 6

2.1 Installation................................................................................................................................... 6
2.2 Mk3 - 9 axis CNC USB controller description..............................................................................7
2.2.1 Mk3 AXIS connector............................................................................................................ 8
2.2.2 Mk3 JOG connector............................................................................................................. 9
2.2.3 Mk3 LIMIT connector......................................................................................................... 10
2.2.4 Mk3 CTRL connector......................................................................................................... 12
2.2.5 Mk3 INPUT connector........................................................................................................13
2.2.6 Mk3 OUTPUT connector....................................................................................................14
2.2.7 Mk3 IO EXT connector.......................................................................................................15
2.2.8 Mk3 SD&I2C connector......................................................................................................16
2.2.9 Mk3 AUX connector........................................................................................................... 17
2.2.10 Mk3 POT connector......................................................................................................... 18
2.2.11 Mk3 USB connector......................................................................................................... 19
2.2.12 Mk3 Ethernet connector...................................................................................................19
2.2.13 Mk3 Power terminal .......................................................................................................19
2.2.14 Mk3 LED indicators.......................................................................................................... 19

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