The EC500 is a high-performance external motion controller designed for use with Mach3 software, featuring an Ethernet interface and support for standard MPG pendants. It facilitates communication with a control computer's network, either directly or via a router/switch. A key advantage of the Ethernet connection over USB is its extended cable length capability, up to 100 meters, and galvanic isolation of the computer from downstream electronics through transformers, which helps in noisy environments.
Function Description:
The EC500 is capable of controlling machine tools equipped with stepper or servo motor controls that utilize pulse and direction interfaces. It supports 3 to 6 axes, offering flexibility for various machine configurations. The controller can output a maximum stepping frequency of 460kHz per axis. The device's primary function is to establish a robust connection between the control computer, stepper/servo drives, and spindle motor, managing LAN network setup and communication. It also details input and output configurations, electrical parameters, and properties, guiding users through Mach3 software setup and parameter adjustments.
Important Technical Specifications:
- Motion Control: Supports 3-6 axes (X, Y, Z, A, B, C) with a maximum frequency output of 460kHz per axis.
- Power Supply:
- Main power supply: 24VDC, current > 1A.
- IO Power supply: 24VDC, current > 1A. The system provides power for IO ports internally, eliminating the need for an external IO port power supply.
- Input/Output Ports:
- Digital Input Ports: 18 opto-isolated.
- Digital Output Ports: 16 opto-isolated.
- Analog Output Port: 1 (0-10V adjustable speed for spindle, convertible to PWM output port).
- Control Chip: ARM motion control chip.
- MPG Compatibility: Compatible with both Standard MPG and Digital Dream MPG pendants.
- Accessories: Includes a 1.5-meter Ethernet cable.
- Physical Dimensions:
- Front Appearance: 190mm (length) x 113mm (width) x 32mm (height). Mounting holes are 4mm in diameter, allowing for installation into a cabinet.
- Installation Dimensions: 119mm (length) x 116mm (width) x 7mm (height) for mounting.
Usage Features:
- Ethernet Communication: Connects to a PC via a standard Ethernet cable. Setup involves configuring the IP address, either automatically or manually (e.g., 192.168.1.10 with subnet mask 255.255.255.0).
- Stepper/Servo Motor Control: Provides dedicated pulse and direction outputs for up to 6 axes (XP+/XP-, XD+/XD- for X-axis, YP+/YP-, YD+/YD- for Y-axis, etc.).
- Spindle Control: Features a spindle control output port with interfaces for COM-, VSO (0-10V speed adjustment), and digital outputs (OUT1-OUT5). VSO voltage is proportional to spindle speed (VSO = 10 * current speed / max speed). Example: for a max speed of 24000 and current speed of 18000, VSO = 7.5V.
- General Output Interface: A DB15 port providing 12 general output channels (OUT6-OUT16) and power (COM+, VCCIO) with common ground (COM-, GND). It includes a built-in relay drive circuit for direct connection to relays under 100mA.
- MPG Functionality: Supports both Standard MPG and Digital Dream MPG. A function switch allows selection between the two types. Specific pins are designated for MPG connections (e.g., BIN/T1OUT for serial port, CIN/R1IN for serial port).
- Serial Extend Port: A UART port for connecting extended serial devices, such as IO extensions or HMI interfaces.
- Input Ports: 18 opto-isolated digital input ports (IN1-IN18) for limit switches, home switches, probes, and other general inputs. Supports NPN type 3-line proximity switches (12V, channel, GND1).
- Mach3 Configuration:
- Plugin: Requires the DigitalDream plugin (e.g., DigitalDream-Plugin-Ver-3.0b) to be installed and enabled in Mach3.
- Motor Tuning: Allows users to configure "Steps per Unit," "Velocity (Units per Minute)," and "Acceleration" for each axis to optimize motor performance and prevent stalling. Settings must be saved for each axis.
- Ports and Pins Setup: Configures motor outputs (Step Pin, Dir Pin, Dir LowActive, Step LowActive, Step Port, Dir Port) and input signals (Pin Number, Active Low, Emulated, HotKey) for various functions like limits, home switches, and E-stop.
- Spindle Setup: Configures spindle rotation (CW/CCW), mist, and flood control pins. Supports PWM speed control and allows mapping outputs to specific functions.
- MPG Settings: Activates the MPG function within Mach3 via the TAB key, opening the MPG panel for jog mode, feedrate, and axis selection.
Maintenance Features:
- Safety Notes: Emphasizes the importance of adhering to machine safety standards, installing E-stop switches, and ensuring equipment meets safety requirements.
- Environmental Protection: Advises keeping the controller dry, away from chips and dust, and protected from direct sunlight, extreme temperatures, and high humidity to prevent damage and operational errors.
- Connection Integrity: Warns against connection mistakes and high voltage damage.
- LED Indicators: LEDs indicate power status (SYSTEM, IO) and communication with Mach3 software (CONN). A red LED for IO power indicates proper configuration.
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