BladeRunner AIO ManualCandCNC

All Content Copyrighted 2008-2010

any reproduction in printed or electronic formats is prohibitedwithout the express written permission of CandCNC

CNC and motion control involves equipment that can cause serious injuries.

CandCNC assumes no liability for ANY damages to any person or propertyfrom the proper or improper use of any equipment CandCNC sells or from anyadvice verbal or written. Use the equipment at your own risk. Practice good

safety precautions. Be smarter than the machine.

REV1

BLADERUNNER AIOQUIK - START

All Content Copyrighted 2008-2010

any reproduction in printed or electronic formats is prohibitedwithout the express written permission of CandCNC

BLADERUNNER AIO QUIKS START

The following is a synopsis of the steps needed to get the BladeRunner installed and setup and moving the motors:

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Unbox and check the unit to make sure it’s undamaged. If there is any visible damage fromshipping retain the shipping boxes. If possible take digital pictures of the damage. ContactCandCNC immediately.

Load the version of MACH3 on the support CD to your PC

Load your license file for MACH (see Software section if you don’t know how)

Use the Support CD and run the BladeRunner_AIO-Install.exe in the AUTO INSTALL FILESfolder on the CD. (some early units had the MP3000E install name)

Plug in the DB25 cable (supplied) to the PC parallel port and the other end the other end toPORT1 input on the side of the BladeRunner AIO

Plug in the MAIN Power to the BladeRunner AIO box.

NO MOTORS Plugged in YET!

Turn on Main Power Switch on end of enclosure. Red LED over OFF swtich should come onand the PWR light on the UBOB panel and the PWR LED on the FRONT PANEL should light up.

Push the ON (Green Button) RUN LED (green) should light. You should hear a faint clickinside the unit. Main fan (end of enclosure) should turn on.

If for any reason the unit fails to power up, unplug it from the AC and open the front cover (4screws) and carefully set the front cover aside and check all of the cables and wires to make surenone have come loose in shipping. Refer to the manual detail pages to confirm cable connections.

Once you have the power on sequence operational TURN THE DC OFF USING THE RED OFFBUTTON ON THE FRONT PANEL. RED LED SHOULD BE ON.

Plug a motor into the X motor connector on the side of the BladeRunner AIO case.

Turn on the DC Motor Power using the FRONT Panel ON Button. Motor will lockup after abouta 1 sec delay. Lock up is defined as the motor becomes difficult or impossible to turn.

Turn off Motor Power (you can leave the Main power Switch on)

Plug in the other motors and make sure they lock up when you turn on the Motor DC using thefront pushbutton.

Start MACH and select the BladeRunner_Router Icon (Profile)

With motor power ON and MACH running the profile. hit the RESET button. The Charge PumpLED on the UBOB Panel should come on. IF it does not you may not have communications to theparallel port on your PC. The EPO jumper may not be in place on the Table I/O card inside. If youstill cannot get MACH out of RESET go to UBOB section in this manual and check the cables.MAKE SURE YOU ARE RUNNING THE RIGHT PROFILE IN MACH.

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BLADERUNNER AIO QUIKS START

! Once you have the power lights and CP light on and out of RESET you are ready to do a preliminary motion test.

The JOG keys on the keyboard are the Arrow Keys (X & Y) and the PageUp / Page Down keys. The motors willNOT be tuned or calibrated to your mechaics but you can test for motion.

Jog each axis and check for rotation of the motors. SHIFT + Jog Key is 100% jog speed.

Once you have the motors turning you can then check any expansion options. Go the the section (DTHC) or theManual for that Module and load the proper profile and run the tests indiacted in those manuals

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NOTE: For Expansion Modules (DTHC; ISS-02) you need to have the PC serial port operational andconnected tot he SERIAL input on the UBOB Module Panel.

HA

RD

WA

RE

SE

TU

P

Connecting up the BladeRunner Control box

PC

Male to Female

. Take a look at the blockdiagram, that gives an overview of the control box,. Note that there are twocables that run from the and connect to the BladeRunner box. These arelabeled Port 1, and Serial It's important that you connect the first parallel port inthe computer (normally the existing printer port or LPT1 port) to Port 1 on theBladeRunner Controller box There are also other cables that connect threesatellite cards (Table I/O, and THC Sensor Card/VFD Interface Card) to theBladeRunner-DTHC or Spindle Speed as well. The Table I/O is connected on thefront of the BladeRunner directly above the Port 1 input. The other end connectsto the DB25 plug on the Table I/O card (inside the PowerCommander on unitswith upgraded Power Supply)

1. Install a DB25 extension cable (All pins straight through)between parallel port (PORT1 on the PC to the part marked Port 1 INPUT(Orange highlight below) on the front of the MP3000-DTHC controller unit.

2. Install a straight through DB9 cable (not a null modem cable) from yourCom1 port on the PC to the Serial port on the MP3000-DTHC

PC

Pa

ralle

lP

or t

1

Se

r ia

lP

or t

PC

POWER SUPPLY &INTERNAL WIRING

THIS SECTION FOR REFERENCE ONLY

ALWAYS UNPLUG AC CORD(S) WHENEVER OPENING THE ENCLOSURE. TOREPLACE ANY OF THE MODULAR POWER COMPONENTS YOU SHOULD REMOVE

THE UPPER MODULES.

DO NOT WORK ON AC SECTION WITH AC CORD PLUGGED INTO AC LINE!

WARNING! HIGH VOLTAGESThe Power Supply section has line level voltages present on

some components. DO NOT TOUCH ANY SECTION OF THEACM-200 MODULE or the FAN-FUSE Module.

Line voltage shocks can be fatal. Please refer any testing orservice to qualified personnel.

DO NOT EXPOSE POWER SUPPLY SECTION TOMOISTURE OR METAL SHAVINGS.

UNPLUG ALL AC CORDS BEFORE REMOVING COVER ofBLADERUNNER AIO ENCLOSURE.

BladeRunner AIO Cover Removed Inside View

G251-4 Motor Driver

G251-SOLO5th Axis OPTION

DTHC EXPANSIONMODULE OPTION

TA

BLE

I/O

CA

RD

UBOB III AdvancedBreakout Card

Cro

ssF

low

FA

NO

PT

ION

FAN-FUSEEND PLATE

Connections to Motors

UBOB

TA

BLE

I/O

SW

ITC

HE

D P

OW

ER

Multip

le Inputs

Sw

itches, pro

bes, sensors

G251-4

Card

Table I/O

AX

IS I/O

TO PC Port1 To PC Serial(See Text)

BASIC BLADERUNNER AIO BLOCK DIAGRAM

BL

OC

K D

IAG

RA

MS

AC

Lin

e C

ord

Un

ive

rsa

l

Po

we

r

Pa

k

48V 12A MODULARPOWER CONTROL

Expansion Module Option

DTHCor

ISS-02

See next page

BladeRunner AIO Control Box

POWER SUPPLY

BladeRunner AIO Controller Interface Block Diagram

EZPlug G251-4Four axis Stepper

Driver

Stepper motors/cables

HARDWARE SETUP

AC ControlModule

DC ControlModule

ACM - 200DCM - 200

FAN-FUSE

MODULE

AC LINEIN

5th AXISOPTION

FRONT PANEL

TOROID

Block diagram of BladeRunner AIO POWER SECTION . AC line is controlledby the ACM module. Remote on/off of power to motors comes from ProcessorCard on EZPlug G251-4. HIgh voltage AC is converted to low voltage AC bythe Toroid Transformer. Low voltage AC is converted to low voltage DC(48VDC Nom) by the DCM module. DC is connected to Motors via the EZPLug

PROCESSOR CARDHas OverVoltage,OverLoad and Over-Temp Auto shutdown

48V 12A MODULARPOWER CONTROL

REV3

SFTY GND

J9

J2

L2 OUT

R2

C1

ADAPTER

L1 OUT

48

V

J1

K1

J11

K

K1 ON

CandCNCPOWER RELAY

SERIES

A27

R1TRANS-RED

D3

J14

+

J17

C2

DC

ON

2324

26

J7

J6

J5

1

RJ45

J8

8

J3

2

11

L2 IN L1 IN

SFTY GND

SWITCH A

+

DC

FA

N

L2 O

UT

TRANS-BLK

J16D

C +

DC

+

DC

-

Brid

ge o

n B

ack

side

~+

-

BR

IDG

E2

J36

10K

1/4

W

R1

++

48V

DC

PW

R

+

C10

C12

++

C11

+

10K

1/4

WR

2

CO

MM

ON

J38

F1

+48V

DC

48V

Can

dCN

CB

R48

-12

AC

1

AC

2

Low

Voltage

48V

DC

NE

UH

OT

AB

Bre

ak h

ot sid

e tie

bar

Bre

aker

SW

ITC

H

Backside View Fan Fuse Plate

ACM-200 REV1Module

DCM-200DC power

Module

570WattTOROID

Transformer

WARNING!HIGH VOLTAGEPRESENT. DONOT TOUCH.

WARNING!HIGH VOLTAGE

PRESENT. DO NOTTOUCH.

48VDC

Bridge on Back side

~+

-

BRIDGE2

J36

10K 1/4W

R1

++

48VDC PWR

+ C1

0

C1

2

++C11

+

10K 1/4WR2

COMMON

J38

F1

+48VDC

48V

CandCNCBR48-12

AC1

AC2

RE

V3

SF

TY

GN

D

J9

J2

L2 O

UT

R2

C1

AD

AP

TE

R

L1 O

UT

48V

J1

K1

J11

K

K1

ON

Can

dCN

CP

OW

ER

RE

LAY

SE

RIE

S

A27

R1

TR

AN

S-R

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D3

J14 +

J17

C2

DC ON2324 26

J7

J6

J5

1

RJ4

5

J8

8

J3

2 12 1

L2 IN

L1 IN

SF

TY

GN

D

SW

ITC

HA

+

DC FAN

L2 OUT

TR

AN

S-B

LK

J16

DC +

DC +

DC -

NE

UH

OT

T1

7 K3

NO

NO

LIMITS J4

K3

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K4

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AH

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Com1

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ARC OK

TA

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ER

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C3

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om

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me K3

K4

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ITS

K5

C1

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K

10

52

J18

AU

X0

UP

T1

4

T1

5

D2

DA

NG

ER

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D9

J5

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UG

J2 13

25

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T2

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C11C13C12

T2

T3

T4

T5

T6

T7

T1

6

6

T8

49

T1

8

1

T9

T1

0

T11

T1

2

T1

3

AB

Bre

ak h

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e tie

bar

Bre

aker

SW

ITC

H

TA

BLE

I/O

is m

ounte

d o

n U

BO

B P

late

+

-

ACM-200 Module

DCM-200 Module

RE

V4

SF

TY

GN

D

J2

L2 O

UT

C1

AD

AP

TE

R

TR

AN

S-B

LK

48V

L2 IN

PWR PAk BLK

SF

TY

GN

D

J1

K1

K1

J11

K

K1

ON

SA

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TY

GN

DC

andC

NC

PO

WE

R R

ELA

Y

TR

AN

S 2

20 C

T

A27

TR

AN

S-R

ED

D3

J14

D3

IN40

01

J12J15

+

J17

DC ON 25

J7

J6

J5

LINE CORD

+

DC FAN

BYPASS

SWITCH B

PWR PAK WHT

TR

AN

S-B

LK

J16

J3

DC +

DC +

DC -

12V

Rel

ay

Saf

ety

Rel

ay

WARNING!HIGH VOLTAGE

PRESENT. DO NOTTOUCH.

Bridge on Back side

~+

-

BRIDGE2

J36

10K 1/4W

R1

++

48VDC PWR

+ C1

0

C1

2

++C11

+

10K 1/4WR2

COMMON

J38

F1

+48VDC

48V

CandCNCBR48-12

AC1

AC2

NE

UH

OT

T1

7 K3

NO

NO

LIMITS J4

K3

EP

O

K4

ZH

om

e

47

AH

om

e

Com1

48

ARC OK

TA

BL

E I

/O

DA

NG

ER

!

Co

m2

T1

9

C3

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om

eY

Ho

me K3

K4

LIM

ITS

K5

C1

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C O

K

10

52

J18

AU

X0

UP

T1

4

T1

5

D2

DA

NG

ER

!

D9

J5

1

PL

UG

J2 13

25

DO

WN

YHome

50

T2

0

T2

1

UP

AUX0

DWN

AHome

ZHome

Xhome

C11C13C12

T2

T3

T4

T5

T6

T7

T1

6

6

T8

49

T1

8

1

T9

T1

0

T11

T1

2

T1

3

AB

Bre

ak h

ot sid

e tie

bar

Bre

aker

SW

ITC

H

TA

BLE

I/O

is m

ounte

d o

n U

BO

B P

late

+

-

ACM-200 Module

DCM-200 Module

Rev4

POWER SUPPLYSECTION

ShowsTOROID

TRANSFORMER

ACM MODULE

DCM MODULE

UNIVERSAL POWERPAK

FAN-FUSE MODULE

BREAKER

MAIN

SWITCH

ON

AC LINE

IN

AC OUTLETSA B

15A MAX 10A MAX

AU

X

AC

IN

FAN-FUSE PLATE DETAIL

90 mm High VolumeCooling Fan

Filter and Fan Grill notShown

Snap-in 15A Breaker

Main AC Switch

OPTIONAL DUALSWITCHED AC

OUTLETS

Main AC Cord

Separate AC inputfor

SWITCHED AC OUTLETSONLY

NOTE: Main AC Switch does not turn on/off theOptional Swtiched Outlets directly but removes therelay voltage to those outlets (turning them off) but

there may be a 1 or 2 sec delay. It is recommended youuse the Front Panel OFF button to shut things down

instantly

Some systems may not havethe OPTIONAL AC

OUTPUTS and will not havethe AUX AC IN cord or

opening.

UBOB Universal Breakout Card

The UBOB provides the logic level interface to the PC running MACH3 software. It usesone parallel port and a special circuit to “Expand” a normal port from 12 outputs and 5inputs to 16 outputs and 9 inputs. This is essential for operation with the optionalexpansion cards (DTHC & ISS-02 Isolated Spindle Speed. It has opto isolation on ALLinputs . It works in conjunction with an external breakout card (Table I/O II Card). TheRS232 (true + & - signals) section is connected to the PC serial port. It is required whenthe Expansion Cards are used to provide card level communications to MACH. If theBladeRunner AIO is only being used to control a mill or router without Digital Torch HeightControl (DTHC) or Spindle Speed (VFD) control, the serial port is not required. It doesprovide feedback parameters from the EZPlug G251-4 section in the form of VOLTS,AMPS and INTERNAL Temp. The automatic fault shutdown and protection featuresoperate even if the Serial is not connected. Serial connection IS required if you have theexpansion modules.

The UBOB is fastened to the back of the UBOB Module panel of the BLADERUNNER AIOand held to the internal mounting plate with two rear mounting screws. The UBOB isconnected to the Universal Power Pak via a 5 conductor cable.

UBOB MODULEDETAILS

BLADERUNNER AIO RIGHT SIDE VIEWINPUTS FOR UBOB III AND EXPANSION OPTIONS

CLOSE UP VIEW UBOB MODULERIGHT SIDE

BLADERUNNER UBOB MODULE PANEL FUNCTIONS

TESTTESTTESTTEST

CP PWR

SERIAL INPUT

To PC

Port1 INPUT

Port2 INPUT

To PC

DTHC SPS

SENSOR INPUT

Isolated Table I/O

INPUT

PENDANT

UBOB III Technology

PORT2 INPUTTo PC 2nd Parallel Port(Used with Added I/O)

SERIAL INPUT

To PC

Port1 INPUT

Port2 INPUT

To PC

DTHC SPS

SENSOR INPUT

Isolated Table I/O

INPUT

CP PWR

TESTPENDANT

UBOB III Technology

SERIAL INPUT

To PC

Port1 INPUT

Port2 INPUT

To PC

DTHC SPS

SENSOR INPUT

Isolated Table I/O

INPUT

CP PWR

TESTPENDANT

UBOB III Technology

DB25 Male Plug for cableinterface to PC Parallel Port. AllStep & Dir signals all logic levelinputs and outputs to/from PC.

Required for operation

DB9 cable to PCserial connector.Only needed for

operation ofExpansion Modules

EXPANSION PORTOne Digital Torch Height Module

orOne Isolated Spindle Speed

Control

For HandController

(requires PORT2 Card)

Connector for RemoteTABLE I/O card

(normally inside unit)

Status LED’s forCHARGE PUMP (CP)and Logic Power (Bias

power)

OPTIONOPTION OPTION

OPTION

R4

J9

NO

J11 C

4

NO

ARC OK

6

T13

LIMITS

J4

K3

EPO

C12

T15

K4

ZHome

ALT4 ALT5 ALT6

C&

CN

C

ALT7

1

AHome

CO

M

K3

D8

ALT3

T AB

LEI/O

-16

DANGER!

Com2

C2 ALT8

J12

D7

RE

V 1

Xhome

D6

YHome

R5

K3

K4

LIMITS

D3

C1

D10

1

QU

AD

K

D5

J7

DOWN

K

ARC OK

10

J18

ALT1

UP

J13

D4 T

10

C11D2

EPO

DANGER!

RE

LAY

ARC OK

J5

1

PLU

G

J2

14

13 25

DOWN

C13

3

UP

KD

15

T5

J14

YHome

T2T19

T21

T20

R3

C8

T17

C6

Q6

K K

AHomeZHomeXhome

C3

D21

R2

D20

C5

2

K

J8 J10

T3

K4

K4

J22

R1

C9

K

D18

D16

C14

R7

D1 1

ALT2

Q5

KR

8

BLADERUNNER UBOB MODULE DETAILS

UBOB Universal Breakout Board

FAN (Optional)

TABLE I/O or TABLE I/O II CARD

TESTTESTTESTTEST

CP PWR

SERIAL INPUT

To PC

Port1 INPUT

Port2 INPUT

To PC

DTHC SPS

SENSOR INPUT

Isolated Table I/O

INPUT

PENDANT

UBOB III Technology

Port 1 toPC Parallel

PORT1

Serial Porttp

PC COM1

Slot for DTHC or ISS-02OPTION

Slot for EXTERNALTABLE I/O

Slot forHand Controller

Front Panel MOUNTING Options

NOTE: Some or all of the cutouts shown in yellow may not be exposed depending on what options youordered with your BladeRunner AIO. The front decal covers any unused options. If you later add an optionthe slots should be cut out using a sharp bladed hobby knife (aka Exacto Knife) prior to installation of theoption. The base BladeRunner AIO only has two connectors (shown in blue). The Table I/O card forconnection to external switches (Homes, Limits, External E-Stop, etc) is mounted inside the BladeRunner AIO.See the section on hooking up the Table I/O for options to move the Table I/O outside the box and use a DB25cable to connect the Table I/O back to the internal UBOB card.

This area open foDTHC or ISS-02

ExpansionCARDS

INSIDE TOP VIEW

UBOB MODULEwith TABLE I/OCard + DTHC

(OPTION).Removed from

enclosure.REAR VIEW

UBOB MODULE withTABLE I/O Card + DTHC

(OPTION). Removed fromenclosure.

FRONT VIEW

NOTE:

BLADERUNNER AIO has an integrated Universal Power Pak AC toDC power converter rated at 100 - 240VAC 50/60hz input. It will

work with virtually any AC source on the MAIN AC input. You dohave to provide any other power to the UBOB

not

REV3

1

+121

Q8

D19

FA

N

SIP

2

AXIS I/O

+5

+

+

1

14

13

25

U51

C5

Q1

J3

1

SKT

1

6

5

RN1

Q2

J57

1

AXIS I/O

J5

6

EXPANSION

EXPANSION

+5

UBOBII

PPORT1

SIP3

J1

TABLE I/O

J29

RN2

Q3

1POWER

SERIAL

SIP

1

Q4

Q9

J6

Q5 Q6

PORT2 INTERCONNECT

PORT2 INTERCONNECT

C1

SERIAL

Q7

+

GN

DG

ND

J63 J65

DTHC/ISS-02

CandCNC

CP

1

1

+

+

REAR

Fro

nt P

anel

+

J7

TABLE I/O

J2 +12

J8

C11

J9

+9VDC

DC-DC

+

+

12VDC IN

5VDC IN

Any source of REGULATED +5 and+12 (PC, external power supply, etc)

On-board DC-DC supply providesSeparate Floating supply for

Isolated inputs.

UB

OB

CO

NN

EC

TIO

NS