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--- wiki:tools:jaxen_cnc_mill [2026/07/28 01:05] – colinl
+++ wiki:tools:jaxen_cnc_mill [2026/07/28 01:30] (current) – colinl
@@ Line 1: / Line 1: @@
-===== 'Jaxen' - CNC Milling Machine =====
+====== 'Jaxen' - CNC Milling Machine ======
 Jaxen is the most powerful CNC mill at VHS, capable of milling steels and other metals harder than aluminum and brass.
@@ Line 78: / Line 78: @@
 {{tool:metal_cnc:jaxencncmill.jpeg?300|Jaxen CNC Milling Machine}}
-----
-==== CNC mill controller setup ====
-All the controller hardware is located in an electrical panel on the wall behind the mill.
-{{tool:metal_cnc:jaxencncmillcontrollerpanel.jpeg?300|NDR-480-48}}
-----
-=== 1. Power Supplies ===
-There are four Mean Well power supplies:
-  * NDR-480-48 (x2): Provide 48V, 10A DC to the stepper/servo drivers (blue modules marked Motor Z/A and Motor X/Y).
-    *  These deliver the high-power DC that actually runs the motors.
-  * MDR-60-24: Provides 24V DC for control electronics (like relays, sensors, and logic boards).
-  * MDR-60-5: Provides 5V DC for logic-level components (controller board, encoders, or optoisolators).
-**Hookup**:
-  * AC mains (100–240V) enters at the bottom (L/N/Earth).
-  * DC outputs (+V and –V) run to the motor drivers and controller boards.
-{{tool:metal_cnc:jaxencncmillcontrollerpower1.jpeg?300|NDR-480-48}}
-{{tool:metal_cnc:jaxencncmillcontrollerpower2.jpeg?200| MDR-60-24 and MDR-60-5}}
-----
-=== 2. Motor Drivers ===
-The blue modules marked X, Y, A, and black module Z, are stepper/servo motor drivers.
-  * Function: Convert low-level step/direction/enable signals from the controller into high-power pulses for the motors.
-  * Each axis has its own driver.
-  * Wiring:
-    *  Signal side (green connectors): Receives Step (Red), Dir (White), Ena (Green) from the motion controller.
-    *  Power side: Fed by 48V from the NDR-480 supplies.
-    *  Motor outputs: Four heavy wires going to each motor coil.
-    *  Rotary encoder inputs: see Motor (XY) Rotary Encoder Pinouts below
-**Motor (XY) Rotary Encoder Pinout**
-^ Pin # ^ Pin Label ^ Description ^ Encoder Wire Color ^
-| 1     | EB+       | Encoder B phase input + | Yellow |
-| 2     | EB-       | Encoder B phase input - | Green  |
-| 3     | EA+       | Encoder A phase input + | Black  |
-| 4     | EA-       | Encoder A phase input - | Blue   |
-| 5     | VCC       | Encoder voltage (+5V)   | Red    |
-| 6     | EGND      | Encoder ground (0V)     | White  |
-**NOTE:** Disconnected encoder wires will damage the driver and/or encoder.
-**Motor (XY) Rotary Encoder Cable Color Mapping**
-The installed 6-wire cable uses three identical black conductors. They are correctly landed on EA−, EB−, and EGND but should be labeled to avoid confusion.
-^ Pin # ^ Signal ^ Function ^ “Standard” Color (from prior table) ^ Jaxen Cable Color ^
-| 1 | EB+  | Encoder B phase input + | Yellow | **Green** |
-| 2 | EB-  | Encoder B phase input - | Green  | **Black** (label: EB−) |
-| 3 | EA+  | Encoder A phase input + | Black  | **White** |
-| 4 | EA-  | Encoder A phase input - | Blue   | **Black** (label: EA−) |
-| 5 | VCC  | Encoder supply +5 V     | Red    | **Red** |
-| 6 | EGND | Encoder ground (0 V)    | White  | **Black** (label: GND) |
-{{tool:metal_cnc: jaxencncmillcontrollermotordrivers.jpeg?300| Motor Drivers}}
-Photos of X,Y and A Servo Drivers
-{{tool:metal_cnc: jaxenhss57hybridservodriver1.jpeg?300| Motor Drivers}}
-{{tool:metal_cnc: jaxenhss57hybridservodriver2.jpeg?300| Motor Drivers}}
-{{tool:metal_cnc: jaxenhss57hybridservodriver3.jpeg?300| Motor Drivers}}
-**HSS57 Hybrid Servo Driver**
-The **HSS57** is a hybrid servo driver used to control the X and Y axis closed-loop stepper motors on the Jaxen CNC mill.
-It drives the **57HSE2N-D25 motors** with encoder feedback, ensuring reliable closed-loop operation.
-[[https://cncdrive.com/datasheets/HSS57.pdf|HSS57 driver datasheet]]
-**Device Identification**
-  * **Model**: HSS57
-  * **Type**: Hybrid Servo Driver (closed-loop stepper controller)
-  * **Voltage Range**: 24–50 VDC
-  * **Control Interface**: Step/Dir inputs
-  * **Feedback**: Encoder input (closed-loop control)
-This driver is designed for **closed-loop stepper motors** (sometimes called “servo steppers”). It prevents lost steps by correcting position via encoder feedback.
-**Connections**
-**Motor (4 terminals)**
-  * A+, A–
-  * B+, B–
-**Encoder (6 terminals)**
-  * VCC
-  * EGND
-  * EA+, EA–
-  * EB+, EB–
-**Control Inputs/Outputs (12 terminals)**
-  * ENA+, ENA– : Enable input
-  * DIR+, DIR– : Direction input
-  * PUL+, PUL– : Step pulse input
-  * ALM+, ALM– : Alarm output (fault status)
-**Pulse/Rev Table (Microstepping)**
-DIP switches SW3–SW6 set the resolution (controller pulses per motor revolution):
-X and Y currenltly set for 10000 Pulses/Rev
-^ Pulses/Rev ^ SW3 ^ SW4 ^ SW5 ^ SW6 ^
-| Default    | on  | on  | on  | on  |
-| 10000      | off | on  | off | off |
-* Lower values = coarser steps, higher speed
-* Higher values = finer steps, smoother motion, higher resolution
-** Key Features **
-  * Closed-loop stepper control with encoder feedback
-  * Prevents lost steps and provides stall detection
-  * Alarm output via ALM pins
-  * Uses standard Step/Dir interface (compatible with AXBB-E controller)
-  * Optimized for NEMA 23/24 closed-loop stepper motors
-**Summary**
-The **HSS57 Hybrid Servo Driver** controls the **X and Y axis motors** on the Jaxen CNC. Powered by the Mean Well 48V supplies, it accepts **step/dir signals** from the AXBB-E motion controller and uses encoder feedback to guarantee position accuracy. This closed-loop setup improves reliability compared to open-loop stepper drivers.
-----
-**Photos of Z Servo Driver**
-{{tool:metal_cnc:jaxsenma860h_zdriver1.jpeg?300| Motor Drivers}}
-{{tool:metal_cnc:jaxsenma860h_zdriver2.jpeg?300| Motor Drivers}}
-{{tool:metal_cnc:jaxsenma860h_zdriver3.jpeg?300| Motor Drivers}}
-**MA860H Stepper Driver (Z axis)**
-The **MA860H** is a digital stepper motor driver used to control the **Z axis** on the Jaxen CNC mill.
-It is designed for high-torque NEMA 34 stepper motors and provides microstepping, current control, and high-voltage operation.
-[[https://www.omc-stepperonline.com/download/MA860H.pdf|MA860H driver manual (PDF)]]
-**Device Identification**
-  * **Model**: MA860H
-  * **Type**: 2-phase digital stepper driver
-  * **Voltage Range**: 18–80 VAC or 24–110 VDC
-  * **Control Interface**: Step/Dir inputs
-  * **Microstepping Resolution**: Up to 40,000 pulses/rev
-  * **Peak Current Output**: Up to 7.2 A
-**Connections**
-**Signal Inputs**
-  * **DIR+ / DIR–** : Direction control input
-  * **PUL+ / PUL–** : Step pulse input
-  * **ENA+ / ENA–** : Enable input
-(Inputs accept **+5V to +24V logic**.)
-**Motor Outputs**
-  * A+, A– : Motor phase A
-  * B+, B– : Motor phase B
-**Power Supply**
-  * AC ~ terminals : 18–80 VAC input
-  * DC terminals : 24–110 VDC input
-**DIP Switch Configuration**
-Your current switch settings: **SW1 = 0, SW2 = 0, SW3 = 0, SW4 = 0, SW5 = 0, SW6 = 1, SW7 = 0, SW8 = 0**
-  * **Motor Current Setting (SW1-SW3 = 000)**: **6.0 A RMS / 7.2 A peak** maximum current
-  * **Idle Current (SW4 = 0)**: **Half-current hold mode** (reduced current when idle)
-  * **Microstep Resolution (SW5-SW8 = 0100)**: **10,000 pulses/rev** (≈ 1/50 microstepping for a 1.8° stepper)
-**Key Features**
-  * High-voltage, high-current driver for large stepper motors (NEMA 34 class)
-  * Microstepping up to 1/128 (40,000 pulses/rev)
-  * Automatic idle current reduction (via SW4)
-  * Step/Dir/Enable compatible with AXBB-E motion controller
-  * Used exclusively for the **Z axis** on the Jaxen CNC
-**Summary**
-The **MA860H** powers the Z-axis stepper motor on the Jaxen CNC. It runs at **6.0 A RMS, half-current hold**, with **10,000 steps/rev microstepping**, providing smooth motion and strong holding torque. It interfaces with the AXBB-E controller via standard Step/Dir signals.
-----
-=== 3. Ethernet Motion Controller ===
-The AXBB-E (CNCdrive) is the central brain. Pic below.
-  * Function: Interfaces between UCCNC on your PC (via Ethernet) and the motor drivers, limit switches, and I/O.
-  * Ports:
-    *  Port 1 (Isolated Outputs): Sends step/dir/ena signals to the motor drivers.
-    *  Port 2 (Isolated Inputs): Reads signals from limit switches, homing switches, estop, etc.
-    *  Port 3 (Non-Isolated Inputs/Outputs): General-purpose inputs/outputs.
-    *  24V/5V Power In: Supplied from the Mean Well MDR units.
-  * Status LEDs show link, power, and I/O states.
-[[https://www.cncdrive.com/downloads/AXBB_E_manual.pdf|AXBB-E Controller and Breakout Board Users Guide]]
-{{tool:metal_cnc:jaxencncmillmotioncontroller.jpeg?300| AXBB-E (CNCdrive) Ethernet Motion Controller}}
-----
-=== 4. UCSB Breakout and I/O Board ===
-The smaller green PCB to connected to left of Ethernet Motion Controller(near orange terminal blocks):
-  * Expands I/O from the AXBB-E.
-  * Provides screw terminals for clean connection of inputs (limit switches, probe, estop) and outputs (coolant pump, spindle relay, etc.).
-  * Optoisolated for noise protection.
-{{tool:metal_cnc:jaxencncmillcontrollerbreakout_io_board.jpeg?300| Breakout I/O Board}}
-----
-Example setup of Ethernet Controller and Breakout I/O Board
-{{tool:metal_cnc:axbb-e_5.png?500| Example Setup Motion Controller and Breakout Board}}
-----
-=== 5. Motors ===
-Jaxen Mill (Grizzly + King base) uses stepper motors on X, Y, Z. There is a fourth driver 'A', that could run a rotary or 4th axis. These receive power and control via the drivers.
-**X and Y axis Motors**
-{{tool:metal_cnc:jaxencncxymotors1.jpeg?300| XY Closed loop stepper motors}}
-{{tool:metal_cnc:jaxencncxymotors2.jpeg?300| XY Closed loop stepper motors}}
-** XY Motor Identification**
-  * Model: 57HSE2N-D25
-  * Type: Hybrid stepper motor with integrated encoder
-  * Manufacturer: JSS Motor (as labeled on the tag: “JSS MOTOR NO:201701”)
-** XY Motor Leads**
-  * The motor side has the usual 4-lead bipolar wiring:
-  * A+ = Red
-  * A- = Green
-  * B+ = Yellow
-  * B- = Blue
-This means it’s a 2-phase, bipolar stepper.
-** XY Encoder Leads**
-  * The encoder provides feedback for closed-loop control:
-  * EA+ = Black
-  * EA- = Blue
-  * EB+ = Yellow
-  * EB- = Green
-  * VCC = Red (supply power for encoder, usually 5 V)
-  * EGND = White (encoder ground)
-**Typical Wiring Diagram**
-{{tool:metal_cnc:typicalwiringdiagram.png?600| Typical Wiring Diagram}}
-This is a standard quadrature encoder setup (channels A and B), giving the controller both position and direction feedback.
-** XY Typical Specifications (based on 57HSE2N series)**
-While exact numbers vary slightly by supplier, the 57HSE2N-D25 generally matches:
-^ Attribute          ^ Value (typical)                                        ^
-| Frame Size         | NEMA 23 (57 mm)                                        |
-| Step Angle         | 1.8° (200 steps/rev)                                   |
-| Holding Torque     | ~2.0–2.5 Nm (280–350 oz-in)                            |
-| Rated Current      | ~4.0–5.0 A/phase                                       |
-| Resistance         | ~0.5–0.8 Ω/phase                                       |
-| Inductance         | ~2.5–4.0 mH                                            |
-| Encoder Resolution | 1000–2500 PPR (typical, quadrature)                    |
-| Voltage Drive      | 48 V DC (as supplied by your Mean Well NDR-480-48 PSU) |
-  * XY axis are closed-loop stepper motors—sometimes marketed as servo-stepper hybrids—which combine the simplicity of stepper drive with the position assurance of encoder feedback.
-**Function in Your CNC (Jaxen)**
-  * X Axis Motor: Moves the table left/right (long axis).
-  * Y Axis Motor: Moves the table front/back (short axis).
-  * Both motors receive step/dir signals from the CNCdrive AXBB-E motion controller via the blue motor drivers you showed earlier.
-The encoders feed back position to the drivers, enabling stall detection and correction, preventing lost steps.
-**Z Axis Motor not documented**
-**Summary:**
-The 57HSE2N-D25 motors on your Grizzly/Jaxen CNC are NEMA 23 closed-loop stepper motors with encoders. They provide about 2–2.5 Nm torque, run at ~4–5 A/phase, and are driven by your 48 V Mean Well PSU through dedicated stepper drivers. Their integrated encoders make the system far more reliable than open-loop steppers.
-----
-=== 7. Limit Switches and RJ-11 Breakout Board ===
-**Limit Switch Configuration**
-Jaxen CNC uses **one limit switch per axis** (X, Y, Z). Each switch is mounted at the **home end of travel** for its axis.
-UCCNC manages the opposite end of travel via **soft limits**. If any limit switch is triggered during machining, motion stops immediately on all axes.
-**Physical Layout**
-  * **X Axis** → Limit switch at the X− end (left side when facing the machine).
-  * **Y Axis** → Limit switch at the Y− end (front of the table).
-  * **Z Axis** → Limit switch at the Z+ end (top of spindle travel).
-Each switch is wired into the controller as both a **homing switch** and a **limit switch**.
-**Function in UCCNC**
-  * During homing, the axis moves toward the limit switch until it triggers, then backs off to establish machine zero.
-  * During normal operation, the same switch acts as a hardware limit in that direction.
-  * The opposite end of travel is protected using **software soft limits**, defined in UCCNC machine setup.
-{{tool:metal_cnc:jaxenlimitswitches_x.jpeg?300| X Minus Limit Switch}}
-{{tool:metal_cnc:jaxenlimitswitches_y.jpeg?300| Y Minus Limit Switch}}
-{{tool:metal_cnc:jaxenlimitswitches_z.jpeg?200| Z Minus Limit Switch}}
-These limit switches are connected through a dedicated **Creltek RJ-11 Sensor Breakout Board v2.1** for safety and homing. This board consolidates up to 8 limit switch inputs into RJ-11 connectors, making wiring cleaner and reducing electrical noise from motors and power electronics.
-  * Each axis (X, Y, Z) has independent limit switches routed through the breakout board.
-  * Output signals can be **wire-OR’d**, allowing multiple switches per axis if needed.
-  * The breakout board is wired into the **AXBB-E motion controller**.
-  * Designed for **reliability in CNC environments** with high electrical interference.
-  * Creltek Datasheet: [[https://d3s5r33r268y59.cloudfront.net/datasheets/6257/2017-07-26-15-29-56/Creltek%20RJ11%20Sensor%20Breakout%20v2.1%20Datasheet.pdf|Creltek RJ-11 Sensor Breakout v2.1 Datasheet]]
-^ Feature              ^ Description                                                                 ^
-| **Name**             | Creltek RJ-11 Sensor Breakout Board v2.1 (by Kevin H. Patterson)             |
-| **Connectors**       | 8 × RJ-11 jacks (each with power, ground, and signal)                       |
-| **Outputs**          | Active-low, open-collector, capable of sinking >200 mA                      |
-| **Pull-ups**         | Optional on-board 4.7 kΩ pull-up resistors                                  |
-| **Noise Filtering**  | Built-in circuitry for robust operation in electrically noisy environments  |
-| **Voltage Support**  | Native 3.3 V, or 5–18 V with onboard regulator                              |
-| **Mounting**         | Panel-mount capable; designed for professional installation                 |
-{{tool:metal_cnc:jaxenlimitswitchboard1.jpeg?300| Creltek Limit RJ-11 Switch Board}}
-{{tool:metal_cnc:jaxenlimitswitchboard2.jpeg?300| Creltek Limit RJ-11 Switch Board}}
-{{tool:metal_cnc:jaxenlimitswitcheboard3.jpeg?200| Creltek Limit RJ-11 Switch Board}}
-----
-=== 8. Spindle Feedback Encoder ===
-The spindle position and speed are monitored using a **rotary encoder** mounted at the top of the spindle assembly.
-{{tool:metal_cnc: jaxenrotaryencodertop.jpeg?300| Rotary Encoder on Top of Jaxen}}
-{{tool:metal_cnc:jaxen_rotary_encoder_e38s6g5-600z.png?300| Spindle Feedback Rotary Encoder}}
-**Device Identification**
-  * **Model**: E38S6G5-600Z
-  * **Type**: Incremental rotary encoder
-  * **Body size**: 38 mm diameter
-  * **Mounting**: Solid shaft, direct-coupled to spindle
-**Specifications**
-  * **Resolution**: 600 pulses per revolution (P/R)
-  * **Channels**: A, B (quadrature) + Z (index pulse, 1 per revolution)
-  * **Supply voltage**: 5–24 VDC
-  * **Output type**: Line driver / push-pull TTL (depending on wiring)
-  * **Shaft**: Solid, 6 mm or 8 mm diameter (variant dependent)
-  * **Output signals**: Differential A, B, Z for accurate detection
-**Function**
-  * Provides real-time spindle speed feedback to the motion controller (AXBB-E).
-  * Index pulse (Z) can be used for precise synchronization tasks:
-    * Rigid tapping
-    * Thread cutting
-    * Accurate spindle homing
-**Role in Jaxen CNC**
-The encoder ensures that the control system knows the **actual spindle RPM** and **rotational position**.
-This allows for advanced machining operations where tool motion must be precisely synchronized with spindle rotation.
-**References**
-  * [[https://www.tenettech.com/product/pro-range-e38s6g5-600z-g24n-rotary-incremental-encoder-38mm-photoelectric-abz-3-channels-600-ppr|Example Rotary Encoder]]
-----
-=== 9. Spindle Control Board ===
-https://www.yumpu.com/en/document/read/24635331/cnc-spindle-control-upgrade-kit-little-machine-shop
-----
-=== 10. E-Stop ===
-tbd
-----
-=== 11. Tool Offset Sensor ===
-**MY20-20-2 CNC Automatic Tool Sensor Gauge**
-{{tool:metal_cnc:tooltouchoffsensor1.jpeg?200| Tool Offset Sensor Gauge}}
-^ **Parameter**              ^ **Specification** ^
-| Model                       | MY20-20-2 |
-| Type                        | Automatic tool setter / touch sensor |
-| Operating voltage           | 24 VDC (nominal, 5–24 V compatible) |
-| Contact type                | Normally Closed (NC) |
-| Construction                | Anodized aluminum body, carbide plunger |
-| Plunger travel              | ~2 mm (spring loaded) |
-| Repeatability               | ±0.001 mm |
-| Output signal               | Switch closure (opens on touch) |
-| Wiring                      | 2-wire NC switch: +24 V → sensor → AXBB-E input (I±) |
-| Recommended AXBB-E input    | Isolated input (e.g. I6+ / I6-) |
-| UCCNC configuration         | Assign as **Probe input** |
-| Application                 | Automatic tool length offset, tool change probing |
-| Notes                       | Wire as NC for fail-safe; if cable breaks, UCCNC sees an open input (probe tripped). |
-----
-=== 12. PC & UCCNC Software ===
-  * [[https://www.cncdrive.com/UCCNC.html|UCCNC]] software (Windows 10) generates the motion control stream.
-  * Sends commands (steps/directions) over Ethernet to the AXBB-E.
-  * The AXBB-E translates them into hardware pulses for the drivers.
-  * Operator inputs (limit switches, estop, spindle control) feed back to UCCNC via the AXBB-E.
-----
-=== Signal Flow Summary ===
-  * Mains AC → Power Supplies → Provide 48V (motors), 24V (control), 5V (logic).
-  * PC running UCCNC → Ethernet → AXBB-E Motion Controller.
-  * AXBB-E Outputs → Step/Dir/Ena → Motor Drivers (X, Y, Z, A).
-  * Motor Drivers → High-voltage pulses → Stepper Motors.
-  * AXBB-E Inputs ← Limit switches, estop, home sensors.
-  * Optional: Outputs control spindle, coolant, etc.