{{tool:metal_cnc:jaxencncmill.jpeg?300|Jaxen CNC Milling Machine}}

===== Jaxen CNC Milling Machine =====

| **Model**              | Grizzly G0619 [[https://cdn0.grizzly.com/manuals/g0619_m.pdf| See Manual]] (CNC Fusion stepper + ballscrew conversion) |
| **Status**             | Operational. Runs [[https://www.cncdrive.com/UCCNC.html|UCCNC]] ,but not user-friendly |
| **Usage Restrictions** | Members with Training                                     |
| **Training**           | Mandatory                                                 |
| **User certification required** | YES                                              |
| **Hackable**           | NO                                                        |
| **Owner**              | Vancouver Hack Space (donated by [[https://talk.vanhack.ca/u/ccudahy| Chris / ccudahy]] )         |
| **If it Breaks**       | Notify champion, put up an Out of Order sign              |
| **Loan Status**        | Donated — VHS purchased for $1;  Chris / ccudahy retains first refusal if disposed |
| **Arrival Date**       | August 29th, 2020                                         |
| **Location**           | CNC Area                                                  |
| **Champion**           | [[https://talk.vanhack.ca/u/androidlx | AndroidLX]]                                                 |

----
==== Specifications ====
  * <del>Gecko G540 stepper controller (see [[https://www.geckodrive.com/support/g540-manual-rev8/|Gecko G540 Manual]]) (parallel port → LinuxCNC PC)</del>
  * <del>Integrated PC, stepper PSU, and controller in enclosure</del>
  * AXBB-E (CNCdrive) controller with UCCNC. See information below
  * CNC mill controller installed in Wall panel. See information below. 
  * Includes R8 tooling
  * New Base: King Industrial base purchased
  * Original Base: Wood 93 × 61 cm footprint, 93 cm tall (engine hoist fits underneath)
  * Weight: ~200 kg
  * Modified with CNC Fusion stepper + ballscrew kit (original parts retained)

----

==== Training ====
  * **Mandatory training required** before use 
  * Must first complete training and certification on the [[tool:6040 CNC Mill|6040 CNC Mill "Loratron"]]
  * Certification must be recorded before using Jaxen

----

==== Speeds & Feeds ====
  * Use the CNC PC’s cutting speed calculator to determine correct RPM and feed rates  
  * Always set both cutting speed and feed rate properly to avoid tool damage and poor results  

----

==== Maintenance Log ====
^ Date       ^ Who        ^ Note                                                                 |
| 2016/2017  | Chris (donor) | Disassembled after poor cut quality; discovered defective saddle, replaced with new Grizzly part, controller box rebuilt. |
| Jul 4, 202X| AndroidLX   | Significant modifications performed. Machine confirmed to run UCCNC, noted as “not particularly user-friendly.” |

----

==== History ====
  * **Donated by:** [[https://talk.vanhack.ca/u/ccudahy | Chris (ccudahy)]]  See [[https://talk.vanhack.ca/t/cnc-milling-machine-donation/10613]]
  * **Donation terms:** Purchased by VHS for $1; donor retains first right of repurchase if disposed  
  * **Donation date:** August 29, 2020  
  * **Arrival location:** Workshop 
  * King Industrial Stand purchased for mill ~$300-$400([[https://www.kmstools.com/king-industrial-stand-for-milling-drilling-machines.html|KMS Tools]])
  * **Most of Tooling that came with machine seems to have gone missing:**

Mill and original stand as donated by Chris
{{tool:metal_cnc:JaxenDonation.jpg?500|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.