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ExtraTech PoleStar HP4 Controller: Difference between revisions

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CNC motion controller with 4 integrated stepper drives that communicates with a VFD/LCD pendant, and a PC via Ethernet (or maybe also RS-232?). It was used by OEMs to provide controls on their machines. ExtraTech was bought by Multicam, who used their controllers, but supposedly the employees soon dispersed and Multicam doesn't have the ability to support repairing the controls anymore.
CNC motion controller with 4 integrated stepper drives that communicates with a VFD/LCD pendant, and a PC via Ethernet (or maybe also RS-232?). It was used by OEMs to provide controls on their machines. ExtraTech was bought by Multicam, who used their controllers, but supposedly the employees soon dispersed and Multicam doesn't have the ability to support repairing the controls anymore.
== Wiring Diagram ==
=== Pendant ===
The KDM20-G pendant's male pin externally threaded circular connector pinout:
{| class="wikitable"
! DIN Pin
! Wire Color
! Function
|-
| 1
| brown
| +24V
|-
| 2
| white
| Tx
|-
| 3
| blue
| GND
|-
| 4
| black
| E-stop
|-
| 6
| red
| Rx
|}
Female pin CPC plug to male pin DIN cable pinout:
{| class="wikitable"
! CPC Pin
! DIN Pin
! Function
|-
| 1
| 5
|
|-
| 2
| 2
| Tx?
|-
| 3
| 6
| Rx?
|-
| 5
| 3
| GND
|-
| 8
| 4
| E-stop
|-
| 9
| 1
| +24V
|}
Male pin CPC receptacle to female pin Molex plug cable pinout:
{| class="wikitable"
! CPC Pin
! Molex Pin
! Color
! Function
|-
| 1
| 1
| black
|
|-
| 2
| 2
| green
| Tx?
|-
| 3
| 3
| yellow
| Rx?
|-
| 4
| 4
| blue
|
|-
| 5
| 5
| brown
| GND
|-
| 6
| 6
| white
|
|-
| 7
| 7
| red
|
|-
| 8
| 8
| orange
| E-stop
|-
| 9
| 9
| pink
| +24V
|}
== Bill of Materials ==
{| class="wikitable"
! Designator
! Marking
! DigiKey
|-
| PFET1-PFET4
| (International Rectifier) FR9024N
| [https://www.digikey.com/en/products/detail/infineon-technologies/IRFR9024NTRLPBF/856772 Infineon IRFR9024NTRLPBF]
|-
| D1-D4,D17
| (Texas Instruments) UG 77A
| [https://www.digikey.com/en/products/detail/vishay-general-semiconductor-diodes-division/US1G-E3-5AT/2149375 Vishay US1G-E3/5AT]
|-
| M1
| Microchip PIC16F877A-I/L
| [https://www.digikey.com/en/products/detail/microchip-technology/PIC16F877A-I-L/446142 Microchip PIC16F877A-I/L]
|-
| U2
| (Texas Instruments) 7406
| [https://www.digikey.com/en/products/detail/texas-instruments/SN7406DR/276661 Texas Instruments SN7406DR]
|-
| U14
| AMD ELAN SC520-133AD
|
|-
| U24
| (National Semiconductor) LM2940CS-15
| [https://www.digikey.com/en/products/detail/diodes-incorporated/AS7815ADTR-G1/5305900 Diodes Incorporated AS7815ADTR-G1]
|-
| U100
| (Intel) 28F320C3TD90
| [https://www.digikey.com/en/products/detail/rochester-electronics-llc/RC28F320C3TD90/12130641 Altera RC28F320C3TD90]
|}
https://en.wikipedia.org/wiki/File:AMD_Elan_SC520-133AC.jpg
https://www.digipart.com/part/SC520-133AC
https://cdn.embeddedts.com/resource-attachments/ElanSC520-datasheet.pdf
https://www.digikey.com/en/products/detail/intel/EP1C12F324C8N/763639
[https://www.digikey.com/en/products/detail/same-sky/TS14-1212-43-BK-160-SCR-D/16562768 CUI TS14-1212-43-BK-160-SCR-D] (reset button)
== Replacement Parts ==
=== Connectors ===
{| class="wikitable"
! Name
! Part
|-
| E1,EK1
| [https://www.digikey.com/en/products/detail/te-connectivity-amp-connectors/206705-1/15598 TE 206705-1]
|-
| Drive 5-6
| [https://www.digikey.com/en/products/detail/amphenol-cs-commercial-products/L17DAFRDA15S/4884549 Amphenol L17DAFRDA15S] (similar)
|-
| L1
| [https://www.digikey.com/en/products/detail/te-connectivity-amp-connectors/206306-1/19379 TE 206306-1]
|-
| L2
| [https://www.digikey.com/en/products/detail/te-connectivity-amp-connectors/206838-1/19349 TE 206838-1]
|-
| Motor 1-4
| [https://www.digikey.com/en/products/detail/te-connectivity-amp-connectors/211398-1/241426 TE 211398-1]
|}
=== Fasteners ===
{| class="wikitable"
! Quantity
! Type
|-
| 2
| M3-0.5x5mm Button Head Socket Cap Screws
|-
| 19
| M4-0.7x6mm Socket Head Cap Screws
|-
| 16
| M4-0.7x12mm Button Head Socket Cap Screws
|-
| 20
| M4-0.7x12mm Flat Head Socket Cap Screws
|}
* 10x M4-0.7x6mm Socket Head Cap Screws for fastening the main motherboard to the bottom of the chassis
* 1x M4-0.7x6mm Socket Head Cap Screws for fastening the "HDSP" board to the bottom of the chassis (if present)
* 8x M4-0.7x6mm Socket Head Cap Screws for fastening the stepper driver modules to the side of the chassis
* 1x M4-0.7x15mm stud for rectifier to mount to bottom of chassis
* 4x M2.5-0.45x6mm studs for internally mounting the "EK1" CPC connector to the side of the chassis
* 2x M3-0.5x5mm Button Head Socket Cap Screws for "AUX 1" blank
* 4x M4-0.7x12mm Button Head Socket Cap Screws for "E1" CPC connector (they protrude 8mm, could use 6mm long screws)
* 16x M4-0.7x12mm Flat Head Socket Cap Screws for "Motor 1-4" CPC connectors
* 4x M4-0.7x12mm Flat Head Socket Cap Screws for "L1" CPC connector
* 4x M4-0.7x12mm Button Head Socket Cap Screws for the "L2" CPC connector
* 8x M4-0.7x12mm Button Head Socket Cap Screws for fastening the side panels to the main chassis
=== Rectifier ===
[https://www.digikey.com/en/products/detail/onsemi/GBPC3502/1057390 onsemi GBPC3502]
=== Fans ===
<pre>NMB-MAT
7G05A73-1AZ
MODEL FBA09A24H
DC24V 0.17A
Minebea-Matsushita
Motor Corporation
Made in China</pre>
[https://www.digikey.com/en/products/detail/nmb-technologies-corporation/FBA09A24H1AZ/143481 NMB FBA09A24H1AZ]
Connected to a custom "HPEM" PCB that runs off +80VDC and provides regulated +24VDC power to the rest of the system.


== Online Resources ==
== Online Resources ==
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[https://web.archive.org/web/20080704165230/http://www.extratech.com/HP4/HP4flyer.html PoleStar HP4 Controller and Motor Drivers - ExtraTech] (Wayback Machine)
[https://web.archive.org/web/20080704165230/http://www.extratech.com/HP4/HP4flyer.html PoleStar HP4 Controller and Motor Drivers - ExtraTech] (Wayback Machine)


[https://web.archive.org/web/20081006153139/http://www.extratech.com/keypad/skd80.html  Hand-Held Serial Keypad - SKD80 - ExtraTech]
[https://web.archive.org/web/20081006153139/http://www.extratech.com/keypad/skd80.html  Hand-Held Serial Keypad - SKD80 - ExtraTech] (Wayback Machine)
 
[https://web.archive.org/web/20081030042954/http://www.extratech.com/controller.html Motion Controller ExtraTech Corporation Products] (Wayback Machine)
 
[https://web.archive.org/web/20080513081216/http://www.extratech.com/software.html Software from ExtraTech Corporation] (Wayback Machine)


[https://web.archive.org/web/20081030042954/http://www.extratech.com/controller.html Motion Controller ExtraTech Corporation Products]
[https://web.archive.org/web/20080704165254/http://www.extratech.com/suite3/mtools.html ExtraTech Software - Machine Tools Suite] (Wayback Machine)


[https://web.archive.org/web/20080513081216/http://www.extratech.com/software.html Software from ExtraTech Corporation]
[https://web.archive.org/web/20171113025316/https://www.extratech.com/motioncontrollers/ Motion Controllers — ExtraTech Systems] (newer Wayback Machine)


[https://web.archive.org/web/20080704165254/http://www.extratech.com/suite3/mtools.html ExtraTech Software - Machine Tools Suite]
[https://web.archive.org/web/20171113025329/https://www.extratech.com/motionperipherals/ Peripherals — ExtraTech Systems] (newer Wayback Machine)


[https://www.autometrix.com/resources/utilities/ Utilities | Autometrix]
[https://www.autometrix.com/resources/utilities/ Utilities | Autometrix]
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[https://www.docdroid.net/MMtOgbc/controller-reference-pdf Controller_Reference.pdf | DocDroid]
[https://www.docdroid.net/MMtOgbc/controller-reference-pdf Controller_Reference.pdf | DocDroid]
[https://dallasmakerspace.org/w/images/b/bf/MultiCAM-GCodes_and_MCodes_with_Software_Ports.pdf MultiCAM-GCodes_and_MCodes_with_Software_Ports.pdf]
[https://www.brightonk12.com/cms/lib/MI02209968/Centricity/Domain/517/Multi_Cam%20Complete%20M%20and%20G%20Code%20list.pdf Multi_Cam Complete M and G Code list.pdf]
[https://cam.autodesk.com/posts/view.php?name=multicam Sample for MultiCam ISO]
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