Mach3 CNC Controller Software Installation and Configuration

1 Mach3 CNC Controller Software Installation and ConfigurationVersion 3 Copyright 2003, 2004, 2005, 2006, 2008 ArtSoft USA. All Rights following are registered trademarks of Microsoft Corporation: Microsoft, Windows. Any other trademarks used in this manual are the property of the respective trademark send queries, comments, complaints, corrections, and suggested improvements for this manual to: Mach Developer Network (MachDN) is currently hosted at November 6, 2008iii ContentsChapter 1 Introduction to CNC SystemsBefore You.

2 Introduction .. Components of a CNC Machining System .. How Mach3 Fits In .. What Mach3 Can Do .. 1-4 Chapter 2 Installing the Mach3 Installation .. If a machine tool is connected, disconnect it now.. Run the Mach3 Software Installation package.. If You re Using Windows Vista .. Vital Reboot .. Testing The Installation .. You Are Using the Default Parallel Port Driver .. Mach3 Profiles .. a Profile .. Installation Problems .. DriverTest After a Mach3 Crash.

3 Driver Installation and Uninstallation .. 2-9 Chapter 3 Introducing the Mach3 Screens and Screens .. of Objects on Screens .. Buttons and Shortcuts .. Entry to DROs .. Jogging .. Manual Data Input (MDI) and Teaching .. 3-5iv Chapter 4 Hardware Requirements and Connecting the Machine The PC Parallel Port and its History .. Logic Signals .. Breakout Boards .. The EStop Control .. Axis Drive Options .. and Servos .. Axis Drive Requirements .. Example 1 - Mill Table Cross Slide.

4 Example 2 - Router Gantry Drive .. the Step and Dir Signals Work .. Limit and Home Switches .. Switches .. to Mount the Switches .. Mach3 Uses Shared Switches .. Referencing in Action .. Home and Limit Options and Hints .. Home Switch not Near Limit Switch .. Separate High Accuracy Home Switch .. Limit Switches of Multiple Axes Connected Together .. Home Switches of Multiple Axes Connected Together .. Slaving .. Wiring Diagram .. Spindle Control.

5 Motor Control .. and Direction Motor Control .. Motor Control .. Coolant .. Knife Direction Control .. Digitize Probe .. Linear (Glass Scale) Encoders .. Spindle Index Pulse .. Charge Pump a Pulse Monitor .. Other Functions .. Sample Schematic of EStop and Limits Using Relays .. 4-24 Chapter 5 Configuring Mach3 for Your Machine and A Configuration Strategy .. Initial Configuration .. Addresses of Port(s) to Use .. Kernel Speed .. Special Features.

6 Defining Input and Output Signals To Use .. 5-4v and Spindle Output Signals to Be Used .. Signals To Be Used .. Input Signals .. Signals .. Encoder and Manual Pulse Generator (MPG) Inputs .. Setting Up Encoders .. Setting Up MPGs .. the Spindle .. Coolant Control .. Spindle Relay Control .. Motor Control .. Modbus Spindle Control .. General Parameters .. Pulley Ratios .. Special Function .. Options Tab .. Testing .. Defining the Setup Units.

7 Tuning Motors .. the Steps Per Unit .. Calculating Mechanical Drive .. Calculating Motor Steps Per Revolution .. Calculating Mach3 Steps Per Motor Revolution .. Mach3 Steps Per Unit .. the Maximum Motor Speed .. Practical Trials of Motor Speed .. Motor Maximum Speed Calculations .. Automatic Setting of Steps per Unit .. an Acceleration Value .. Inertia and Forces .. Testing Different Acceleration Values .. Why You Want To Avoid a Big Servo Error.

8 Choosing an Acceleration Value .. and Testing Axis .. Repeat Configuration of Other Axes .. Motor Speed Control Setup .. Motor Speed, Spindle Speed, and Pulleys .. Pulse Width Modulated Spindle Controller .. Step and Direction Spindle Controller .. Testing the Spindle Drive .. Other Configuration .. Homing and Soft Limits .. Referencing Speeds and Direction .. Position of Home Switches .. Configure Soft Limits .. G28 Home Location.

9 System Hotkeys .. Backlash .. Slaving .. 5-33vi Toolpath .. Configuration .. General Logic Configuration , Column 1 .. General Logic Configuration , Column 2 .. General Logic Configuration , Column 3 .. General Logic Configuration , Column 4 .. How The Profile Information Is Stored .. Documenting Your Setup .. 5-40 Appendix A Torch Height Controls in Mach3 Figures1-1 Main Parts of a CNC System ..1-32-1 Select Program Components Screen ..2-22-2 Create a Custom Profile Screen.

10 2-32-3 Create Mill Profile ..2-32-4 The Running DriverTest Program ..2-62-5 Profile Selection Window ..2-72-6 Create Profile Window ..2-82-7 Shortcut to MyMill ..2-83-1 Select Control Device Screen ..3-13-2 Screen Selection Tabs ..3-23-3 Control Buttons Flyout ..3-43-4 MDI Example ..3-53-5 Teaching a Rectangle ..3-63-6 Taught Program Running ..3-74-1 Parallel Port Female Connector (seen from back of PC) ..4-24-2 Three Examples of Commercially Available Breakout Boards ..4-44-3 Example of Servo Motor with Encoder.