Mach3 CNC Controller Software Installation and Configuration Version 3 Copyright © 2003, 2004, 2005, 2006, 2008 ArtSoft USA. All Rights Reserved. The following are registered trademarks of Microsoft Corporation: Microsoft, Windows. Any other trademarks used in this manual are the property of the respective trademark holder. Please send queries, comments, complaints, corrections, and suggested improvements for this manual to: [email protected]. The Mach Developer Network (MachDN) is currently hosted at http://www.machsupport.com. Printed November 6, 2008 Contents Chapter 1 Introduction to CNC Systems Before You Begin.... 1-1 1.1 Introduction . 1-2 1.2 Components of a CNC Machining System . 1-2 1.3 How Mach3 Fits In . 1-4 1.4 What Mach3 Can Do . 1-4 Chapter 2 Installing the Mach3 Software 2.1 Installation . 2-1 2.1.1 Downloading . 2-1 2.1.2 Installing . 2-1 2.1.2.1 If a machine tool is connected, disconnect it now. 2-1 2.1.2.2 Run the Mach3 software installation package. 2-2 2.1.2.3 If You’re Using Windows Vista . 2-4 2.1.3 The Vital Reboot . 2-4 2.2 Testing The Installation . 2-4 2.2.1 If You Are Using the Default Parallel Port Driver . 2-5 2.3 Mach3 Profiles . 2-7 2.3.1 Creating a Profile . 2-7 2.4 Installation Problems . 2-9 2.4.1 Running DriverTest After a Mach3 Crash . 2-9 2.4.2 Manual Driver Installation and Uninstallation . 2-9 Chapter 3 Introducing the Mach3 Screens and Com- mands 3.1 Screens . 3-1 3.1.1 Types of Objects on Screens . 3-2 3.1.2 Using Buttons and Shortcuts . 3-3 3.1.3 Data Entry to DROs . 3-3 3.2 Jogging . 3-3 3.3 Manual Data Input (MDI) and Teaching . 3-5 3.3.1 Teaching . 3-5 iii Chapter 4 Hardware Requirements and Connecting the Machine Tool 4.1 The PC Parallel Port and its History . 4-1 4.2 Logic Signals . 4-2 4.2.1 Isolating Breakout Boards . 4-3 4.3 The EStop Control . 4-4 4.4 Axis Drive Options . 4-5 4.4.1 Steppers and Servos . 4-5 4.4.2 Determining Axis Drive Requirements . 4-6 4.4.2.1 Example 1 - Mill Table Cross Slide . 4-6 4.4.2.2 Example 2 - Router Gantry Drive . 4-8 4.4.3 How the Step and Dir Signals Work . 4-8 4.5 Limit and Home Switches . 4-9 4.5.1 The Switches . 4-10 4.5.2 Where to Mount the Switches . 4-13 4.5.3 How Mach3 Uses Shared Switches . 4-14 4.5.4 Home Referencing in Action . 4-14 4.5.5 Other Home and Limit Options and Hints . 4-15 4.5.5.1 Home Switch not Near Limit Switch . 4-15 4.5.5.2 Separate High Accuracy Home Switch . 4-15 4.5.5.3 Limit Switches of Multiple Axes Connected Together . 4-15 4.5.5.4 Home Switches of Multiple Axes Connected Together . 4-15 4.5.5.5 Slaving . 4-15 4.5.6 Summary Wiring Diagram . 4-17 4.6 Spindle Control . 4-18 4.6.1 On/Off Motor Control . 4-18 4.6.2 Step and Direction Motor Control . 4-18 4.6.3 PWM Motor Control . 4-18 4.7 Coolant . 4-20 4.8 Knife Direction Control . 4-20 4.9 Digitize Probe . 4-20 4.10 Linear (Glass Scale) Encoders . 4-20 4.11 Spindle Index Pulse . 4-22 4.12 Charge Pump — a Pulse Monitor . 4-22 4.13 Other Functions . 4-23 4.14 Sample Schematic of EStop and Limits Using Relays . 4-24 Chapter 5 Configuring Mach3 for Your Machine and Drives 5.1 A Configuration Strategy . 5-1 5.2 Initial Configuration . 5-1 5.2.1 Defining Addresses of Port(s) to Use . 5-2 5.2.2 Choosing Kernel Speed . 5-3 5.2.3 Defining Special Features . 5-3 5.3 Defining Input and Output Signals To Use . 5-4 iv 5.3.1 Axis and Spindle Output Signals to Be Used . ..