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RapidPath™ Series

machmotion-logo.jpg

 

RapidPath™ is MachMotion's trademarked EtherCAT motion controller. 

WARNING!
Improper setup of this motion controller can cause DEATH, INJURY or serious PROPERTY DAMAGE. Do not attempt to use this controller until thoroughly reading and understanding this manual.

1. Introduction

1.1  Overview

RapidPath™ is MachMotion's trademarked EtherCAT motion controller. 

1.2  Tools Required

A small, flat head screwdriver is needed for the I/O terminals.

1.4  Specifications

1.5    Software Startup

On the desktop of your control, there is a Mach4 shortcut for your machine type. Below is an example of the Mach4 shortcut.

 mach4-icon.JPG
Profile

There is also a shortcut for Mach4 Loader. This allows any of the profiles to be loaded from one location. Double clicking on the Mach4 Loader shortcut opens the following window: 

 mach4-loader.JPG
Mach4 Profile Loader

After double clicking on a profile or opening a profile from Mach4 Loader, a window will come up (see below) asking to Press Cycle Start to Enable Mach and Home All Axes. Select [Cancel] since motion is not yet possible.

 cycle-start-prompt.jpg
Enable and Home All axes

On subsequent startups, once motion and limit switches are set, press [Cycle Start] and the control will enable and home all axes. This prompt can be turned off in the MachMotion plugin if desired. 

2. Axis Setup

2.1    Enabling Axes

Note: This may already be setup depending on your system.

  1. On the menu bar, click Configure->Mach. Then select the Motors tab (pictured below).
    • Note, if menu options are grayed out (not active/selectable), click the button to disable the system
  2. Enable all the motors that are to be controlled by setting the respective boxes in the right pane to checks. In the example below, motors 0, 1, and 2 are enabled.

mach4-motors-tab.jpg
Motor Setup

  1. Press [Apply] to save any changes.
  2. Next, select the Axis Mapping tab as pictured below. Associate the enabled motors to the applicable axis. In the below example, Motor0 is the X master, Motor1 is the Y master, and Motor2 is the Z master.

axis-mapping.JPG
Axis Mapping

  1. Press [Apply] and [OK] to save and close.

The system is now set up for motion, however,....

WARNING
The machine can be crashed very easily. No limits have been set up and the units have not been configured yet.

2.2    Axis Calibration

For the machine to move the correct distance, the axes need to be calibrated. To get the units perfect, they must be calculated automatically from the machine specifications. However, you can get them extremely close if you manually calibrate especially if you measure at greater distances of travel.

Go to Configure-> Plugins -> Machine Calibration.

Note, if menu options are grayed out (not active/selectable), click the button to disable the system

Select the type of configuration you would like to perform from the window:

  1. Manual; Calculate the steps per by comparing distance traveled vs. distance commanded. See the next section for instructions.
  2. Automatic; Calibrate motors using specifications of your motor type. Continue for instructions.
  3. Screw Mapping; Calibrate motors using points on the ball screw.

2.2.1    Automatic Calibration 

  1. Select the type of configuration you would like to perform
    1. Manual; Calculate the steps per by comparing distance traveled vs. distance commanded. See the next section for instructions.
    2. Automatic; Calibrate motors using specifications of your motor type. Continue for instructions.
    3. Screw Mapping; Calibrate motors using the wizard to map the ball screw.
  2. Select the drive type of the axis being configured.
  3. Select the max motor RPM.
  4. Verify the correct drive ratio.
      Drive Type
      CTB
      Delta
      Yaskawa
    Default Drive Ratio Value

    automatic-calibration.JPG
    MachMotion Plugin Calibration Calculator
  5. Choose the machine configuration for the axis from the following three options.
    • Ball Screw
      • Enter the ball screw pitch
      • Enter the ball screw pulley # teeth and motor pulley # teeth

        Note: If the system has a pulley ratio and a gear box use this equation to get the total gear ratio: [Gear Box Ratio] x [Pulley Ratio] = [Total Gear Ratio] Ex: [10:1 Gear Box] x [30 Motor Pulley Teeth/15 Ball Screw Pulley Teeth] = [10] x [30/15] = [20 Total Gear Ratio](20 Motor Pulley Teeth, 1 Ball Screw Pulley Teeth)
    • Rack and Pinion – Pinion Diameter
      • Enter pinion diameter
      • Enter the gearing ratio between the shaft and the motor
    • Rack and Pinion – Rack Pitch
      • Enter number of teeth on pinion
      • Enter the rack pitch
      • Enter the gearing ratio between the shaft and the motor
  6. Select the axis to calibrate.
  7. Press the [Calculate] button.
  8. Choose [Accept] or [Ignore] to save or discard the changes.
  9. Repeat starting at step 2 for each additional axis.
  10. Press [OK] and restart the software to save the calibration settings.

2.2.2    Manual Calibration

manual-calibration.JPG
Manual Calibration

  1. Select Manual Calibration from the Machine Calibration Selector menu.
  2. Select the axis to calibrate.
  3. Select either Jog Distance or Commanded Distance.
  4. Enable the system and either press [Move] or [Record Jog].
    • For Jog Distance mode, manually jog the axis a distance that can be accurately measured.
  5. Measure how far the axis moved.
  6. Enter in the distance the axis moved and press [Submit].
  7. Choose [Accept] or [Ignore] to save or discard the changes.
  8. Repeat this procedure until the axis is within the required accuracy.

If you want to adjust your velocity, select Configure on the top menu bar, then Mach. Select the Motors tab as shown below.

 

<Insert Image>

Motor Setup

 

In the right pane, select the motor you want to set up. The selected motor’s parameters will be loaded and the velocity or acceleration settings can be adjusted.  

Press [Apply] before clicking on another motor or closing out the Mach Configuration window.

WARNING
No limits have been set up.  DEATH, INJURY or serious PROPERTY DAMAGE can occur if the system is not operated carefully.

2.2.3    Screw Mapping Calibration

manual-calibration.JPG
Screw Mapping

  1. Select Screw Mapping from the Machine Calibration Selector menu.
  2. Select the axis to calibrate.
  3. Select either Jog Distance or Commanded Distance.
  4. Enable the system and either press [Move] or [Record Jog].
    • For Jog Distance mode, manually jog the axis a distance that can be accurately measured.
  5. Measure how far the axis moved.
  6. Enter in the distance the axis moved and press [Submit].
  7. Choose [Accept] or [Ignore] to save or discard the changes.
  8. Repeat this procedure until the axis is within the required accuracy.

 

2.3    Backlash Calculation

Mach Motion controls have has backlash compensation. Use the MDI line to enter G-Code to move the axes. To calculate the machine’s backlash, follow the steps below.

        1. Move an axis in one direction farther than the maximum possible backlash.
        2. Mount a dial indicator and zero it.
        3. Move the axis again in the same direction for a specific distance (it doesn’t matter how far).
        4. Move the axis backwards the same distance.
        5. Note how far the dial indicator was off from zero to see the axis’s backlash value.
        6. Backlash is configured in the Mach4 software located in Configure->Control->Motors Tab.
        7. Select the desired motor tab and enter the value (see explanation below). Select [OK] to save settings.

Backlash – This field sets the backlash amount in inches or millimeters, depending on the setup units.

RapidPath-Backlash.JPG

Backlash

WARNING
For best performance, backlash should be less than .0015 inches.

2.4    Reversing Direction

If a motor moves the wrong direction, it can be reversed in the software.

1. Navigate to the menu bar and click Configure->Control and select the Motors

The following window will come up:

RapidPath-Reverse.JPG

Reverse Motor

2. Check the Reverse? box if the motor direction needs to be reversed.

3. After making all the changes, press [OK].

The motor will now move the opposite direction than it did before.

2.5    Slaving a Motor

To configure a motor as a slave, follow the steps outlined below.

        1. Click Configure->Mach on the main menu bar and select the Axis Mapping
        2. Select the motor from the dropdown menu for the axis that the motor will be slaved to. Each enabled axis must have one master and up to 5 slave motors. For example, the configuration below is used to slave Motor3 to Motor0 on the X axis.

insertimage Figure 18 Motor3 slaved to Motor0

        1. Press [OK] to save changes.

3. Spindle Setup  (is this still applicable for the 2000 series kneemill?)

 

3.1    Wiring a Spindle

3.1.1    VFD from MachMotion

The process for setting up a VFD from MachMotion is extremely simple. 

3.1.2    VFD Other Than from MachMotion

Any VFD can be wired into the Spindle Control RJ45 jack by cutting the end off of a CAT5 cable and wiring the loose ends to the VFD according the following pin out.

Function

Analog 0-10VDC

CW Relay

CW Relay

Drive Enable

GND

N/C

CCW Relay

CCW Relay

RJ45 Pins

1

2

3

4

5

6

7

8

Colors

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

 

3.1.3    No VFD

Figure 21 No VFD Spindle Wiring

3.2    Spindle Configuration

3.2.1    Spindle Range Setup

For the control to know how to scale the analog voltage output, the maximum RPM for the spindle motor must be defined. If the machine has different ranges, the software can have multiple maximum speeds. The software uses a different range for each different speed configuration.

For example, one range could be set as 75 to 300 RPM for a low speed. A medium speed range could go from 300 to 1200 RPM and high speed range could run from 1200 to 2400 RPM. The control will output 10V when the MaxRPM is called for any speed range.

To define the range(s), go to Configure->Mach. Select the Spindle tab as shown below.

 Pulley Speed Setup

Enter in the maximum and minimum speeds for each range. The accel and decel time should also be defined for each range (seconds to max rpm). Press [OK] to save changes.

Note: Only set up multiple ranges if the machine has different gears/pulleys.

Note: If the spindle is turning the wrong direction check the reversed box in the applicable range.

The ranges can be changed from the control by using M40-M45. The macros can be used to just change ranges or they can be used to automatically change gears on the machine. To shift the machine range 0, run M40. M41 is range 1, M42 is range 2, and so on.

3.3    Turning on the Spindle

To control the spindle use the following M-Codes with an S word for spindle RPM in the MDI line (Ex. M3 S2000).

M-Code

Function

M3

Clockwise

M4

Counterclockwise

M5

Stop

Table 5 Spindle M-Codes

If the spindle is not running correctly at this point some settings may need to change inside the VFD. In this situation, reference the VFD manufacturer manual.

Note: See the Mitsubishi VFD Installation Guide for setup information if it was purchased from MachMotion.

4. Limits and Homing Setup

Note: For the highest level of safety, wire the limit switches Normally Closed.

Note: Each motor has three signals, the max travel (motor ++), the min travel (motor --), and the home (motor home). All three must be enabled and set to the correct device and input name for everything to work correctly using the wiring description above.

Note: Under the active low column the active state can be changed by clicking on the [X] or check mark. If the limit switches are normally open the red X should be used. However, this is not recommended as it is not as safe.

4.1    Homing Setup

WARNING

        1. Open to the menu bar and click Configure->Mach. Select the Homing/SoftLimits tab as shown below.

4.2    Soft Limits Setup

With machine homed correctly and soft limits set, the machine will not hit a physical limit switch. If at any time a command is made for the machine to move outside of the soft limits (while they are enabled), an error will appear in the status line and motion will stop. To set up the soft limits, follow the procedure outlined below.

        1. Home the machine.
        2. Select to view Machine Coordinates on the Locked screen view so that the DRO’s are red.
        3. Jog the machine to the maximum distance from the homing switches.

Note: Make sure to stay inside the physical limit switches. If the machine is jogged outside of the limit switches, it completely defeats the purpose of soft limits.

        1. Record the machine coordinates at the end of the travel.
        2. Open the menu bar and click Configure->Mach and select the Homing/SoftLimits tab as shown below.
        3. Enable soft limits on each desired axis and enter in the recorded values.

Note: If the value is positive, place it into the Soft Max limit and set the Soft Min limit to zero. Otherwise, with a negative value, set the Soft Max to zero and the Soft Min to the recorded value.

        1. Press [OK] to save changes. Test the soft limits by jogging the axes to maximum amounts in all directions.

Figure 26 Soft Limits

Note: When loading a G-code file, the tool path display will show the soft limits as dashed lines. If any part of the tool path renders outside the soft limits, check your file.

5. Input Setup

6. Output Setup

6.4    Using Outputs

Outputs 0-5 can be controlled with M-Codes. One M-Code will turn an output on, and the next M-Code turns the output off. Use the table below for a reference.

Custom M-Codes

Functions

Default Output

M200

Output 0 on

 

M201

Output 0 off

M202

Output 1 on

 

M203

Output 1 off

M204

Output 2 on

 

M205

Output 2 off

M206

Output 3 on

 

M207

Output 3 off

M208

Output 4 on

 

M209

Output 4 off

M210

Output 5 on

 

M211

Output 5 off

Table 7 M-Codes for Outputs

The outputs can also be accessed inside the MachMotion plugin.

7. Advanced Options

A number of advanced features can be accessed and configured in the MachMotion plugin such as periodic oiler control and custom user messages (Global Messaging). Begin by going to Configure->Plugins to open the MachMotion plugin.

insertimage Figure 39 - MachMotion Plugin Options

The Machine Parameters tab contains custom options for the control, including dialogue options, lube system, tool measurement/offsets, and tool changer options.

7.1    Lube System Setup

The system may require an oiler. Enable the lube system, choose an action trigger, set the lube output, set the time run time of the oiler, and the time between cycles. In the example below the lube output will turn on when the spindle is running for 10 seconds every 15 minutes.

Figure 40 Lube System Setup

It is also possible to define input activated user messages/actions. See the section on the Global Messaging System below.

7.2    Tool Setter Setup

Before you measure tool to setup your tool table, the tool setter options must first be defined. Begin by going to Configure->Plugins to open the MachMotion plugin.

Figure 41 tool Setter options

The Tool Setter Type options are manual or automatic. The Tool Setter/Gage-Block Position Type options are fixed (e.g., a bed mill) and random (e.g., a knee mill). If fixed, the tool setter/gage block position should be determined. In machine coordinates, the Z-axis position of the table should recorded and saved.

To use the automatic tool setter, the remaining tool setter options must be configured. A probe input must also be wired in and setup as the Digitize input signal.

Figure 42 Digitize input signal

7.3    Global Messaging System

Global Messaging is used to setup user alerts or messages as well as to control I/O functionality based on certain conditions. To access the Global Messaging System, go to Configure -> Plugins -> MachMotion and select the Global Messaging System tab. The system allows the machine to watch for specified conditions, and take action when those conditions are met. For information on creating, editing, or deleting a message, visit our knowledge base online at: http://machmotion.com/support/kb#11714098. You can also navigate to it by visiting MachMotion.com and selecting the Knowledge Base link under the Support menu option.

 __________Not editing below this point _____________

Part 2:

 Advanded Setup

8         Part 2: Advanced Setup

 

 

Ethernet

Figure 43 Ethernet Connector

8.1.1    Direct Connection

To set up the Apollo III to communicate with the control directly, the network configuration needs to be assigned a static IP address. The default static IP configuration is defined below.

 

Location

IP Address

Apollo III

192.168.208.35

Computer

192.168.208.10

Table 9 Static ip addresses

 

Figure 44 Direct Network Configuration

8.1.1.1    Configuring a Static IP Address on Windows 7

        1. Click on the network icon on the system tray.

Figure 45 System Tray

        1. Click on Open Network and Sharing Center.
        2. In the top left corner of the Network and Sharing Center window click on Change adapter settings.
        3. Right click on the network port that the Apollo III is connected to and select
        4. From the list below double click on Internet Protocol Version 4.

Figure 46 Local Area Connection Properties

        1. Fill out the options as seen below.

Figure 47 IPv4 Properties

        1. Press [OK] and close out the rest of the windows.

The control now has the correct static IP address.

8.1.2    Router Connection

When using a network router to connect the Apollo III to the control there is no special network setup required. The router will take care of the IP assignments.

Figure 48 Network Connection Through a Router

8.2    Apollo III Software Installation

8.2.1    Installing Apollo III Plugin and Firmware

The plugin and firmware manage the communication and operation of the Apollo III.

Once the files are downloaded on the control, put them in the locations specified below.

 

File Type

File Name

Location

Plugin

M4HiCON.m4pw M4HiCON .sig

C:\Mach4\PlugIns

Firmware

HiCONfw-X.XX.bin

C:\Mach4\MotionControllers\Apollo III

Table 9 Apollo III Files and Locations

Note: If the file location for the firmware does not exist, create the folders.

8.2.2    Using VSI Manager

The VSI manager interfaces with the Apollo III motion controller for updating firmware and managing the connection.

 

To download the firmware to the Apollo III, follow the procedure below:

        1. Open the VSI Device Manager
        2. Click on the [Scan Network]

Figure 49 VSI Device Manager

Note: A device should show up as shown.

        1. Select the device and press [Switch To Loader].
        2. Click through the message windows that pop up and click on [Load File].
        3. Select the .bin file from the location specified above.
        4. Press [Program Flash] and wait until it finishes programming.
        5. Press [OK] when it asks to reboot to launch the new firmware.
        6. Close the device manager.
        7. Manually cycle power to the Apollo III by removing the 24V power supply to the board and repower.

The firmware should now be updated.

 

 

WARNING
 Install the plugin AND download the firmware to the Apollo III. If the firmware and plugin versions do not match, it could cause serious damage to the machine or cause the Apollo III not to operate at all.

8.3    Mach4 Integration

8.3.1    Mach4 Startup

Open up the Mach4 software, making sure to select the correct profile. If you are starting from a blank profile you may be asked to select a motion device. Select the M4HiCON plugin as shown below. Otherwise, the profile had previously selected the device. Navigate to the selection menu by selecting Configure->Select Motion Dev…

Figure 50 Motion device Selection Window

After Mach4 has completely loaded, attempt to enable the control. If the status bar in Mach4 says “ERROR: Connection to HiCON lost…,” then check the Ethernet cable’s connection and the control’s IP configuration. If Mach4 continually pops up with errors, make sure that the correct firmware (that matches the current plugin) is downloaded in the Apollo III. You can also check the HiCON status window (see below) for connection status in the properties section.

8.4    Apollo III Status Window

To view the status of the Apollo III from inside the software, select Diagnostic on the top menu bar and then select the HiCON option.

 

The HiCON Status window shows the current state of the encoders, the inputs, and the outputs.

 

Figure 51 HiCON Status Window

This window can be left open while running the software. The statuses of input and output names for the HiCON device are also shown.

Note: The HiCON Status window is a great place to check for encoder feedback.

8.5    Apollo III Configuration

To change anything inside the controller, the HiCON plugin must be used. Select Configure->Plugins and then select the HiCON (vX.XX.XX) – Vital System Inc. plugin.

 

Once the HiCON plugin config is launched, a window with the following seven tabs will appear:

        1. System
        2. Motor[0]
        3. Motor[1]
        4. Motor[2]
        5. Motor[3]
        6. Motor[4]
        7. Motor[5]

 

Each motor tab besides the System tab represents a motor to be controlled through the Apollo III.  By default, the System tab will be selected as shown below.

 

Figure 52 HiCON Configuration Window

At any time while inside the plugin, clicking on the [Update HiCON] button will transmit the settings to the Apollo III motion controller.  Clicking [OK] will also transmit the settings to the controller and save them in the selected Mach4 profile (e.g. Mach4Mill, etc).

 

To exit the plugin, press [OK] and then [OK] again on the PlugIn Control and Activation window. Now, with a brief overview of the Apollo III, it is time to start configuring the controller.

 

 

9         Enable Circuit

The Apollo III has a hardware enable and a drive enable circuit. However, before they will work, the emergency stop circuit must be set up. Use the table below as a quick reference for the different signals.

 

Mach4 Name

Signal Name

Device

Name

Active

Input / Output

Hardware Enable

---

HiCON

[P14]Output0

---

Output

Drive Enable

---

HiCON

[P14]Output1

---

Output

E-Stop

E-Stop

HiCON

[P14]Input5

Low (Green Check)

Input


Table 10 Enable Circuits

See details for Hardware and Drive Enable in the following sections.

 

 

WARNING
Do NOT connect 115VAC to any part of the Apollo III motion controller.
It could cause serious damage to the controller.

 

 

9.1    Emergency Stop

The emergency stop connector is located right below the power connector on the Apollo III. When the emergency stop terminals are connected together, the red E-Stop LED turns on and the controller can then enable.

 

E-Stop

E-Stop

Figure 53 Emergency Stop Connection

Note: Nothing will work on the Apollo III motion controller unless the Emergency Stop terminals are connected together!

Emergency stop input is set up inside the software by setting the E-Stop to HiCON [P14] Input5. When it is set up correctly, any time the emergency stop terminals are disconnected, the system will be disabled.

Figure 54 Software E-Stop Setup

9.2    Hardware Enable

The hardware enable is the main enable circuit. It enables all the components on the Apollo III, turns on the 5V enable (5EN) and the 24V enable signals (24EN), and activates the hardware enable relay (HEN). When the hardware enable is set up correctly, it will only activate when there are no emergency conditions. Tripping the emergency circuit or a limit switch will disable the hardware enable. Remember that the emergency stop terminals must be connected for anything to enable.

 

The 5V and 24V enable signals can be used for any low current applications. The hardware enable relay can be used for higher current applications up to 48V if an external voltage source is provided (see Specifications section for more detail). The signals are labeled 5EN, 24EN, and HEN on the Apollo III terminal block TB2 as shown below.

Figure 55 Hardware Enable Signals

View the diagram below for an example of the hardware enable relay wiring.

Figure 56 Hardware Enable Relay Example

The green LED (labeled Enable) turns on as soon as the controller detects the enable signal from the control. The LED does not mean that the hardware enable circuit is activated. The hardware enable circuit is only activated when the red (E-Stop), orange (Power), and green (Enable) LEDs are on.

Enable

Figure 57 Hardware Enable LED

Hardware enable is set up inside the MachMotion plugin. 

 

 

Figure 58 Mach4 Hardware Enable Setup

Double click to change the value and the following window will appear:

Figure 59 Device and Signal Selector

Select the appropriate device, option, and I/O signal. Settings for Hardware Enable are shown above.

9.3    Drive Enable

Drive enable is used to enable all the drives. When activated the drive enable relay connects the external enable (EXT) to the servo enable (SOV) terminals on TB2.  The signal SOV runs to each axis control RJ45 jack. EXT can be jumpered to 5V, 24V, GND, or any other DC voltage up to 48V for different enable signals depending on what the servo drives require.

Figure 60 Drive Enable Signals

The Mitsubishi, Yaskawa, and TECO servo drives from MachMotion are all enabled with a ground signal. Therefore EXT and GND are connected together as shown below.

Figure 61 Drive Enable Example

The blue LED (labeled Drive Enable) on the top middle of the controller turns on as soon as the drive enable signal from the control is detected. The blue LED does not mean that the drive enable relay is activated. The drive enable relay is only activated when the red (E-Stop), green (Enable), and blue (Drive Enable) LEDs are on.

Drive

 

 

Figure 62 Drive Enable LED

If the system needs to use the drive enable signal without using the axis control cables, just connect the signal directly to SOV.

 

Drive enable is set up inside the MachMotion plugin.   

Figure 63 Drive Enable Setup

Double click to change the value and the following window will appear:

 

Figure 64 Device and Signal Selector

Select the appropriate device (HiCON), option (I/O), and I/O signal ([P14] Output 1). With the enable circuits set up, the next step is to set up the machine motors.

 

 

10    Motors

To set up the motors, the drives must be connected to the controller, the Apollo III controller must be configured, and the control software must be set up as defined below.

10.1    Connecting Drives

The Apollo III motion controller uses step and direction to control the axes. It can use differential or single-ended outputs. For differential outputs there are two signals for step (step + and step -) and two signals for direction (direction + and direction -). For single-ended there is only one signal for both step and direction. All MachMotion products use differential outputs.

10.1.1    Differential Control

Most systems use differential step and direction. The step and direction outputs are located on the bottom row of RJ1, the large RJ45 jack block. See the diagram below.

 

Motor0

1 Axis

2

3

4

5

Figure 65 Differential Step and Direction RJ45 Jacks

 The pinout for the RJ45 jacks is shown below.

Function

Reserved

Drive Error

Direction +

Drive Enable

GND

Direction -

Step +

Step -

RJ45 Pins

1

2

3

4

5

6

7

8

Colors

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

Table 11 Axis Control RJ45 Jack Pinouts

Any drive from MachMotion can be plugged directly into the motor control RJ45 jacks.

10.1.2     Single-Ended Control

To use single-ended control use the terminals on TB1 (the large green terminal block). The top row is for the direction signals and the middle row is for the step signals. The first letter on each terminal is the axis name and the second letter is the function (D for direction and S for step). See the picture below.

 

Step

Direction

Table 10 Singled-Ended Step and Direction Terminals

With the drives connected it is time to connect the encoder feedback. Skip the next section if the system does not have encoder feedback or if it is not going to be set up at this time.

10.1.3     Encoder Feedback

The encoder feedback inputs are located on the top of RJ1. The encoder signal for each axis is directly above the control signal. See the diagram below.

 

Motor 0

 

1

2

3

4

5

Figure 66 Encoder Feedback RJ45 Jacks

The Apollo III uses a 5V encoder signal. See the pinout below.

Function

A+

A-

B+

5V

GND

B-

I+

I-

RJ45 Pins

1

2

3

4

5

6

7

8

Colors

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

Table 12 Encoder Feedback RJ45 Jack Pinout

Again any drives purchased from MachMotion can have their encoder feedback plugged directly into the encoder RJ45 jacks.

10.2    Configuring Motors

The motors must also be configured inside the HiCON plugin. Begin by opening up the plugin in the Configure->Plugins menu. Select the tab corresponding to the motor to be configured.

Figure 67 X Axis Configuration

The control parameters are used to configure the motor. Verify that the index values match the motor value.

 

The default parameters are shown below:

 

Parameter Name

Value

Source

MACHxx

Index

N*

Gain

1

Output

Stepper

Feedback

Encoder

Max Follow Error

10000

Table 13 Control Parameters

*N is the motor number with 0 being Motor0, 1 being Motor1, 2 being Motor2, etc.

To update the control parameters, press the [Update HiCON] button.  Clicking on [OK] or the [SAVE CONFIGURATION] buttons saves the entire configuration to the selected Mach4 profile.

 

The motors should now be set up enough to jog the machine.

WARNING
The machine has not been calibrated so it could jog at extremely high speeds and move erroneous distances. Also, no limits have been set up so DEATH, INJURY or serious PROPERTY DAMAGE could result if extreme caution is not used.



If more information is desired about the control parameters, please read the section below.

10.2.1     Control Parameters

Control Input Source – Source defines the input type for the controller for a particular axis.  This should be set to MACHxx.  If the axis is not used, it must be disabled by selecting Undefined.

Index – Index defines the index of the controller source.  This is equal to the motor number. 

Gain – The control input (commanded) is multiplied by this number. Leave this at 1 for most applications.

Control Output – Output defines the output for the controller for a particular motor.  The possible values are:

StepGenX: This setting uses step and direction as the output. X refers to the motor number.

Undefined: This setting is used to disable the motor and to ignore the control output index.  If the motor is not enabled, then the Output must be set to Undefined.

Feedback – Feedback defines the feedback type for the controller for the selected axis.  The possible values are:

Encoder: Use one of the differential hardware encoder inputs 0…8 as the feedback.

Max Follow Error – Defines the number of steps between the commanded position and the actual position (from the encoder feedback) before an emergency condition is triggered. This value is only applicable if the system is using encoder feedback. A common value is 70% of the steps per value.

Homing Type – Defines the homing sequence for each axis.  Two types of homing sequences are supported:

Home Sensor:  (Homing with or without an Index Pulse)
The axis moves in the configured direction until a home sensor is seen.  It then moves in the opposite direction at 20% of initial speed until the sensor is not seen. If Use Index Pulse is checked, then the axis will continue moving until it finds the index pulse.  At this point the home position is defined. 

IndexPulseOnly: (Use only the Index pulse to Home)

The axis moves in the configured direction to locate the index pulse to home the axis.  As soon as the index pulse is detected, it clears the position counter to indicate the home position and stops the axis.

Slave Misalignment – A value in machine units that moves a slaved motor this specified distance after homing to re-align with the master motor.

Independent Master/Slave Home –  If checked, a master and slave motor will home to signals setup for the respective motors.

10.3    Testing Motion

The test motion module is only useful if encoder feedback is being used. For most applications this will never be needed. However, this can be used to optimize the system acceleration and velocity. It allows the following error of the machine to be viewed during commanded movements. Utilize the figure below as a reference.

Figure 68 Test Motion

Follow the steps below to test motion.

        1. Enter in the desired axis velocity in units per minute
        2. Enter in the desired acceleration value for the machine
        3. Select the Relative or Absolute option

Note: Relative moves the machine X distance from its current position. Absolute moves the machine to the machine coordinate position (distance from home). Relative is generally recommended.

        1. Enter the distance in the Position user input.
        2. Press the button DRIVE ON to turn on the LED beneath the button. This enables the drives. When the LED is green, the drives are enabled.

Note: To download a new configuration to the Apollo III, DRIVE ON must be disabled.

        1. Press EXECUTE to command the movement

The motor can also be homed by pressing the HOME button. Make sure that homing is set up in the software before using this function.

 

By selecting the AutoReverse check box, the system can make the axis reverse direction automatically for the next motion command and thus avoid the motor continuing on in one direction during testing.  The Ready LED shows if the Apollo III is ready to accept a motion command.  If the Ready LED is green, it implies that the controller is ready to accept new motion commands.  While executing a motion profile, the Ready LED turns to red and Apollo III cannot accept a new motion command until the current motion sequence is completed or cancelled.

 

Once the test motion command has completed, the accuracy of the commanded motion profile can be seen on the on the Motor/Drive Response graph.  The acceleration and velocity can be optimized to get the machine’s following error to a minimum.

 

Figure 69 Motor/Drive Response Graph

The blue line represents the actual position, the red line shows the commanded position, and the green line displays the actual speed. Therefore the distance between the blue line and the red line is the following error.

Below is a review of all the test motion parameters. Read this section for more information.

10.3.1     Test Motion Parameters

Position – Test motion final position or displacement in terms of Position Units, e.g. 1.5, 10.093, mm or inches etc.

Acceleration – Test motion acceleration value in terms of Units per second squared, e.g. inches/second2, mm/sec2 etc.

Velocity – Test motion velocity value in terms of Units per minute, e.g. inches/minute, mm/minute etc.

Relative and Absolute – These check boxes indicate whether the value in the Position field is the distance to travel (relative) or the final position (absolute).

Execute Button – Transmits Execute Motion command to Apollo III.  In addition, it also downloads control parameters before starting the motion.  User can press the CANCEL button to cancel the motion execution anytime during the machine operation.   Make sure that the motor control settings have been downloaded by clicking UPDATE HICON before clicking on EXECUTE.  Motion commands can be run by pressing the EXECUTE button when the Ready LED is green.

DRIVE ON Button – By clicking this button, the plugin downloads the parameters and enables the drives.  If DRIVE ON is active, the LED below this button will turn to green. Otherwise it will be red.

HOME Button – Executes the homing sequence based on selected homing settings.

Reverse - Checking this option will multiply the parameter in the position box with -1 and thus the direction of motion will be reversed.

Auto Reverse -  Checking the auto reverse option will toggle the “reverse” option between two consecutive motion commands, thus the user does not have to manually reverse the direction of the motion every time.

Axis Position Display (DRO) – Shows the position of the motor based on the different settings as described below:

Show units - When this option is selected, the data shown will be converted and shown in units (mm, inches etc), otherwise data will be displayed in raw encoder counts.

Figure 70 Axis display position

Commanded position - Displays the value of the internal variable for the commanded position for the selected motor.

Load Encoder - Displays the axis position derived from backlash count and selected feedback encoder.

Motor Encoder – Displays the current value of the axis position derived only from the encoder feedback.

 

 

10.4    Backlash Compensation

The Apollo III has backlash compensation. The backlash amount is applied in the motion controller configure menu (Configure->Mach). Select the desired Motor tab as below.

 

Figure 71 Backlash Compensation

Backlash (mm, inch) – This field represents the amount of backlash present in the selected motor/axis in setup units.

Backlash Speed % – This field adjusts the maximum acceleration that the backlash counts can be applied. The Apollo III takes the max acceleration from the motor tuning and multiplies it by this percentage. Valid values are 10-400 (0.1 to 4 times max acceleration).

10.5    Reversing Direction

If a motor moves the wrong direction, it can be reversed in the control software.

        1. Navigate to the menu bar and click Configure->Mach and select the Motors Then select the desired motor from the right pane.

The following window will come up:

 

Figure 72 Reversing Direction

        1. Place a check in the Reverse? box to reverse the motor.
        2. After making all the changes, press [OK].

 

 

10.6    Axis Mapping and Slaving a Motor

To map motors to axes or to configure a motor as a slave, follow the steps outlined below.

        1. Click Configure->Mach on the main menu bar and select the Axis Mapping

Figure 73 Axis mapping tab

        1. Each enabled axis must have one master motor and up to five slave motors
        2. Press [OK] and then restart the software

 

 

11    Spindle

This section goes through the wiring and configuration process for spindle integration with the control software. The Apollo III spindle control consists of a 0-10V analog signal for spindle speed and two relays (CW and CCW) for spindle direction. Below the spindle terminals there are two LEDs for spindle forward (FWD) and reverse (REV). If these LEDs turn on correctly, then the spindle is set up.

 

Figure 74 Spindle LEDs

11.1    Wiring a Spindle

11.1.1      VFD

Any VFD can be wired into the Spindle Control RJ45 jack by cutting the end off of a CAT5 cable and wiring the loose ends to the VFD according the following pin out.

 

Function

Analog 0-10VDC

CW Relay

CW Relay

Drive Enable

GND

N/C

CCW Relay

CCW Relay

RJ45 Pins

1

2

3

4

5

6

7

8

Colors

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

Table 14 Spindle Control RJ45 Jack

11.1.2     VFD from MachMotion

The process for setting up a VFD from MachMotion is extremely simple. Simply plug the control cable into the Spindle Control RJ45 jack located on the bottom row of the large RJ45 jack block.

 

Figure 75 Spindle Control RJ45 Jack

11.1.3     No VFD

If the system does not use a VFD to control the spindle, wire the spindle into the small green connecter as shown below. Notice that 24V is wired to the CW and CCW relay contacts on the top row of the green connector.

Figure 76 Relay-only Spindle wiring

11.1.4    Spindle Feedback

The Apollo III takes a 5V encoder signal as spindle feedback. Connect it into the top row of RJ1 as shown below.

 

Figure 77 Spindle Feedback RJ45 Jack

The pin out for the spindle feedback RJ45 jack is shown below.

Function

A+

A-

B+

5V

GND

B-

I+

I-

RJ45 Pins

1

2

3

4

5

6

7

8

Colors

White & Orange

Orange

White & Green

Blue

White & Blue

Green

White & Brown

Brown

Table 15 Spindle Feedback RJ45 Jack

11.2    Configuring the Spindle

11.2.1     Enabling the Spindle

Follow the directions below to enable the spindle inside the control software.

        1. Select Configure->Mach and then click on the Output Signals tab
        2. Enable Spindle Fwd and Spindle Rev signals and set them up to Device/Input Name of HiCON [P14] Input6 and [P14] Input7 respectively as shown below. Make sure that the Active Low column is set to a red “X” for both outputs.

Figure 78 Spindle Outputs

        1. Press [APPLY] to save the changes and then [OK].

The spindle is now enabled.

11.2.2     Spindle Pulley Setup

For the software to know how to scale the analog voltage output, the maximum RPM for the spindle motor must be defined. If the machine has different gears, the software can have multiple maximum speeds. The control software uses a different pulley for each different speed configuration.

 

For example, one pulley could be set to 75 to 300 RPM for a low speed (at 300 RPM the control will output 10V). A medium speed pulley could go from 300 to 1200 RPM and high speed pulley could run from 1200 to 2400 RPM.

 

To change the pulleys, go to Configure->Mach and select the Spindle tab.

 

Figure 79 Pulley Speed Setup

Note: Only set up multiple pulleys if the machine has different gears.

Note: If the spindle is turning the wrong direction check the reversed column for the corresponding pulley.

 

The ranges can also be changed by using M40-M45. The macros can be used to just change ranges or they can be used to automatically change gears on the machine. To shift the machine range 0, run M40. M41 is range 1, M42 is range 2, and so on.

11.2.3     Analog Calibration

On the Systems tab if the HiCON plugin, the spindle voltage can be adjusted by changing the percentage (10-200%). Most systems will not require this value to be changed. However, if the voltage is not close enough, the percentage adjustment can be calculated with the following formula:

 

Analog Spindle Scale % = Commanded Voltage/Actual Voltage*100

 

Figure 80 Spindle DAC

11.2.4     RPM Feedback

If the spindle has encoder feedback, set up the Threading section. Set the RPM Sync Source to Encoder, the RPM Sync Index to 6, and the RPM Counts/Rev to the number of encoder pulses per revolution.

Figure 81 Spindle Feedback Settings

11.2.5     Turning on the Spindle

In addition to the screen controls the spindle can also be controlled using M-codes. Use the table below as a reference.

M-Code

Function

M3

Clockwise

M4

Counter/Clockwise

M5

Stop


          Table 17 Spindle M-Codes

 

 

 

 

12    Inputs

The Apollo III has 16 configurable inputs. These inputs can be used for limit switches, home switches, tool changers, or anything else. As shown below, the inputs are located on the main green terminal block, TB1.

Jumper

LEDs

Input

Figure 82 Inputs

Each input has an LED that shows the current state of the input. Both the LED and input are labeled with the input name. The inputs start counting from X0 and up to X15. If the LED is on, then the input is activated. Different configurations can be selected for each input by using the jumpers near the bottom right of Apollo III. The jumpers start counting from the left at X0 and increment up to X15. Each jumper corresponds to an input. For example, the jumper labeled X10 corresponds to the input on TB1 labeled X10 and the LED X10.

 

Figure 83 Input Jumpers

Figure 84 Jumper Positions

 

WARNING
Input X0 is configured as drive fault by default. If you have servo drives from MachMotion, DO NOT connect anything to X0. It could damage your drives or Apollo III motion controller.

 



 

 

The figure below shows the schematic of an input where S is the input number. The jumper only shows the three pins used for that input. Comparing it to Figure 89, pin 3 is on the top and the pin 1 is on the bottom.

Figure 85 Input schematic

12.1    Wiring Inputs

12.1.1   Standard 24V Inputs

For a standard 24V input, place the jumper on the bottom two pins. Next, connect C0+ to 24V and C0- to GND on TB1 as shown below.

Figure 86 - 24V Configuration

Then connect the input to the input terminal on the middle row (X1, X2, etc.). See the diagram below.

Figure 87 Standard 24V Input

To activate the input, 24V must be supplied to the input. A floating signal or a ground will not turn on the input. The LED corresponding to the input will turn on brightly when the input is activated.

12.1.2  High Voltage Sourcing Inputs (PNP)

For 9-48V inputs, supply the positive voltage to the C0+ terminal and connect ground to C0-. Set the jumper for the input to the bottom two terminals. Then connect the signal into the corresponding input.

For example, the Apollo III shown below is set up for 30V. Notice that input X4 is connected to a switch.

Figure 88 - High Voltage Sourcing Inputs

Note: All the inputs use the same common.

Below is another example with a 12V PNP proxy sensor.

Figure 89 - 12V Proxy Example

12.1.3     Low Voltage Sourcing Inputs (PNP)

For 2.5-10V inputs, connect the positive voltage to the C0+ terminal and ground to C0-. Completely remove the jumper corresponding to the input and connect XNL (where N represents the input number) to GND. Then connect the signal to the corresponding input.

Assuming that the jumper for X5 has been removed, the example below shows how to wire in a 5V toggle switch.

 

Figure 90 - 5V Toggle Switch Example

Note: The 5V supply could come from TB2 on the Apollo III.

12.1.4   Sinking Inputs (NPN)

For most NPN proxies place the jumper on the top two pins. Then connect the signal into the corresponding input. See the example below.

 

Figure 91 Standard NPN Proxy

If the proxy has an internal pull-up resistor, depending on its size, it could require the jumper to be completely removed. Use a 3.9k ohm resistor and connect it between XSL and C0+.

 

Below is an example of a 24V NPN proxy with an internal pull-up resistor. The jumper on the Apollo III must be completely removed for this to work.

 

Figure 92 NPN Proxy with Internal Pullup

12.1.5     Isolated Inputs

To isolate inputs, supply an external power supply to C0- (GND) and C0+ (positive voltage supply). Do not power the C0+ with more than 48V. All the other wiring configurations (PNP, NPN, etc…) are the same whether or not the inputs are isolated. In the example below the inputs are isolated using a separate 5V power supply.

Figure 93 - 5V Isolated Power Supply

7.1     Configuring Inputs

To configure an input, follow the procedure below.

        1. On the menu bar click on Configure->Mach.
        2. Select the Input Signals Scroll down to the desired input. There are 64 input signals available.

Figure 94 Input Configuration

Note: Input #0 is setup by default for drive fault.

        1. Enable the input by clicking on the red “X”. If it is a green check mark, it is already enabled.
        2. Set the device and input name to the desired input.

Note: Device will be HiCON and Input Name will be [P11] Input X number (X4 would be Input4)

 

        1. To change when the input is active, click on the Active Low A green check mark means that the input is active low and a red X means that the input is active high.
        2. Press [OK] to save changes.

The inputs are now set up.

8         Output Setup

8.1    Generic Outputs

The Apollo III has 8 logic outputs that can be used for any low current application. They are located on the small green terminal block as shown below.

Figure 95 Outputs

Each output has an LED that shows its current state. The outputs and LEDs are labeled Y0 through Y7. If the LED is on, the output is activated.

8.2    Wiring Outputs

There are two separate commons for the outputs. The common C1+ is for outputs Y0-Y3 and C2+ is for Y4-Y7. Each common can take 7-48VDC. If the outputs being used are using the voltage supply from Apollo III, each output can only supply 125mA. However, if they are supplied using a separate voltage source, each output can source up to 250mA.

 

For standard operation the outputs can have their commons jumpered to 24V on the Apollo III. At that point simply connect the load between the output and GND. See the figure below.

Figure 96 Standard 24V 125mA Outputs

8.3    Configuring Outputs

To configure an output, follow the procedure below.

        1. On the menu bar click on Config->Mach.
        2. Select the Output Signals
        3. Scroll down to the desired output (There are 64 output signals available).

 

Figure 97 Output Configuration

        1. Enable the output by setting the Mapping Enabled box to a green check.
        2. Set the Device the Output Name as shown above (Y3 would be Output3).
        3. Set the Active Low column to a green check for a normally closed signal or red x for normally open.
        4. Press [OK] to save changes.

8.4    Using Outputs

Outputs 0-5 can be controlled with M-Codes. Use the table below for a reference.

Custom M-Codes

Functions

Default Output

M200

Output 0 on

Y2

M201

Output 0 off

M202

Output 1 on

Y3

M203

Output 1 off

M204

Output 2 on

Y4

M205

Output 2 off

M206

Output 3 on

Y5

M207

Output 3 off

M208

Output 4 on

Y6

M209

Output 4 off

M210

Output 5 on

Y7

M211

Output 5 off

Table 11 M-Codes for Outputs

The outputs can also be accessed inside the MachMotion plugin.

13   Appendices

13.1    Default Factory Settings

These are default settings but are not required for the system to function correctly.

Signal

Mapping Enabled

Device

Input Name

Active Low

Input #0

ü

HiCON

[P11] Input0

X

Motor 0 Home

ü

HiCON

[P11] Input1

ü

Motor 1 Home

ü

HiCON

[P11] Input2

ü

Motor 2 Home

ü

HiCON

[P11] Input3

ü

Motor 0 ++

ü

HiCON

[P11] Input1

ü

Motor 1 ++

ü

HiCON

[P11] Input2

ü

Motor 2 ++

ü

HiCON

[P11] Input3

ü

Motor 0 – – 

ü

HiCON

[P11] Input1

ü

Motor 1 – – 

ü

HiCON

[P11] Input2

ü

Motor 2 – – 

ü

HiCON

[P11] Input3

ü

E-Stop

ü

HiCON

[P14] Input5

ü

Table 20 – Default Inputs Signals

Signal

Mapping Enabled

Device

Input Name

Active Low

Output #0

ü

HiCON

[P11] Output2

X

Output #1

ü

HiCON

[P11] Output3

X

Output #2

ü

HiCON

[P11] Output4

X

Output #3

ü

HiCON

[P11] Output5

X

Output #4

ü

HiCON

[P11] Output6

X

Output #5

ü

HiCON

[P11] Output7

X

Spindle FWD

ü

HiCON

[P14] Output6

X

Spindle REV

ü

HiCON

[P14] Output7

X

Coolant On

ü

HiCON

[P11] Output0

X

Mist On

ü

HiCON

[P11] Output1

X

Table 21 – Default Outputs

 

 

 

13.2    Apollo III Drawing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13.3    Apollo III Case Mount Drawing

 

                                                                                                                                                                 

14. Appendix

14.1 Warranty Information

MachMotion warranty policy is subject to change. Updated information is available at our website:
https://machmotion.com/warranty

The MachMotion Team
http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
(573) 368-7399 • Fax (573) 341-2672

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