Install Instructions

Tensile Mill Install

M31 CONTROLLER INSTALLATION & WIRING Step 1.1 — Mount the M31 Controller

Install the M31 Motion Controller in the bottom-left section of the control panel.
Ensure it is firmly mounted and positioned so that the J1–J18 terminals face outward for wiring access.

Step 1.2 — Install the X Limit Wire Into J1 Input 00

Insert the X-axis limit switch wire into terminal J1 → Input 00.
Tighten the screw terminal firmly.

Step 1.3 — Install the Y Limit Wire Into J1 Input 01

Insert the Y-axis limit switch wire into terminal J1 → Input 01.

Step 1.5 — Install the Z Limit Wire Into J1 Input 02

Insert the Z-axis limit switch wire into terminal J1 → Input 02.

Step 1.6 — Verify Limit Order

Ensure the limit switches are connected in this order:

00 → X
01 → Y
02 → Z

SECTION 2 — EMERGENCY STOP WIRING Step 2.1 — Route E-Stop Wires to J6

Locate the E-Stop pair and route them into the J6 terminal on the M31.

Step 2.2 — Connect E-Stop (ESTP) and +24V at J6

Connect:

ESTP → E-Stop signal
+24V → E-Stop supply

SECTION 3 — POWER WIRING Step 3.1 — Wire 24V Power Inputs

Connect the main 24V power to J8 Power:

24V+ → brown wire
24V– → blue wire

SECTION 4 — OUTPUTS AND RELAY WIRING Step 4.1 — KM1 Pump Relay Output into J10 Output 0

Insert the wire labeled J4KM1 or KM1 pump relay into:

J10 → Output 0

SECTION 5 — J12 MOTOR / ENCODER / SIGNAL BLOCK Step 5.1 — Connect S+ Using Wire 6208

Insert wire 6208 into terminal J12 → HwEN.

Step 5.2 — J12 slot 01 Using Wire 6209

Insert wire 6209 into terminal J12 → H-

Step 5.3 — Connect DrEN and D– in the J12 terminal

You have two paired wires:

+24V → goes to DrEN
6210 → goes to D–

SECTION 6 — ETHERCAT CONNECTION Step 6.1 — Plug EtherCAT Cable into M31

Connect the EtherCAT cable from the servo drives into the EtherCAT port on the M31.

Step 6.2 — Connect MACHJ20 Cable to HMI

Plug the top Ethernet port labeled MACHJ20 into the HMI LAN port.

SECTION 7 — HMI ARM INSTALLATION Step 7.1 — Replace Factory Bolts with M8 × 1.25 × 35mm

Use four M8 × 1.25 × 35mm hex-head screws

ensure you have a length (horizontal) measurement of (13 1/2in ) on your arm

and a height (vertical) measurement of ( 9in) on your arm

Step 7.2 — Mount Base of HMI Arm

Secure the HMI arm base to the cabinet using the four upgraded screws.

Step 7.3 — Feed HMI Cables Through Cabinet and Arm

Feed all HMI cables:

Through front cabinet bottom panel
Through the HMI arm base
Up through arm segments

Step 7.4 — Insert and Tighten Arm Elbow

Install the horizontal arm (Cut to 13 1/2 inches), insert the internal cushion, then the elbow piece,

tighten screws,

Step 7.5 — Install vertical arm (Cut to 9 inches) and route Cables Into HMI Back Panel

Feed cables up into the rear panel opening of the HMI.

Step 7.6 — Before mounting HMI Rotate HMI to (Confirm Movement in the correct direction and not backwards)

Ensure the screen rotates freely in the correct direction.

then mount the HMI

SECTION 8 — NETWORK CABLING Step 8.1 — Route Motion Control Cable to LAN1

connect from M31 and route cable into the LAN1 port on the HMI.

along with plugging in the power and zero and ground into the back panel

SECTION 9 — SOFTWARE SETUP (HMI) Step 9.1 — Download Correct MachMotion Version

On the HMI:

Power on
Download MachMotion
Find latest tensile mill customer backup
Compare version numbers on server vs. local machine

Step 9.2 — Copy Machine Backup to USB

Copy newest backup onto USB → transfer to machine.

Step 9.3 — Rename Old Mach4 Folder

Rename existing folder:

Mach4 → Mach4_old

Step 9.4 — Copy New Mach4 Folder

Paste new backup, rename folder to:

Mach4 (no spaces, no periods)

SECTION 10 — DRIVE SOFTWARE (VFD + SERVO) Step 10.1 — Install Required Software

Install:

DCISoft 1.26 (for VFD)
Leadshine software (for Servos) (witing the M Drive)
MotionStudio v2.3.2

Ensure computer/HMI has:

USB-B
USB-C

Step 10.2 — Set MotionStudio Language to English

Open MotionStudio → Click language → select English → press Yes → restart.

Step 10.3 — Locate Correct MS300 Software Version

Use:

DELTA_IA-MDS_VFDSoft_V1-58_SW_20180725

10.4.1 — Install the Software

Locate the installer file.
Right-click and select Run as Administrator.
Install using all default settings.
When completed, launch the program.

10.5 — Connect to MS300 VFD

10.5.1 — Prepare the VFD

Power ON the machine.
Ensure the VFD is connected to the control PC via your USB-to-RS485/Modbus adapter.

10.5.2 — Detect the VFD in Software

Open MDS VFDSoft.
Click Scan.
Select the COM port the USB adapter uses.
Press Connect.

10.5.3 — Upload Correct Parameters

Load your saved MS300 configuration file (if provided).
Press Write to Drive.
Cycle power to the VFD.

10.6 — Install Servo Drive Software

The Yaskawa, Delta ASDA-B2, Leadshine, or other servo drives require their manufacturer configuration utility.

10.6.1 — Install Servo Utility (Example: Delta ASDA-Soft)

Open installer.
Install with default settings.
Connect USB-RS232/USB-Mini cable to servo drive.
Open the utility software.

10.6.2 — Load Drive Parameters

Identify each drive (X, Y, Z).
Load the correct .prm file or factory configuration.
Write parameters to the drive.
Reboot the servo drive.

10.7.1 — Open VSI Device Manager

Go to:
C:\Mach4Hobby\VSI Device Manager
Launch VSI Device Manager.
Click Scan in the top-left.

10.7.2 — Select the Controller

After scanning, you should see a device with the following IP:

192.168.208.35
(This is the MachMotion M31 control board.)

Click to highlight 192.168.208.35.
Verify that the device information loads in the lower panel.

10.7.3 — Enter Loader Mode

In the lower panel of VSI Device Manager:

Click “Load Mode”
(sometimes labeled Boot Mode, Loader Mode, or Load Boot File Mode depending on software version)

The M31 will switch into loader mode, allowing firmware changes.

10.7.4 — Update the FPGA

Click Fast FPGA (button in lower panel).
Browse to the most up-to-date FPGA file provided by MachMotion.
(File extension is usually .rbf)
Click Open / Write to begin flashing the FPGA.
Reboot the controller when prompted.

10.7.5 — Update the Firmware

After reboot:

Click Firmware Update (or Load Firmware File).
(Button is in the same lower panel as the FPGA option.)
Browse to the latest firmware file (.bin).
Click Write to flash firmware.
Wait for confirmation.
Reboot the controller again.

10.7.6 — Finalize

Close VSI Device Manager.
Power cycle the entire machine:
- Turn OFF main power
- Wait 10 seconds
- Turn power ON again

This ensures the M31 loads the new firmware and FPGA.

10.8 — Verify EtherCAT & Controller Status in Mach4

After updating the FPGA and Firmware and power cycling the machine, you must confirm that Mach4 recognizes the controller and all EtherCAT devices correctly.

10.8.1 — Launch Mach4

Open Mach4 normally from the HMI.

Wait for the main screen to finish loading.

10.8.2 — Check M31 Status

Open:

Diagnostics → M31 Status Panel

Verify:

Controller: Connected
Firmware Version: Updated
FPGA Version: Updated
EtherCAT: Running
Axis Drives: Enabled / Idle
No Faults or Lost Steps warnings

If anything shows red or Not Connected, power-cycle again.

10.8.3 — Check EtherCAT Devices

Open:

Diagnostics → EtherCAT

You should see:

M31 Controller
X-Axis Servo Drive
Y-Axis Servo Drive
Z-Axis Servo Drive
Any additional EtherCAT devices (IO blocks, tool setter blocks, etc.)

All devices should show:

Status: OK / Operational
Heartbeat: Active

If any drive is offline, check:

EtherCAT cable connections
Drive power
Termination (if required)
Drive alarms

10.8.4 — Verify Physical Inputs/Outputs

Before programming IO in Mach4, confirm that the hardware physically works.

Open:

Diagnostics → M31 I/O Monitor

Check:

Press the E-Stop → EStop changes state
Activate each Limit Switch → corresponding input toggles
Probe/tool setter → toggles input when depressed
Turn ON outputs manually (if toggling allowed) → coolant relay clicks / output LED activates

This proves the board and wiring are correctly connected before configuring Mach4.

10.9 — Program Inputs in Mach4 (Correct Method)

Now that inputs are verified, configure them in Mach4’s control system.

10.9.1 — Open the Control Configuration

Click the Input Signals tab.

10.9.2 — Assign Each Machine Input

For each input:

Check Enabled
Device should be set to M31
Set the correct Input Number (0–7 depending on J1 terminal)
Set Active Low if your switch is wired Normally Closed (NC)

Recommended Mapping (Based on Your Wiring):

Function	Mach4 Signal Name	M31 Input #	Physical Terminal
X Limit	X--	0	J1-00
Y Limit	Y--	1	J1-01
Z Limit	Z--	2	J1-02
Probe	Probe Input	As wired	J1-xx
E-Stop	EStop	ESTP input	J6

10.9.3 — Save Inputs

Click OK, then restart Mach4 when prompted.

10.10 — Program Outputs in Mach4

Now configure coolant, spindle enable, and any auxiliary outputs.

10.10.1 — Open Output Signals

10.10.2 — Assign Outputs

For each output:

Enable the output
Set Device to M31
Assign Output # (0–7 depending on J10 terminals)

Your Likely Output Mapping:

Function	Mach4 Output	M31 Output #	Terminal
Coolant Pump	Flood	0	J10-00
Mist (optional)	Mist	1	J10-01
Spindle Enable	SpindleOn	2	J5 or J10-02
PWM Spindle/Laser	PWM	J7 PWM pin	J7

If a relay behaves backward, toggle Active Low.

10.10.3 — Save Outputs

Click OK
Restart Mach4.

10.11 — Configure Homing & Soft Limits

Homing MUST be set up before calibrating the machine.

10.11.1 — Open Homing Settings

Mach4 → Configure → Control → Homing/Soft Limits

10.11.2 — Assign Homing Order

Recommended order for a tensile mill:

Z Axis — Home Order 1
X Axis — Home Order 2
Y Axis — Home Order 3

10.11.3 — Set Homing Directions

Based on typical tensile mill design:

Z homes Positive (UP)
X homes Negative
Y homes Negative

Reverse direction in Motor Config if needed.

10.11.4 — Test Homing

Click Ref All Home

Verify:

Z raises to switch
X moves to its limit
Y moves to its limit
No axis crashes or moves opposite

If incorrect direction:
Mach4 → Configure → Control → Motors → check Invert Motion

10.12 — Axis Calibration (from Your PDF)

Based on “mach4-axis-motor-calibration.pdf”

Mach4 supports Manual and Automatic axis calibration.

10.12.1 — Open Calibration Tool

Mach4 → Configure → Plugins → Machine Calibration

Choose Manual Calibration or Automatic Calibration.

Manual Calibration Procedure (Recommended for Precision)

10.12.2 — Manual Calibration Steps

Select the axis (X/Y/Z).
Enter a commanded distance (e.g., 2.0000 inches).
Click Enable.
Click Move.
Measure actual travel using:
- Dial indicator
- Caliper
- Gauge block
Enter the actual distance traveled.
Click Submit — Mach4 calculates new Steps Per Unit.
Click Accept.

Repeat for each axis.

Automatic Calibration Procedure

10.12.3 — Automatic Method

Enter:

Motor model
Gear ratio
Ball screw pitch
Microstep setting

Mach4 calculates theoretical values and loads them.

Fine-tune afterward with manual calibration.

10.13 — Final Machine Validation Checklist

Before running production or test cycles, verify:

10.13.1 Mechanical

✔ All axes home correctly
✔ No binding or sticking
✔ Motors run smoothly

10.13.2 Electrical

✔ IO states correct
✔ Outputs activate correct devices
✔ All limits function
✔ E-stop functions every time
✔ No servo drive alarms
✔ VFD responds to Mach4 commands

10.13.3 Software

✔ EtherCAT online
✔ M31 connected with firmware/FPGA updated
✔ Correct Mach4 profile loaded
✔ Calibration accuracy within tolerance
✔ Soft limits verified

Step 11- Mount and wire Tool Setter

11.1- Enlarge Tool Setter cable pass-through hole to fit the armored section of the cable and add 2 cable tie down points (8/32 screws and nuts)

11.2- Run Tool Setter cable through the cable track

11.3- Run Tool Setter Cable out of the cable track and into the black loom, down into the cabinet

11.4- Wire the Tool Setter into the M31

Orange Wire- Tool Setter Touch- Label 6114- J1 Port 5

Blue Wire- Tool Setter Limit- Label 6116- J1 Port 6

Green Wire- 24VDC+ Common- Label 6115- J2 Port 2

Brown Wire- 24VDC+ Common- Label 6113- J2 Port 3

Red Wire- 24VDC+ Common- Label 6112- J2 Port 4

Grey Wire- 0VDC- Common- Label 0V- J11 Port 1